Integrated Urea Sensor Probe for Multi-Parameter Monitoring
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Solution Overview
Problem
Current systems for monitoring and controlling urea solution characteristics in diesel engine exhaust systems require multiple separate sensors and devices, taking up space and increasing costs, as they need to detect level, temperature, concentration, and contamination of the urea solution effectively.
Innovation Solution
An integrated apparatus with a probe section featuring a layered heating circuit and sensing circuit formed on a substrate, where the resistance of the heating circuit changes with temperature, allowing the control module to determine fluid characteristics such as concentration, temperature, and level based on resistance changes, thus combining multiple functions into a single compact unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple separate sensors and devices are used to monitor level, temperature, concentration, and contamination of urea solution, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple separate sensors (level sensor, temperature sensor, concentration sensor) and control devices (heating device, pump) into a single integrated probe assembly. The probe includes a substrate with layered circuits that simultaneously perform heating, temperature sensing, and fluid level detection, eliminating the need for multiple separate components while maintaining comprehensive monitoring capabilities
Solution Approach 2:
The integrated probe serves multiple functions simultaneously: the heating circuit heats the urea solution to prevent freezing, the temperature sensor monitors solution temperature, the level sensor detects fluid level, and the concentration sensor monitors urea concentration. This multi-functional design allows one component to replace several separate devices, reducing system complexity
2Reliability
If multiple separate sensors and devices are used to ensure sufficient urea solution and good quality, then reliability is improved, but space requirements and cost increase
Solution Approach 1:
The patent merges multiple sensing functions into a single compact probe assembly that can be installed in a limited space within the urea tank. The substrate-based integration allows all sensors to occupy minimal volume while maintaining their individual measurement capabilities, thus preserving reliability without increasing space requirements
Solution Approach 2:
The probe design nests multiple functional elements within a compact structure: the substrate contains layered heating circuits, temperature sensors, level sensors, and concentration sensors all integrated within a single probe body. This nested arrangement allows comprehensive monitoring in a compact footprint, reducing the space needed compared to separate devices
3Ease of operation
If separate control systems are used for heating device and sensors, then ease of operation is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the heating circuit, temperature sensor, level sensor, and concentration sensor into a single integrated probe with unified control electronics. The control module receives inputs from all sensors and manages the heating device through a single integrated system, simplifying operation while reducing the complexity of multiple separate control systems
Solution Approach 2:
The integrated control module performs multiple functions: it controls the heating circuit based on temperature sensor feedback, monitors fluid level through the level sensor, and tracks concentration via the concentration sensor. This multi-functional control approach consolidates what would otherwise require separate control systems into one unified unit
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 integrated solution allows for efficient monitoring and control of urea solution characteristics, reducing space and cost requirements while ensuring effective NOx reduction and emission compliance by providing real-time quality verification and engine control.
Implementation Method 1
a heating device may be required to heat the urea solution to prevent the urea solution from freezing at around 11° F
Implementation Method 2
The resistance of the heating circuit changes with temperature. The control module is in communication with the heating circuit and determines at least one of concentration, temperature and level of the fluid based on a change of resistance of the heating circuit
Implementation Method 3
Urea is converted into gaseous ammonia through thermal decomposition before the reduction reaction takes place
Implementation Method 4
NO contained in the exhaust gas undergoes a reduction reaction as the exhaust gases pass through the catalyst chamber of the SCR and is reduced into nitrogen (N2) and water (H2O)
Data Source
AI summary
An apparatus for determining and controlling characteristics of a fluid is provided that includes a substrate, a heating circuit, and a sensing circuit applied on the substrate by a layered process. A control module is in communication with the heating circuit and the sensing circuit for determining, for example, type, concentration, liquid level, and temperature of the fluid, which in one form is a urea solution.