Recirculated Exhaust Gas Burner for Emissions Testing

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Solution Overview

Problem

Engine-based test systems for evaluating emissions control devices are inconsistent, maintenance-intensive, and expensive, and fail to allow separate evaluation of individual variables such as fuel and oil constituents, which complicates the assessment of long-term effects on aging emissions control devices.

Innovation Solution

A burner-based exhaust gas generation system that recirculates exhaust gas back into the system, allowing for the simulation of exhaust gas production without running an internal combustion engine, enabling controlled evaluation of emissions control devices under various conditions, including the effects of fuel and oil additives, and incorporating a heat exchanger and oil injection system for precise temperature and composition control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If engine-based test systems are used to evaluate emissions control devices, then realistic exhaust conditions can be achieved, but the systems become maintenance-intensive, expensive, and inconsistent

Engineering Contradiction:

Improveconsistency of test resultsVSAvoidmaintenance requirements

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent creates a simplified copy of engine exhaust conditions using a burner-based system that reproduces the chemical composition and temperature characteristics of real engine exhaust without requiring an actual engine. This copying approach maintains test realism while eliminating the maintenance and consistency issues of engine-based systems

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the complex mechanical engine system with a simpler burner-based combustion system. This substitution maintains the essential function of producing exhaust-like conditions while reducing mechanical complexity, maintenance requirements, and improving operational consistency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If engine-based test systems are used, then comprehensive exhaust conditions are produced, but separate evaluation of individual variables such as fuel and oil constituents is not permitted

Engineering Contradiction:

Improveability to evaluate individual variablesVSAvoidsystem configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent segments the exhaust generation process into separate controllable components - fuel injection system, oil injection system, burner system, and air supply system. This segmentation allows individual variables to be independently adjusted and evaluated while maintaining the overall exhaust simulation capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements dynamic control systems that allow real-time adjustment of individual parameters such as fuel type, oil additives, and combustion conditions. This dynamic capability enables separate evaluation of individual variables while maintaining comprehensive exhaust simulation

Inventive Principle:

Principle #15Dynamics

3Use of energy by moving object

If recirculated exhaust gas is used in burner-based systems, then fuel consumption is reduced and cooling is improved, but system complexity increases

Engineering Contradiction:

Improvefuel consumptionVSAvoidsystem configuration

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent implements a feedback mechanism where exhaust gas is recirculated back to the burner inlet. This feedback loop allows the system to reuse exhaust gas for combustion support, reducing fuel consumption while the recirculation path integrates smoothly into the existing burner configuration

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The recirculated exhaust gas serves multiple functions simultaneously: it acts as a combustion support gas, provides cooling effect, and maintains atmospheric conditions in the test chamber. This multi-functionality reduces the need for separate systems while improving overall efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces fuel consumption, allows for accurate simulation of engine exhaust conditions, and provides a cost-effective method to evaluate the aging of emissions control devices under simulated extended driving conditions, enabling precise testing of emissions control devices.

Implementation Method 1

incorporating a heat exchanger and oil injection system for precise temperature and composition control

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

A portion of the exhaust gas is diverted from the main exhaust path downstream the burner, a heat exchanger, and test ECD's. It is re-circulated such that it re-enters the main exhaust path after the burner.

Methodology Applied

Scientific EffectThermal energy absorption: Absorption (physical)

Data Source

PatentUS7748976B2Use of recirculated exhaust gas in a burner-based exhaust generation system for reduced fuel consumption and for cooling

Publication Date: 2010.07.06 SOUTHWEST RES INST

AI summary

A burner-based exhaust gas generation system, for producing exhaust gas, typically for use in testing exhaust system devices. Post-burner exhaust gas is recirculated back to a main exhaust line, and used for purposes such as cooling or enhancing the burner output.