Segmented Cartridge Exhaust Filter with Selective Electric Heating

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Solution Overview

Problem

Conventional exhaust particulate filters face challenges in efficiently regenerating accumulated particulates without excessive energy consumption and complex systems, particularly in off-highway machines, where frequent regeneration is needed and existing electrically regenerable systems require substantial electrical power.

Innovation Solution

An exhaust particulate filter system with a fixed exhaust gas distribution pattern and electrically powered heating elements in each filter cartridge, allowing selective regeneration of less than all cartridges at a time, using conventional electrical power sources and minimizing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional electrically regenerable filter systems are used, then filter regeneration can be achieved, but excessive electrical power consumption occurs

Engineering Contradiction:

Improvefilter regeneration capabilityVSAvoidelectrical power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The filter system is divided into multiple independent filter cartridges, each with its own heating element. This allows selective regeneration of individual cartridges rather than requiring power to regenerate the entire filter system at once, significantly reducing peak electrical power consumption while maintaining regeneration capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system enables partial regeneration by selecting and regenerating only the specific filter cartridges that require it, rather than regenerating the entire filter system. This partial action approach reduces energy consumption while achieving the necessary regeneration effect for maintaining filter performance.

Inventive Principle:

Principle #16Partial or excessive action

2Reliability

If auxiliary burners or complicated subsystems are added for regeneration, then PM combustion can be initiated, but device complexity increases

Engineering Contradiction:

ImprovePM combustion initiationVSAvoidregeneration subsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical/thermal regeneration systems (auxiliary burners, throttling valves) with an electrical heating system. Electric heating elements directly heat the filter cartridges to initiate PM combustion, eliminating the need for complex mechanical subsystems while reliably achieving the required combustion initiation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If exhaust flow is blocked or reduced during regeneration, then self-sustaining combustion can be achieved, but productivity decreases

Engineering Contradiction:

Improveself-sustaining combustionVSAvoidexhaust flow throughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

By segmenting the filter into multiple independent cartridges, the system can regenerate individual cartridges while others remain in service. This maintains exhaust flow throughput (productivity) while achieving self-sustaining combustion in the cartridges being regenerated, eliminating the need to block entire exhaust streams.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The segmented cartridge design allows continuous filtering operation in non-regenerated cartridges while regeneration occurs in selected cartridges. This continuity ensures that exhaust flow and productivity are maintained without interruption, while still achieving reliable self-sustaining combustion in the cartridges undergoing regeneration.

Inventive Principle:

Principle #20Continuity of useful action

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

The system achieves efficient regeneration with reduced energy consumption and complexity, enabling flexible mounting and operation in spatially constrained environments while maintaining filter efficacy and extending the filter's working life.

Implementation Method 1

electrically powered heating elements coupled one with each of the filter cartridges

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

combustion of the accumulated PM is induced, it can be consumed rather than passed out to the environment

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS7981174B2Electrically regenerated exhaust particulate filter for an engine system and operating strategy therefor

Publication Date: 2011.07.19 CATERPILLAR INC

AI summary

An exhaust particulate filter for an engine system includes an array of filter cartridges positioned within a shell, each of the cartridges having an electrically powered heating element coupled therewith. Exhaust gases are distributed among the cartridges according to a single distribution pattern, and the filter can be regenerated without diverting, dividing or bypassing exhaust gases from the filter. Other aspects include feedback control and feedforward control of regeneration based on sensing an electrical resistance property of each of the electrically powered heating elements.