U.S. patent application number 13/313573 was filed with the patent office on 2012-06-07 for temp-a-start regeneration system.
Invention is credited to Loran Sutton.
Application Number | 20120137658 13/313573 |
Document ID | / |
Family ID | 46160913 |
Filed Date | 2012-06-07 |
United States Patent
Application |
20120137658 |
Kind Code |
A1 |
Sutton; Loran |
June 7, 2012 |
Temp-A-Start Regeneration System
Abstract
A regeneration module is usable in conjunction with a diesel
engine to control the operation of a regeneration cycle of the
diesel engine. During the regeneration cycle, particulate matter
collected in or on a diesel particulate filter of the diesel engine
is removed to improve the operation of the diesel particulate
filter. In various embodiments, the regeneration module only
functions when manually activated by a user of the diesel engine
such that the regeneration cycle is only initiated during desirable
idle periods of the diesel engine.
Inventors: |
Sutton; Loran; (East Peoria,
IL) |
Family ID: |
46160913 |
Appl. No.: |
13/313573 |
Filed: |
December 7, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61420612 |
Dec 7, 2010 |
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Current U.S.
Class: |
60/274 ;
60/311 |
Current CPC
Class: |
F01N 2900/1606 20130101;
F01N 2900/0422 20130101; F01N 3/029 20130101; F01N 9/002 20130101;
F02D 41/1448 20130101; Y02T 10/40 20130101; F01N 2900/1406
20130101; F02D 41/029 20130101; F01N 2430/04 20130101; F01N 3/027
20130101; F01N 3/028 20130101; Y02T 10/47 20130101; F01N 2900/08
20130101; F02D 41/08 20130101 |
Class at
Publication: |
60/274 ;
60/311 |
International
Class: |
F01N 3/023 20060101
F01N003/023 |
Claims
1. A method for regenerating a diesel particulate filter comprises:
sending a request from an engine controller of a diesel engine to a
regeneration module; putting the diesel engine into a base idle
mode of operation; waiting for a first defined time period; closing
a regeneration switch; waiting for a second defined time period;
initiating a regeneration cycle of the engine controller; and
putting the diesel engine into a high idle mode of operation.
2. The method of claim 1, wherein initiating a regeneration cycle
of the engine controller comprises heating a diesel particulate
filter to at least a first desired temperature.
3. The method of claim 2, wherein heating a diesel particulate
filter comprises heating the diesel particulate filter to at least
the first desired temperature for a third defined time period.
4. The method of claim 1, wherein initiating a regeneration cycle
of the engine controller comprises activating an external heating
source.
5. The method of claim 1, wherein initiating a regeneration cycle
of the engine controller comprises adding an additive to at least
one of a fuel mixture, an exhaust line, and a diesel particulate
filter.
6. The method of claim 1, further comprising: measuring an
operating parameter of a diesel particulate filter; and determining
a regeneration status of the diesel particulate filter.
7. The method of claim 6, further comprising terminating the
regeneration cycle of the engine controller if the diesel
particulate filter is determined to be sufficiently
regenerated.
8. The method of claim 6, wherein measuring a regeneration quality
of a diesel particulate filter comprises measuring a pressure drop
across the diesel particulate filter.
9. The method of claim 8, wherein determining a regeneration status
of the diesel particulate filter comprises comparing the pressure
drop across the diesel particulate filter to a desired value.
10. The method of claim 6, wherein measuring an operating parameter
of a diesel particulate filter comprises measuring a mass of the
diesel particulate filter.
11. The method of claim 10, wherein determining a regeneration
status of the diesel particulate filter comprises comparing the
mass of the diesel particulate filter to a desired value.
12. The method of claim 6, wherein measuring an operating parameter
of a diesel particulate filter comprises measuring an efficiency of
filtration of the diesel particulate filter.
13. The method of claim 12, wherein measuring an efficiency of
filtration of the diesel particulate filter comprises comparing an
amount of particulate matter in an intake of the diesel particulate
filter to an amount of particulate matter in an exhaust from the
diesel particulate filter.
14. The method of claim 13, wherein determining a regeneration
status of the diesel particulate filter comprises comparing the
ratio of the amount of particulate matter in the exhaust from the
diesel particulate filter over the amount of particulate matter in
the intake of the diesel particulate filter to a desired value.
15. A system for regenerating a diesel particulate filter
comprises: a diesel engine that utilizes a diesel particulate
filter which is usable to remove at least some particulate matter
from an exhaust gas of the diesel engine during operation; a
regeneration module in communication with the engine controller;
and a manual switch in communication with the regeneration module
wherein the manual switch is usable to activate and deactivate the
regeneration module; wherein the regeneration module is usable to
receive a request from the engine controller to initiate a
regeneration cycle of the engine controller; and the regeneration
cycle is usable to remove particulate matter from the diesel
particulate filter.
16. The system of claim 15, further comprising: a heater usable to
raise the temperature of the diesel particulate filter to at least
a first desired temperature.
17. The system of claim 15, further comprising an injection system
usable to inject an additive into at least one of a fuel line, an
exhaust line, and the diesel particulate filter.
18. The system of claim 17, wherein the exhaust line is provided
between the diesel engine and the diesel particulate filter.
19. The system of claim 15, wherein the regeneration module is
usable to determine a condition of regeneration of the diesel
particulate filter.
20. The system of claim 19, wherein the regeneration module is in
communication with one or more sensor usable to determine at least
one operating condition of the diesel particulate filter and
wherein the at least one operating condition is usable to determine
the condition of regeneration of the diesel particulate filter.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. patent
application Ser. No. 61/420,612 filed on Dec. 7, 2010.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention:
[0003] This invention is related to a system, method, and apparatus
for regenerating a particulate filter. This invention is more
particularly related to a system, method, and apparatus for
regenerating a particulate filter for a heavy duty diesel
engine.
[0004] 2. Related Art:
[0005] Due, at least in part, to incomplete combustion, diesel
engines produce various amounts of particulate matter during
operation. This particulate matter may be dangerous to the
environment, an operator's health or otherwise undesirable.
Additionally, engine exhaust may be regulated by local and/or
federal laws such that removal of the particulate matter (e.g.,
pollutants) may be desirable and/or obligatory.
[0006] Removing particulate matter from engine exhaust often
involves the use of filters such as a diesel particulate filter. In
various embodiments, the engine exhaust is forced through the
diesel particulate filter depositing at least some of the
particulate matter on or in the diesel particulate filter. Over
time, particulate matter collects on the filter and the filter may
become less effective (e.g., by restricting flow of the engine
exhaust, reducing fuel economy, and/or by reducing the amount of
particulate matter that is removed from the engine exhaust). As
such, various types of diesel particulate filters are designed to
be replaced and/or regenerated. Failing to replace and/or
regenerate a diesel particulate filter may have an adverse effect
on engine performance, engine life expectancy, and/or other factors
related to the operation of the diesel engine.
BRIEF DESCRIPTION OF DRAWINGS
[0007] Various exemplary embodiments of the systems and methods
according to this invention will be described in detail, with
reference to the following figures, wherein:
[0008] FIG. 1 illustrates exemplary methods of connecting a
regeneration module to an engine controller such as an engine
control module;
[0009] FIG. 2 illustrates an exemplary schematic of a regeneration
module; and
[0010] FIG. 3 is a flow chart illustrating an exemplary method of
regenerating a particulate filter.
DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS
[0011] Regenerating a diesel particulate filter removes accumulated
particulate matter (e.g., soot) from the filter to improve the
operation of the diesel particulate filter (e.g., by reducing the
pressure drop across the filter, improving the efficiency of the
filter, etc.). Typically, the particulate matter is removed by
increasing the temperature of the diesel particulate filter and/or
the engine exhaust to a temperature sufficiently high enough to
cause the particulate matter to combust (e.g., burn off).
[0012] It should be appreciated that the temperature required to
combust the particulate matter will vary depending on the chemical
composition of that particulate matter, which itself may be
dependent on the chemical composition of the fuel used, additional
additives combined with the fuel and/or exhaust gas, and/or the
composition of the diesel particulate filter. In various
embodiments, it may be desirable to decrease the combustion
temperature below a critical threshold (e.g., the temperature at
which the diesel particulate filter may be compromised).
[0013] FIG. 1, illustrates exemplary methods of connecting a
regeneration module to an engine controller. As shown in FIG. 1,
the regeneration module may be connected to either a high side
driver or a low side driver of an engine controller (e.g., an
engine control module, an engine control unit, an electronic
control module, and/or the like). The engine controller manages the
operation of the engine. In various exemplary embodiments, the
engine controller manages various parameters of the engine, which
may be a diesel engine, such as, for example, rate of fuel flow,
ignition timing, and air intake. The engine controller may also
communicate with various sensors that monitor various parameters of
the engine, such as, for example, exhaust temperature, engine
temperature, engine speed, and/or any other desirable engine
parameter.
[0014] In various exemplary embodiments, if the engine controller
utilizes a low side driver, a diode kit is provided between the
regeneration module and the engine controller to prevent damage to
any other devices previously connected to the engine controller.
The diode kit may include, for example, a diode, one or more
resistors and/or any other desirable electrical component(s). The
regeneration module is also connected to an indicator, such as a
light emitting diode (LED) or the like, to indicate whether the
regeneration module is operating. In various exemplary embodiments,
a red LED indicates that the regeneration module is active but not
operating (e.g., in a standby mode). In various exemplary
embodiments, a green LED indicates that the regeneration module is
active and operating (e.g., a regeneration cycle is operating).
[0015] The regeneration module is designed to operate with a diesel
engine to automatically regenerate a diesel particulate filter only
when the diesel engine is idling. Additionally, the regeneration
module will only operate when selected by a user operated switch.
In various exemplary embodiments, an operator of a diesel engine,
such as, for example a truck driver, may engage the regeneration
module by activating a switch in a cab of the truck before leaving
the truck unattended. When engaged, the regeneration module
interrupts a regeneration cycle of the engine controller for
various time periods.
[0016] FIG. 2 shows an exemplary schematic of a regeneration
module. As shown in FIG. 2, the regeneration module is connected to
an engine controller of a diesel engine. As outlined above, the
regeneration module may be connected to either a high side or a low
side driver of the engine controller. A request is received by the
regeneration module (either via the "high side driver signal in" or
the "low side driver signal in") indicating that the engine
controller can initiate a regeneration cycle. As shown in FIG. 2,
the high side driver signal and the low side driver signal are
electronically isolated via one or more diodes. The regeneration
module processes the signal received from the engine controller and
controls an idle state of the diesel engine (e.g., by turning off a
high or fast idle state). The regeneration cycle then activates the
regeneration cycle, which is operated by the engine controller.
After the regeneration cycle is completed, the regeneration module
returns the engine to the high or fast idle state.
[0017] It should be appreciated that the schematic shown in FIG. 2
is exemplary. In various embodiments, the operation of the
regeneration module may be achieved via one or more integrated
circuits, discrete electrical components and/or any other suitable
known or later developed compatible electrical circuit.
[0018] FIG. 3 shows an exemplary embodiment of a method of
operation of a regeneration module (e.g., a stationary regeneration
cycle). As shown in FIG. 3, the stationary regeneration cycle
begins when the regeneration module receives a request for a
regeneration cycle. It should be appreciated that in various
exemplary embodiments the regeneration module may only receive a
stationary regeneration cycle if a manual switch, for example a
switch located in the cab of a diesel engine, has been turned on
(e.g., closed) by an operator of the diesel engine. In such
exemplary embodiments, the operator has control over whether a
stationary regeneration cycle will be executed. In various
exemplary embodiments, the regeneration module receives the request
from an engine controller of the diesel engine, such as, for
example, an engine control unit, an engine control module, an
electronic control unit, or the like. In various ones of these
exemplary embodiments, the engine controller sends the request to
the regeneration module via a high side driver. In various other
ones of these exemplary embodiments, the engine controller sends
the request to the regeneration module via a low side driver.
[0019] Upon receiving the request, the regeneration module
electronically opens a high idle switch, thereby ending a high idle
cycle of the diesel engine (e.g., returning the diesel engine to a
base idle condition). In various exemplary embodiments, a first
time period is begun. In various ones of these exemplary
embodiments, the first time period is, for example, a four second
time period. After the first time period is concluded, a
regeneration toggle is electronically closed for a second time
period. In various ones of these exemplary embodiments, the second
time period is, for example, a five second time period.
[0020] After the second time period has concluded, the engine
controller begins a regeneration cycle. During the regeneration
cycle, particulate matter collected in a diesel particulate filter
is heated to a point of combusting. By combusting the particulate
matter, it is removed from the diesel particulate filter thereby
returning the particulate filter to a more efficient mode of
operation (e.g., decreasing a pressure drop across the filter,
improving the efficiency at which particulate matter is collected
by the diesel particulate filter, and/or improving any other
parameter of the diesel particulate filter).
[0021] It should be appreciated that regenerating the diesel
particulate filter may have differing effects on various operating
parameters of the diesel particulate filter; each of which may be
considered in determining the efficiency of the diesel particulate
filter and the current regenerative condition of the diesel
particulate filter. For example, a diesel particulate filter may
remove more particulate matter before regeneration than after
regeneration due to the increased restriction caused by the
accumulated particulate matter. However, the increased restriction
caused by the accumulated particulate matter may have an
undesirable effect on other operating parameters of the diesel
particulate filter (e.g., by increasing a pressure drop across the
diesel particulate filter). As such, in various exemplary
embodiments, while one parameter may indicate an increased
efficiency (e.g., a greater amount of particulate matter being
removed by the diesel particulate filter), other parameters may
indicate that the diesel particulate filter should be desirable
regenerated. Likewise, an increase in the amount of particulate
matter removed by a diesel particulate filter may indicate that the
diesel particulate filter is nearing a point of use indicated by
maximum capacity of the diesel particulate filter; at which point
it may cease to remove any further particulate matter or otherwise
decrease in efficiency.
[0022] The engine controller operates the regeneration cycle until
conclusion. It should be appreciated that a regeneration cycle may
be concluded for any desirable reason. In various exemplary
embodiments, the regeneration cycle is concluded after a
predetermined time period. In various other exemplary embodiments,
the regeneration cycle is concluded when a predetermined amount
(e.g., volume) of particulate matter has been removed from the
diesel particulate filter. In yet other exemplary embodiments, the
regeneration cycle is concluded when the operation of the diesel
particulate filter has reached a predetermined level of
functionality or efficiency, such as, for example, when a pressure
drop across the filter has been reduced to a desirable level. After
the regeneration cycle is concluded, the high idle switch is
electronically closed, returning the diesel engine to a high idle
state and the method of operation is concluded.
[0023] It should be appreciated that the regeneration cycle of the
engine controller may utilize any suitable known or later developed
method of regeneration. For example, the diesel particulate filter
may be heated through an external source, such as, for example, a
microwave heater, additives may be introduced to the diesel
particulate filter, either directly or at an earlier point in the
engine exhaust system (e.g., as a fuel additive or an additive to
the exhaust line between the engine and the diesel particulate
filter) to decrease the combustion temperature of the particulate
filter, or the like.
* * * * *