Vibration-Based Diesel Filter Ash Removal
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Solution Overview
Problem
Conventional methods for cleaning diesel particulate filters, such as forced air, are ineffective in removing ash from plugged regions, leading to increased exhaust backpressure, reduced soot storage capacity, and potential engine failure, as they often remove ash from areas with high flow but leave behind ash in low-flow regions that pack and restrict exhaust flow.
Innovation Solution
A vibration-based cleaning system that applies vibrations to loosen and remove ash from plugged regions, using vibrating elements attached to the filter or a separate cleaning station, with ash collection bins to capture the dislodged material, allowing for targeted energy application to areas with high ash deposits and optional heating to facilitate ash removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If forced air is used to blow off retentate from filters, then cleaning speed is improved, but airborne particles and dust are generated causing health and environmental hazards
Solution Approach 1:
The patent replaces the pneumatic forced air system with a mechanical vibration system. Vibrating elements attached to the filter housing generate vibrations that mechanically loosen and dislodge retentate from the filter surface, eliminating the need for forced air and thereby preventing airborne particle generation while maintaining effective cleaning capability
Solution Approach 2:
The patent directly applies mechanical vibration to the filter structure through vibrating elements mounted on the housing. The vibration frequency and amplitude are controlled to optimize retentate removal efficiency, providing a clean, contained cleaning process that avoids aerosolization of particles
2Ease of operation
If forced air is used to clean filters, then easy operation is improved, but effectiveness in removing sintered or adhered retentate deteriorates
Solution Approach 1:
The vibration-based system generates mechanical oscillations that physically break the bonds between sintered or adhered retentate particles and the filter surface. This mechanical action is inherently more effective than air flow at removing strongly adhered contaminants, while the system remains simple to operate through automated vibration control
Solution Approach 2:
The patent controls vibration parameters (frequency, amplitude, duration) to optimize cleaning effectiveness for different types of retentate adhesion. By adjusting these parameters, the system adapts to various contamination levels and types, maintaining high reliability while preserving ease of operation
3Device complexity
If forced air cleaning is used, then device complexity is reduced, but effectiveness in removing retentate from low-airflow areas deteriorates
Solution Approach 1:
The vibration system uniformly distributes mechanical energy across the entire filter surface through the housing structure, ensuring that retentate in low-airflow areas is equally effectively loosened and removed. This eliminates the airflow-dependent limitations of forced air systems while maintaining simple device architecture
Solution Approach 2:
The vibration transmission through the filter housing creates equipotential cleaning conditions across all filter surfaces, regardless of local airflow variations. Every area of the filter experiences similar vibration intensity, ensuring uniform and complete retentate removal throughout the entire filter structure
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
Effectively removes ash from plugged regions, reducing exhaust backpressure, preserving the beneficial ash layer on filter walls, and extending the filter's soot storage capacity and useful life, while avoiding the generation of airborne particles and dust.
Implementation Method 1
The filter is subjected to vibrations, which serve to loosen trapped and packed retentate from the filter
Implementation Method 2
The regeneration process oxidizes the soot, but leaves incombustible ash behind
Implementation Method 3
the filter may be heated (generally up to 650 C) to oxidize and remove soot as well
Data Source
AI summary
A cleaning system and method of cleaning filters that removes the ash in the plugged regions is disclosed. The filter is subjected to vibrations, which serve to loosen trapped and packed retentate from the filter. The loosened retentate is then captured by a collection bin. The cleaning system can be integral with the intended application, such as within an automobile. In another embodiment, the cleaning system is a separate cleaning station, where the filter is removing from its intended application, cleaned, and then reinstalled.