Helical Heater and Sensor for DEF Exhaust Systems
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Solution Overview
Problem
Existing exhaust systems face challenges in quickly and efficiently heating diesel exhaust fluid (DEF) to optimal temperatures for reducing NOx emissions, especially at low temperatures where insufficient heat from exhaust gases leads to thermolysis and deposit issues.
Innovation Solution
A heater integrated within a helical body within the exhaust system's fluid chamber, equipped with a temperature sensor and heating element, efficiently heats DEF to a predetermined temperature using a feedback loop for precise control, ensuring rapid and effective heating of DEF before injection into the exhaust gas flow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If DEF is heated quickly and efficiently to prescribed temperature, then NOx emission reduction is improved, but device complexity increases due to integrated heater and sensor components
Solution Approach 1:
The heater assembly integrates multiple functions into a single component: the helical body serves as both the heating element support and the temperature sensor mounting structure, while the housing combines fluid chamber, sensor protection, and electrical connection functions. This merging reduces the number of separate components and simplifies the overall system while maintaining rapid heating capability
Solution Approach 2:
The helical body simultaneously serves as a structural support element, a mounting platform for the temperature sensor, and a heat transfer component. The housing provides both mechanical protection and electrical connectivity. This multi-functionality allows the device to achieve prescribed heating temperatures quickly without requiring additional separate components
2Use of energy by moving object
If integrated heater and sensor are used, then heating efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The heater assembly is divided into distinct functional segments that can be manufactured separately and then assembled: the housing is formed as a separate component, the helical body is manufactured independently with sensor integration, and the heating element is a separate component that fits within the helical structure. This segmentation allows each part to be optimized for its specific manufacturing process while simplifying the overall manufacturing complexity
Solution Approach 2:
The temperature sensor is integrated within the helical body structure, with the sensor positioned inside the hollow helical form. The heating element is nested within the helical body as well. This nested arrangement allows compact integration of multiple components without requiring complex assembly procedures, as each nested component fits into a pre-formed space
3Measurement precision
If helical body with integrated sensor is used, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The temperature sensor is integrated directly into the helical body structure, with the sensor positioned inside the hollow helical form. This merging of the sensing function into the structural component eliminates the need for separate sensor mounting hardware and reduces the number of connections required, thereby reducing device complexity while maintaining precise temperature measurement and control capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables rapid and efficient heating of DEF to desired temperatures, improving atomization and mixing, thereby enhancing NOx emission reduction and reducing thermolysis and deposit issues, even at low temperatures.
Implementation Method 1
a heating element that is embedded within the spiraling body portion and spirals about the cylindrical center body from the first end to the second end such that an electrical current that is passed through the heating element heats the helical body along an entirety of the length of the helical body
Implementation Method 2
At least one temperature sensor is integrated into the helical body to measure a temperature of the DEF
Data Source
AI summary
A heater for a vehicle exhaust system includes a housing defining a fluid chamber, and the housing has a fluid inlet configured to receive fluid from a fluid supply and a fluid outlet. A helical body is positioned within the fluid chamber and a heater is integrated into the helical body to heat fluid supplied from the fluid supply such that heated fluid can be injected into a vehicle exhaust component via the fluid outlet. At least one sensor is integrated into the helical body to measure a fluid characteristic.