Iced Sensor Detection in Exhaust After-Treatment Systems
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Solution Overview
Problem
Exhaust after-treatment systems face interruptions due to malfunctions caused by iced conditions in pressure sensor assemblies, leading to unnecessary engine shutdowns and costly maintenance, especially in cold temperatures where water vapor can freeze, causing inaccurate pressure signals and fault signals.
Innovation Solution
A control module is implemented in the combustion system to predict iced conditions of the pressure sensor assembly, allowing the system to operate without using the pressure sensor data during icing and switching back to sensor control once the condition is resolved, thereby preventing unnecessary shutdowns and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the pressure sensor assembly is used to monitor exhaust after-treatment system conditions, then measurement precision is improved, but reliability deteriorates under cold conditions due to icing
Solution Approach 1:
The control module predicts iced conditions before they occur by monitoring ambient temperature and engine operating conditions. When an iced condition is predicted, the system switches to alternative control modes that do not rely on pressure sensor data, preventing faulty measurements from causing unnecessary shutdowns.
Solution Approach 2:
The control module acts as an intermediary between the pressure sensor assembly and the combustion system operation. It filters out unreliable sensor data during iced conditions and uses alternative parameters or predictive models to maintain control decisions, preventing direct propagation of faulty measurements.
2Reliability
If the combustion system shuts down when a fault signal is generated by the pressure sensor assembly, then reliability is improved by preventing damaged operation, but productivity deteriorates due to unnecessary interruptions
Solution Approach 1:
The control module predicts iced conditions before they cause faulty readings. By anticipating the problem and switching to alternative control modes in advance, the system avoids generating false fault signals that would trigger unnecessary shutdowns, maintaining continuous operation.
Solution Approach 2:
The control module continuously monitors ambient temperature and engine conditions to predict iced conditions. This feedback mechanism allows the system to adjust its operation dynamically, switching between sensor-based control and alternative control modes based on predicted conditions, thereby preventing false shutdowns while maintaining safety.
3Productivity
If the pressure sensor assembly operates in cold temperatures, then productivity is maintained, but measurement precision deteriorates due to ice formation in sensing tubes
Solution Approach 1:
The control module predicts iced conditions by monitoring temperature and operating parameters before ice forms in the sensing tubes. When prediction indicates freezing conditions, the system switches to alternative control modes that do not rely on pressure sensor data, preventing inaccurate measurements from affecting combustion control.
Solution Approach 2:
The control module changes the operating parameters used for combustion control based on predicted iced conditions. Instead of relying on pressure sensor readings, the system uses alternative parameters such as engine operating conditions, predictive models, or other sensor data to maintain accurate combustion control without frozen sensor readings.
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 continuous operation of the combustion system by disregarding unreliable pressure signals during icing conditions and resuming normal operation once the sensor assembly is de-iced, reducing unnecessary engine shutdowns and maintenance costs.
Implementation Method 1
During cold conditions, water vapor can condense and freeze in pressure sensing tubes of the pressure sensor assembly
Implementation Method 2
During cold conditions, water vapor can condense and freeze in pressure sensing tubes of the pressure sensor assembly
Data Source
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AI summary
A combustion system (100), a control module (104) for a combustion system (100) and a method of operating the combustion system (100) are disclosed. The method may be implemented by the control module (104) in the combustion system (100). The method comprises predicting an iced condition of the pressure sensor assembly (240); responsive to predicting the iced condition, controlling exhaust emissions without using a pressure parameter sensed with the pressure sensor assembly (240) in the iced condition; predicting a de-iced condition of the pressure sensor assembly (240); and responsive to predicting the de-iced condition, controlling the exhaust emissions using the pressure parameter sensed with the pressure sensor assembly (240) in the de-iced condition.