Exhaust Manifold Integrated Combustion Heater for Aftertreatment
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Solution Overview
Problem
Conventional exhaust aftertreatment systems for compression ignition engines require bulky thermal units for heating, which are inefficient in space-constrained areas and complicate installations due to separate fuel and air feed systems.
Innovation Solution
A system and method where a fuel delivery device and igniter are integrated within the exhaust manifold, controlled by a controller to deactivate cylinders, mix fuel and air, and ignite the mixture for combustion products to heat the exhaust aftertreatment setup, eliminating the need for a separate thermal unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional thermal unit with separate fuel and air feed systems is installed to heat the exhaust stream, then the aftertreatment devices can achieve elevated activation temperature, but the overall assembly becomes bulky and complex
Solution Approach 1:
The patent combines the fuel delivery device and air supply into a single integrated system within the exhaust manifold. The fuel delivery device injects fuel directly into the exhaust manifold where it mixes with exhaust gases that provide the oxygen for combustion, eliminating the need for separate air feed systems and reducing overall system complexity while maintaining the heating function
Solution Approach 2:
The exhaust manifold serves multiple functions: it collects exhaust gases from cylinders, provides a combustion chamber for the thermal unit, and acts as a mixing zone for fuel and exhaust gases. This multi-functionality eliminates the need for dedicated separate components for each function, reducing system bulk and complexity
2Temperature
If a conventional thermal unit with separate fuel and air feed systems is installed to heat the exhaust stream, then the aftertreatment devices can achieve elevated activation temperature, but the overall assembly becomes bulky
Solution Approach 1:
The fuel delivery device is disposed within the exhaust manifold, nesting the fuel delivery function inside the existing exhaust flow path. This nesting approach utilizes the existing space in the exhaust manifold rather than adding external components, thereby reducing the overall system volume while maintaining heating capability
Solution Approach 2:
By merging the fuel delivery device and air supply (exhaust gases) into a single integrated system within the exhaust manifold, the patent eliminates the need for separate air feed systems and external thermal units, significantly reducing the overall system volume while maintaining the heating function
3Temperature
If a conventional thermal unit is retrofitted to an existing aftertreatment system, then heating capability is added, but installation becomes difficult due to tight space constraints
Solution Approach 1:
The exhaust manifold is designed to serve multiple functions including exhaust collection, fuel injection, and combustion chamber. This multi-functionality allows the same component to be used across different engine configurations and retrofit scenarios, improving installation ease by eliminating the need for multiple dedicated components
Solution Approach 2:
The fuel delivery device is nested within the existing exhaust manifold structure, utilizing available space rather than requiring additional external mounting areas. This nesting approach facilitates retrofitting in tight space constraints by integrating new functionality into existing structural voids
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 approach provides efficient thermal management for exhaust aftertreatment systems, reduces system bulk and complexity, and allows for retrofitting in various engine types without significant modifications, optimizing combustion and emissions.
Implementation Method 1
The igniter is configured to ignite a mixture of the fuel and air. The controller is also configured to control the igniter to ignite the mixture of the fuel and the air to generate combustion products within the exhaust manifold for heating the exhaust aftertreatment setup
Data Source
AI summary
A system includes an engine having multiple cylinders and an exhaust manifold. A fuel delivery device and an igniter are disposed in the exhaust manifold. The fuel delivery device injects a fuel into the exhaust manifold. The system also includes an exhaust aftertreatment setup in fluid communication with the exhaust manifold, and a controller in communication with the multiple cylinders, the fuel delivery device and the igniter. The controller is configured to deactivate at least one cylinder to provide air to the exhaust manifold, and control the fuel delivery device to provide the fuel within the exhaust manifold such that the fuel and the air from the at least one deactivated cylinder forms a mixture within the exhaust manifold. The controller is configured to control the igniter to ignite the mixture to generate combustion products within the exhaust manifold for heating the exhaust aftertreatment setup.