Particulate Filter Regeneration Using Virtual Brick Temperature Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional regeneration systems for particulate filters in internal combustion engines face challenges in uniformly controlling the temperature of catalyst bricks during regeneration, leading to potential thermal damage due to non-uniform temperature distribution and reliance on average exhaust gas temperatures for control.
Innovation Solution
A regeneration system that includes a temperature sensor, a temperature estimation module, and an exhaust condition adjustment module to measure and estimate the highest temperature of the particulate filter based on outlet exhaust gas temperature, exhaust mass flow rate, catalyst brick mass, and heat transfer coefficients, allowing for precise control of the regeneration process to avoid thermal damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional exhaust gas temperature sensors are used to monitor average upstream and downstream temperatures, then the system can monitor exhaust gas temperature, but the temperature distribution within the particulate filter remains non-uniform leading to thermal damage
Solution Approach 1:
The patent introduces an intermediary mathematical model that acts as a mediator between the measurable exhaust gas temperature and the unmeasurable catalyst brick temperature. The model uses exhaust temperature, mass flow rate, and heat transfer coefficients to calculate and estimate the internal catalyst brick temperature, thereby indirectly obtaining accurate internal temperature data without direct sensing
Solution Approach 2:
The patent replaces the mechanical/physical temperature sensing system (multiple internal sensors) with a computational/mathematical system. Instead of using physical sensors to directly measure catalyst brick temperature, the system uses mathematical calculations based on heat transfer principles and measurable exhaust parameters to estimate the internal temperature
2Reliability
If multiple temperature sensors are installed within the particulate filter to monitor catalyst brick temperature, then accurate temperature control is achieved, but system complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the temperature measurement function from the internal catalyst brick environment and relocates it to the external exhaust gas stream. By measuring only the exhaust gas temperature externally and using mathematical modeling to infer internal temperature, the system eliminates the need for complex internal temperature sensing while maintaining temperature monitoring capability
Solution Approach 2:
The patent makes the exhaust gas temperature measurement serve multiple functions: it directly provides exhaust temperature data for emission control and simultaneously serves as the primary input for estimating catalyst brick temperature through the mathematical model, thereby eliminating the need for separate internal temperature sensors
3Ease of operation
If regeneration is controlled based on average exhaust gas temperature, then the control system is simple to operate, but regeneration efficiency is reduced due to inability to detect peak temperatures
Solution Approach 1:
The patent replaces simple average temperature control with a computational temperature estimation system that calculates peak catalyst brick temperature using heat transfer equations. This substitution enables precise identification of temperature peaks and optimal regeneration timing while maintaining ease of operation through automated calculation
Solution Approach 2:
The patent implements a feedback mechanism where the mathematical model continuously estimates catalyst brick temperature based on real-time exhaust parameters and feeds this information back to the control system. This feedback enables dynamic adjustment of regeneration timing and duration based on actual internal temperature conditions
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 effectively controls the regeneration process, preventing thermal damage to catalyst bricks and improving regeneration efficiency by accurately estimating and managing the highest temperature within the particulate filter, reducing manufacturing costs through the use of a single downstream temperature sensor.
Implementation Method 1
The temperature estimation module estimates a highest temperature of the particulate filter based on the outlet temperature, exhaust mass flow rate, catalyst brick mass, and heat transfer coefficients
Implementation Method 2
the particulate filter may be subject to exothermic heat released from an oxidizing reaction of HC in the oxidation catalyst that is provided upstream from the particulate filter
Implementation Method 3
oxidizing reaction of HC in the oxidation catalyst
Implementation Method 4
regeneration of the particulate filter includes oxidizing soots or particulates trapped on surfaces of the catalyst bricks. Oxidizing the soots or particulates releases heat to the surfaces of the catalyst bricks
Data Source
AI summary
An exhaust control system includes a temperature sensor, a temperature estimation module, and an exhaust condition adjustment module. The temperature sensor measures an outlet temperature of an exhaust gas downstream from an emission reduction device. The temperature estimation module estimates a highest temperature of the emission reduction device. The exhaust condition adjustment module controls operation of the exhaust control system based on the highest temperature of the emission reduction device.