Exhaust Aftertreatment Soot Adsorption Monitoring and Cleaning Control

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Solution Overview

Problem

Aftertreatment systems in internal combustion engines face challenges in removing soot deposits, leading to visible smoke emissions, especially during extended low load engine operations.

Innovation Solution

A system and method that monitor the adsorption rate of soot in the exhaust aftertreatment system, determine the adsorption amount, and initiate an exhaust cleaning event when the adsorption amount exceeds a predefined limit, thereby removing soot deposits and reducing visible smoke emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the engine operates in low load condition for extended periods, then fuel efficiency is improved, but soot deposits accumulate in the aftertreatment system leading to visible smoke emissions

Engineering Contradiction:

Improvefuel efficiencyVSAvoidvisible smoke emissions

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The system performs preliminary monitoring of soot adsorption rate and accumulation amount during low load operation, and proactively initiates an exhaust cleaning event before visible smoke emissions occur. This prevents the harmful effect while maintaining the fuel efficiency benefit of extended low load operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements periodic monitoring of soot adsorption parameters and periodically initiates exhaust cleaning events based on accumulated adsorption amount. This periodic action removes soot deposits before they become visible smoke, resolving the contradiction between extended low load operation and emission control.

Inventive Principle:

Principle #19Periodic action

2Object-generated harmful factors

If soot deposits are removed frequently to prevent visible smoke, then emission compliance is improved, but system complexity and operational interruptions increase

Engineering Contradiction:

Improvevisible smoke emissionsVSAvoidsystem complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The system continuously monitors exhaust flow and determines soot adsorption rate in real-time, using this feedback to dynamically assess soot accumulation. This feedback mechanism enables precise control of cleaning events, removing soot only when necessary based on actual adsorption conditions, thereby reducing unnecessary cleaning operations and associated complexity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces complex mechanical soot removal mechanisms with a control-based approach that uses sensor data and algorithms to determine when cleaning is needed. The controller monitors adsorption parameters and automatically initiates cleaning events, substituting mechanical complexity with intelligent control logic.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If soot adsorption is monitored continuously to optimize cleaning timing, then cleaning efficiency is improved, but measurement and control complexity increase

Engineering Contradiction:

Improvecleaning efficiencyVSAvoidmeasurement complexity

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The system uses exhaust flow rate as an intermediary parameter to determine soot adsorption rate, rather than directly measuring soot accumulation. This intermediary measurement approach simplifies detection by using readily available exhaust flow data combined with temperature information to calculate adsorption characteristics, reducing measurement complexity while maintaining cleaning efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution effectively reduces visible smoke emissions by periodically removing soot deposits from the exhaust aftertreatment system, improving the system's efficiency and compliance with emissions regulations.

Implementation Method 1

determine an adsorption rate of soot in the exhaust aftertreatment system based at least partly on the exhaust flow; determine an adsorption amount of soot for a predefined amount of time based on the adsorption rate

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS12221913B2Methods and systems for removing deposits in an aftertreatment system to minimize visible smoke emissions

Publication Date: 2025.02.11 CUMMINS INC

AI summary

Systems and methods for removing soot in an aftertreatment system are disclosed. A method includes: receiving data regarding an exhaust gas flow rate of exhaust gas; receiving data regarding a selective catalytic reduction (SCR) inlet temperature; determining an adsorption amount of soot in the exhaust aftertreatment system based on the exhaust gas flow rate of the exhaust gas and the SCR inlet temperature; comparing the adsorption amount of soot to a predefined adsorption amount limit; in response to the adsorption amount of soot exceeding the predefined adsorption amount limit; initiating an exhaust cleaning event to remove at least some accumulated soot in the exhaust aftertreatment system; receiving exhaust gas data during the exhaust cleaning event; determining a desorption amount of soot based on the exhaust gas data; comparing the desorption amount of soot to a predefined desorption limit; and ceasing the exhaust cleaning event based on the comparison.