Soot Filter Regeneration Control Using Predicted Max Temperature
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Solution Overview
Problem
Current after treatment control systems for diesel engines are unable to calculate or predict a target maximum temperature for soot filter regeneration, leading to uncontrolled heat spikes and potential mechanical failure due to insufficient heat dissipation during the oxidation process.
Innovation Solution
An apparatus and method that includes an average temperature module to determine the average bed temperature and a max temperature module to calculate a target maximum bed temperature, with a dosing controller adjusting the temperature within a specific range to initiate regeneration, using equations such as T3,max,SF=TSF,AVG+[780r3+38r3-116r33](Te,SF,in-Te,SF,out) to ensure controlled regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the temperature of the exhaust stream is raised to trigger oxidation burn-off, then the soot removal speed is improved, but local temperature spikes occur causing unnecessary wear or mechanical failure of the particulate filter
Solution Approach 1:
The system performs preliminary calculation of the target maximum temperature using the average bed temperature and temperature differential across the filter before initiating the burn-off event. This advance preparation allows the control system to set appropriate temperature limits and prevent runaway heat spikes before they occur, thereby protecting the filter while enabling effective soot removal.
Solution Approach 2:
The system continuously monitors the bed temperature and uses feedback control to adjust the oxidation process. By comparing the actual temperature against the calculated target maximum temperature, the control system can modulate the burn-off event to maintain temperatures within safe operating limits, preventing filter damage while ensuring complete soot oxidation.
2Reliability
If the dosing controller monitors temperature to maintain exhaust temperature within a range of average temperature, then heat spike risks are reduced, but the system cannot utilize the higher temperature tolerance of the particulate filter for faster regeneration
Solution Approach 1:
The system changes the temperature control parameter from simply maintaining exhaust temperature within a narrow range of average temperature to actively controlling the bed temperature to reach a calculated target maximum temperature. This parameter change allows the system to exploit the filter's higher temperature tolerance for faster regeneration while preventing dangerous heat spikes through mathematical modeling and predictive control.
3Device complexity
If current control systems use average temperature for regulation, then simple control logic is maintained, but the systems are unable to calculate or predict target maximum temperature for optimized regeneration
Solution Approach 1:
The control system performs preliminary calculation of the target maximum temperature using a mathematical model that incorporates the average bed temperature and the temperature differential across the filter. This advance calculation provides the optimized temperature setpoint before the regeneration event begins, enabling efficient soot removal without requiring complex real-time adjustments during the burn-off process.
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 allows for controlled soot filter regeneration, reducing the risk of mechanical failure and extending the lifespan of the particulate filter by maintaining temperatures within a safe range, thereby optimizing the regeneration process.
Implementation Method 1
an average temperature module to determine an average bed temperature
Implementation Method 2
a max temperature module to calculate a target maximum bed temperature based upon the average bed temperature
Implementation Method 3
The engine naturally generates some NO2 in the exhaust stream. At low temperatures, this NO2 oxidizes some of the soot on the filter. This mechanism is called 'noxidation.'
Implementation Method 4
a faster oxidation mechanism is sometimes required. One implementation of this mechanism is to raise the temperature of the exhaust stream to the point where simple O2 will oxidize the soot. This mechanism is called 'oxidation.'
Implementation Method 5
These filters accumulate soot over time, and the soot must be removed from the filter periodically.
Data Source
AI summary
An apparatus, system, and method are disclosed for controlling soot filter regeneration. The apparatus includes an average temperature module configured to determine an average bed temperature, and a max temperature module configured to calculate a target maximum bed temperature based upon the average bed temperature. The system includes a vehicle having a motor, an exhaust system, an after treatment system, an after treatment controller module, and the apparatus. The method includes determining an average bed temperature, and calculating a target maximum bed temperature based upon the average bed temperature.