MPC for Two-Can SCR System NOx Conversion

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Solution Overview

Problem

Current exhaust aftertreatment systems for internal combustion engines face challenges in maximizing nitrogen oxide (NOx) conversion efficiency and minimizing ammonia slip in selective catalytic reduction (SCR) systems, due to non-uniform ammonia distribution and suboptimal reductant injection strategies.

Innovation Solution

The implementation of a multivariable model predictive control (MPC) system with a Linear Parameter Varying (LPV) architecture for a two-can SCR system, which employs a simplified SCR model and an Extended Kalman Filter for real-time data updates to optimize NOx conversion and ammonia injection, thereby achieving improved trade-offs between NOx conversion and ammonia slip.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a traditional exhaust aftertreatment system is used with standard reductant injection strategies, then the system structure remains simple, but nitrogen oxide conversion efficiency is not maximized and ammonia slip increases

Engineering Contradiction:
ImproveNOx conversion efficiencyVSAvoidammonia slip
Core Design Contradiction:
Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The system performs preliminary actions by predicting future NOx levels and ammonia storage states using a catalyst model before actual measurements are taken. The controller uses engine operating parameters (RPM, load, temperature) to anticipate exhaust conditions and pre-adjusts reductant injection rates, allowing the system to proactively optimize NOx conversion while preventing ammonia slip before it occurs.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system implements feedback control by continuously monitoring ammonia storage capacity in the catalyst and comparing it against target values. The controller adjusts reductant injection rates based on feedback from the catalyst model predictions and actual sensor measurements, creating a closed-loop control system that dynamically optimizes NOx conversion efficiency while maintaining ammonia slip below harmful thresholds.

Inventive Principle:
Principle #23Feedback

2Manufacturing precision

If a complex control model is used to optimize SCR system performance, then NOx conversion efficiency improves, but model and control calibration complexity increases

Engineering Contradiction:
ImproveNOx conversion efficiencyVSAvoidmodel calibration complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system changes parameters by using a simplified catalyst model that relies on readily available engine operating parameters (RPM, load, exhaust temperature) rather than requiring complex calibration data. The model uses predictable relationships between engine parameters and catalyst ammonia storage, avoiding the need for extensive experimental calibration while still achieving accurate predictions for control optimization.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The system uses inexpensive, easily measurable engine operating parameters (RPM, load, temperature) as substitutes for complex, difficult-to-obtain catalyst state measurements. Instead of requiring expensive sensors or complex calibration procedures, the system leverages data already available from the engine control unit, simplifying implementation while maintaining control effectiveness.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

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 enhances NOx conversion efficiency while minimizing ammonia slip, optimizing reductant injection, and reducing the complexity of model and control calibration, leading to improved performance in SCR systems for internal combustion engines.

Implementation Method 1

This dosing agent includes a reductant that is absorbed onto an SCR catalyst surface

Methodology Applied
Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

The SCR catalyst may then break down or reduce the NOx into water vapor (H2O) and nitrogen gas (N2)

Methodology Applied
Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10167762B2Model predictive control for multi-can selective catalytic reduction system
Publication Date: 2019.01.01 GM GLOBAL TECHNOLOGY OPERATIONS LLC
  • US10167762B2 patent drawing
  • US10167762B2 patent drawing
  • US10167762B2 patent drawing

AI summary

Disclosed are model predictive control (MPC) systems, methods for using such MPC systems, and motor vehicles with selective catalytic reduction (SCR) employing MPC control. An SCR-regulating MPC control system is disclosed that includes an NOx sensor for detecting nitrogen oxide (NOx) input received by the SCR system, catalyst NOx sensors for detecting NOx output for two SCR catalysts, and catalyst NH3 sensors for detecting ammonia (NH3) slip for each SCR catalyst. The MPC system also includes a control unit programmed to: receive desired can conversion efficiencies for the SCR catalysts; determine desired can NOx outputs for the SCR catalysts; determine maximum NH3 storage capacities for the SCR catalyst; calculate the current can conversion efficiency for each SCR catalyst; calculate an optimized reductant pulse-width and/or volume from the current can conversion efficiencies; and, command an SCR dosing injector to inject a reductant into an SCR conduit based on the calculated pulse-width/volume.