Emission control system with frequency controlled induction heating and methods for use therewith

• US 10,590,818 B2
• Filed: 11/21/2017
• Issued: 03/17/2020
• Est. Priority Date: 11/24/2016
• Status: Active Grant

• Current Assignee: Advanced Technology Emission Solutions Inc
• Original Assignee: Advanced Technology Emission Solutions Inc
• Inventors: Crawford, Robin, Douglas, John
• Primary Examiner(s): Maines, Patrick D
• Application Number:
  US15/819,324
• Publication Number:
  US 20180142592A1
• Time in Patent Office: 847 Days
• Field of Search: 42218601, 42218603, 42218604
• CPC Class Codes: F01N 2330/06 Ceramic, e.g. monoliths
• CPC Class Codes: F01N 2330/18 Composite material
• CPC Class Codes: F01N 3/2013 using electric or magnetic heating means
• CPC Class Codes: F01N 3/202 using microwaves
• CPC Class Codes: F01N 3/2828 Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: F01N 9/00 Electrical control of exhaust gas treating apparatus monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00
• CPC Class Codes: H05B 6/108 for heating a fluid
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

Aspects of the subject disclosure may include, for example, an emission control system that includes an emission control device having a plurality of passages to facilitate emission control of an exhaust gas from a vehicle engine. A controller generates a control signal to initiate induction heating of the emission control device. An electromagnetic field generator responds to the control signal by generating a power signal applied to a coil to cause the induction heating of the emission control device, wherein a frequency of the power signal is adjusted to control a power transferred to the coil.

Claims

1. An emission control system comprising:

an emission control device having a plurality of passages to facilitate emission control of an exhaust gas from a vehicle engine;

a controller, that generates a control signal to initiate induction heating of the emission control device; and

an electromagnetic field generator having a coil, wherein the electromagnetic field generator responds to the control signal by generating a power signal applied to the coil to cause the induction heating of the emission control device, wherein a frequency of the power signal is adjusted to control a power transferred to the coil;

wherein the controller monitors a temperature of the electromagnetic field generator and wherein the controller generates the control signal to discontinue induction heating of the emission control device when the temperature of the electromagnetic field generator exceeds a temperature threshold.

2. The emission control system of claim 1 wherein the power signal is square wave signal.

3. The emission control system of claim 2 wherein the square wave signal has 50% duty cycle.

4. The emission control system of claim 1 wherein the electromagnetic field generator monitors a voltage of the power signal and adjusts the frequency of the power signal based on the voltage of the power signal to control the power transferred to the coil.

5. The emission control system of claim 1 wherein the control signal indicates a power set point, wherein the controller determines the power transferred to the coil, compares the power transferred to the coil to the power set point and adjusts the frequency of the power signal based on a comparison of the power transferred to the coil and the power set point.

6. The emission control system of claim 1 wherein the control signal indicates a power set point, wherein the electromagnetic field generator adjusts the frequency of the power signal by:

decreasing the frequency of the power signal when the power transferred to the coil is below the power set point; and

increasing the frequency of the power signal when the power transferred to the coil is above the power set point.

7. The emission control system of claim 1 wherein the frequency of the power signal is above a resonant frequency of the coil.

8. The emission control system of claim 1 wherein the frequency of the power signal is adjusted between a maximum frequency limit and a minimum frequency limit.

9. The emission control system of claim 8 wherein the maximum frequency limit is above a resonant frequency of the coil.

10. The emission control system of claim 8 wherein the minimum frequency limit is determined based on a resonant frequency of the coil.

11. The emission control system of claim 1 wherein the frequency of the power signal is adjusted in first frequency steps and second frequency steps, wherein the first frequency steps are larger than the second frequency steps.

12. The emission control system of claim 11 wherein the control signal indicates a power set point, and wherein the frequency of the power signal is adjusted in the first frequency steps in response to a change in the power set point.

13. The emission control system of claim 11 wherein the control signal indicates a power set point, and wherein the frequency of the power signal is adjusted in the second frequency steps in response to no change in the power set point.

14. The emission control system of claim 1 wherein the controller generates the control signal to initiate induction heating of the emission control device a predetermined time after start-up of an engine that contains the emission control device.

15. The emission control system of claim 1 wherein the controller generates the control signal to discontinue induction heating of the emission control device a predetermined time after induction heating of the emission control device is initiated.

16. The emission control system of claim 1 wherein the controller generates the control signal based on comparison of a temperature of the emission control device to a reference temperature.

17. The emission control system of claim 16 wherein the temperature of the emission control device is determined based on a temperature sensor or based on a change in impedance of the coil.

18. The emission control system of claim 1 wherein the controller generates the control signal to suspend induction heating of the emission control device in response to a no-load condition of the coil.

19. A method comprising:

generating, via a controller, a control signal to initiate induction heating of an emission control device;

generating, in response to the control signal and via an electromagnetic field generator that includes a coil, a power signal, wherein the power signal is applied to the coil to cause the induction heating of the emission control device;

adjusting a frequency of the power signal, to control a power transferred to the coil; and

monitoring, via the controller, a temperature of the electromagnetic field generator and wherein the controller generates the control signal to discontinue induction heating of the emission control device when the temperature of the electromagnetic field generator exceeds a temperature threshold.