Working Machine Manual Regeneration Control
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Solution Overview
Problem
Existing exhaust gas treatment systems for diesel engines face challenges in efficiently and reliably performing manual regeneration of diesel particulate filters, particularly in cold weather conditions, which can lead to decreased work efficiency and reliability due to prolonged warm-up times and potential flame-out issues.
Innovation Solution
A working machine equipped with a manual regeneration system that utilizes a variable displacement hydraulic pump and a controller to selectively adjust engine revolution speed, hydraulic pump displacement volume, and discharge pressure to rapidly increase cooling water and exhaust temperatures, allowing for simple and efficient manual regeneration of the filter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cooling water temperature is increased to a preset temperature Tw0 or higher before compulsory regeneration, then flame-out is prevented and regeneration reliability is improved, but the warm-up time increases and work efficiency decreases
Solution Approach 1:
The system performs preliminary detection of cooling water temperature before initiating compulsory regeneration. When the temperature is below the preset Tw0, the system preemptively starts warm-up operations using the hydraulic pump to increase engine load, ensuring temperature conditions are met before regeneration begins, thus preventing flame-out while minimizing delay
Solution Approach 2:
The system dynamically adjusts the engine load through variable displacement hydraulic pump control during the warm-up phase. By modulating the pump displacement based on real-time temperature feedback, the system optimizes the heating rate to reach Tw0 as quickly as possible without excessive fuel consumption or prolonged warm-up time
2Adaptability or versatility
If a manual regeneration system is installed in working machines with hydraulic pumps, then regeneration can be performed at arbitrary timing, but the system complexity increases and installation difficulty rises
Solution Approach 1:
The system utilizes the existing variable displacement hydraulic pump, which is already a standard component in working machines, to serve dual purposes: normal hydraulic operations and warm-up operations for manual regeneration. This eliminates the need for dedicated warm-up hardware, reducing system complexity while maintaining regeneration flexibility
Solution Approach 2:
The system leverages the machine's own hydraulic pump and engine to generate the heat required for regeneration, rather than requiring external heating equipment. The hydraulic pump's variable displacement capability is repurposed to control engine load and exhaust temperature, making the system self-sufficient and easier to install
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 enables quick warm-up and efficient manual regeneration of the diesel particulate filter, preventing flame-out and reducing work inefficiencies, while simplifying the control processes and making it easier to install in real machines.
Implementation Method 1
a variable displacement hydraulic pump (11) and a controller (25), wherein the controller (25) controls at least one of a revolution speed (N) of the engine (1), a displacement volume (q) of the hydraulic pump (11), and a discharge pressure (P) of the hydraulic pump (11) to increase a cooling water temperature (Tw) and an exhaust temperature (Te) in a short period of time
Implementation Method 2
a diesel engine (1)... burning unburned fuel contained in exhaust gas to compulsorily increase the exhaust temperature to a regenerative temperature
Data Source
Figure 1
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Figure 4
AI summary
Provided is a working machine that is equipped with a manual regeneration system that can simply be controlled and enables warm-up in a short time. After a manual regeneration switch (22) is shifted to an ON-position and when cooling water temperature is lower than flame-out prevention temperature T1, a load control section (66) keeps at least one of the revolution speed (N) of an engine (1), the displacement volume (q) and discharge pressure (P) of a hydraulic pressure pump (11) at a corresponding first target value (N1, q1, or P1). In addition, after the manual regeneration switch is shifted to the ON-position and when the cooling water temperature is equal to or higher than T1, the load control section keeps at least one of the revolution speed (N) of the engine, the displacement volume (q) and discharge pressure (P) of the hydraulic pressure pump at a corresponding second target value (N2, q2, or P2). On the other hand, a regeneration control section (67) starts the compulsory regeneration after the manual regeneration switch (22) has been shifted to the ON-position and when the cooling water temperature is equal to or higher than T1.