APPARATUS, SYSTEM, AND METHOD FOR RAPID DESIGN OF EMISSIONS COMPONENT INSTALLATIONS

• US 20080156569A1
• Filed: 12/29/2006
• Published: 07/03/2008
• Est. Priority Date: 12/29/2006
• Status: Active Grant

• Current Assignee: Cummins Filtration Incorporated (Cummins Incorporated)
• Original Assignee: Cummins Filtration Incorporated (Cummins Incorporated)
• Inventors: Clevenger, John W., Senetar, Michael J., Sarcona, David, Gibson, Donald A.
• Granted Patent: US 8,296,949 B2
• Time in Patent Office: Days
• US Class Current: 180/296
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 13/08 Other arrangements or adaptations of exhaust conduits pipes, joints or supports therefor in general F16L; collecting or removing exhaust gases of vehicle engines in workshops B08B15/00, on highways E01C1/005
• CPC Class Codes: F01N 2450/00 Methods or apparatus for fitting, inserting or repairing different elements
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• 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: Y10T 29/49398 Muffler, manifold or exhaust pipe making
• CPC Class Codes: Y10T 29/5185 Tube making
• CPC Class Codes: Y10T 29/5199 Work on tubes
• CPC Class Codes: Y10T 29/53652 Tube and coextensive core

Abstract

An apparatus, system, and method are disclosed for rapid design of emissions component installations. The method assists in the rapid design of emissions component installations by: interpreting a tube design input which may be an exhaust pipe with one or more aftertreatment components, calculating a final tube design and tube drawing, determining the manufacturability of the final tube design, determining the manufacturing cost of the final tube design, and displaying the drawing, manufacturability result, and manufacturing cost to a user. The method also evaluates the final tube design for portions that can be replaced with a more cost effective alternative. The method also receives the emissions reduction features of the installation from the user, and recommends secondary components to mitigate operational consequences, such as reduced fuel economy or reduced oil change intervals, of the emissions reduction features. Thus, the invention allows a user to quickly design an installation of an emissions component with an internal combustion engine into a target application.

Claims

1. An apparatus to design a tubing configuration comprising:

a tube configuration module configured to interpret a tube design input, the tube design input comprising point locations, bend criteria, and end conditions;

a tube calculator module configured to calculate a final tube design based on the tube design input; and

a display module configured to display the final tube design to a user.

2. The apparatus of claim 1, further comprising a user interface module configured to receive the tube design input from the user and provide the tube design input to the tube configuration module.

3. The apparatus of claim 2, further comprising a complexity verification module configured to determine whether the tube design input exceeds a complexity threshold, and to prompt the user to simplify the tube design input if the tube design input exceeds the complexity threshold.

4. The apparatus of claim 1, further comprising a design integrity module configured to set an error indicator if the tube design input does not comprise a minimum set of information.

5. The apparatus of claim 1, further comprising a design compatibility detection module configured to set a conflict indicator if the tube design input comprises one of a conflicting design input and an erroneous design input.

6. The apparatus of claim 1, wherein the end conditions comprise at least one member selected from the group consisting of a flare definition, a dent condition, a slot type, a threading specification, specifications for a half couple, and a size change adapter.

7. The apparatus of claim 1, wherein the tube design input further comprises at least one aftertreatment component.

8. The apparatus of claim 1, wherein the tube design input further comprises at least one member selected from the group consisting of a tube outer diameter, a tube wall thickness, and a tube material.

9. The apparatus of claim 1, wherein the tube comprises a material comprising a member selected from the group consisting of aluminum, steel, copper, plastic, rubber, and silicone.

10. The apparatus of claim 1, wherein the tube design input further comprises at least one member selected from the group consisting of a tube coating, a tube interior finish, and a tube exterior finish.

11. The apparatus of claim 1, wherein the tube design input further comprises a cross-sectional shape of the tube, the cross-sectional shape of the tube comprising a member selected from the group consisting of a square, a rectangle, a parallelogram, a triangle, an ellipse, and a circle.

12. The apparatus of claim 2, further comprising a manufacturing module configured to determine the final tube design manufacturability, a costing module configured to determine a manufacturing cost of the final tube design, and wherein the display module is further configured to display the manufacturing cost to the user.

13. The apparatus of claim 12, wherein the costing module is further configured to update the manufacturing cost in response to user-entered changes in the tube design input.

14. The apparatus of claim 13, further comprising an optimization module configured to alert the user when a user-entered change in the tube design input contributes a threshold amount to the manufacturing cost.

15. The apparatus of claim 14, wherein the optimization module is further configured to determine a tube design input alternative, similar to the user-entered change in the tube design input that contributes a threshold amount to the manufacturing cost, such that the tube design alternative contributes less than the threshold amount to the manufacturing cost, and wherein the threshold amount comprises a member selected from the group consisting of an absolute amount of money, a percentage of cost higher than the cost of an available alternative, and a percentage of the manufacturing cost.

16. The apparatus of claim 12, wherein the user interface module is further configured to receive a desired quantity from the user, and wherein the costing module is further configured determine the manufacturing cost based on the desired quantity and a plant capacity.

17. The apparatus of claim 1, wherein the display module is further configured to display one of a drawing suitable for manufacture of the final tube design, and drawing data suitable to specify a drawing of the final tube design in a computer aided design program.

18. The apparatus of claim 17, wherein the display module is further configured to update the one of a drawing suitable for manufacture of the final tube design, and drawing data suitable to specify a drawing of the final tube design in a computer aided design program, in response to user-entered changes in the tube design input.

19. The apparatus of claim 1, wherein the final tube design comprises a design for a tube comprising a fluid conduit for an application.

20. The apparatus of claim 1, wherein the final tube design comprises a design for a tube comprising a structural element of an application.

21. The apparatus of claim 2, further comprising:

an emissions challenge module configured to store a set of operational challenges corresponding to a set of emissions reduction features, and further configured to store a set of operational challenges addressed corresponding to a set of secondary components; and

a secondary component selection module configured to;

interpret a user-specified emissions scheme comprising at least one emissions reduction feature;

provide the set of emissions reduction features to the emissions challenge module;

receive at least one secondary component recommendation from the emissions challenge module such that the at least one secondary component recommendation addresses at least one of the set of operational challenges corresponding to the at least one emissions reduction feature; and

provide the at least one secondary component recommendation to the display module;

wherein the display module is further configured to display the at least one secondary component recommendation to the user.

22. The apparatus of claim 21, wherein the set of emissions reduction features comprises at least one member selected from the group consisting of high pressure fuel injection, multiple fuel injections, exhaust gas recirculation (EGR), a diesel oxidation catalyst (DOC), a NO_x adsorption catalyst, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) system, a three-way catalyst, and a four-way catalyst, an ultra-low sulfur fuel requirement, and a low crankcase emissions requirement.

23. The apparatus of claim 21, wherein the set of secondary components comprises at least one member selected from the group consisting of an improved lubricity fuel filter, a fuel filter with improved fuel water separation, a fuel-borne catalyst additive filter, an acid-neutralizing lubrication filter, a micro-screen bypass lubrication filter, a centrifuge lubrication filter, an ultra-low ash oil specification, an open crankcase ventilation filter, a closed crankcase ventilation filter, and an enhanced air intake system.

24. A method for rapid design of an emissions component installation comprising:

receiving a tube design input from a user, the tube design input comprising point locations, bend criteria, and end conditions;

interpreting the tube design input;

calculating a final tube design;

determining the manufacturability of the final tube design;

determining the manufacturing cost of the final tube design; and

displaying the final tube design, the manufacturing cost, and a drawing suitable for manufacture of the final tube design to the user.

25. The method of claim 24, further comprising determining whether the tube design input exceeds a complexity threshold, and prompting the user to simplify the tube design input if the tube design input exceeds the complexity threshold.

26. The method of claim 24, further comprising determining whether the tube design input one of a conflicting design input, an erroneous design input, and a tube design input comprising less than a minimum set of information.

27. The method of claim 24, further comprising updating the manufacturing cost and the drawing suitable for manufacture in response to user-entered changes in the tube design input.

28. The method of claim 27, further comprising alerting the user when a user-entered change in the tube design input contributes a threshold amount to the manufacturing cost.

29. The method of claim 24, further comprising interpreting a user-specified emissions scheme, determining at least one secondary component recommendation based on the emissions scheme, and displaying the at least one secondary component recommendation to the user.

30. An apparatus for rapidly addressing emissions component challenges comprising:

an emissions challenge module configured to store a set of operational challenges corresponding to a set of emissions reduction features, and further configured to store a set of operational challenges addressed corresponding to a set of secondary components; and

a secondary component selection module configured to;

interpret a user-specified emissions scheme comprising at least one emissions reduction feature;

provide at least one emissions reduction feature to the emissions challenge module;

receive at least one secondary component recommendation from the emissions challenge module such that at least one secondary component recommendation addresses at least one operational challenge corresponding to at least one emissions reduction feature; and

provide at least one secondary component recommendation to the display module;

wherein the display module is further configured to display at least one secondary component recommendation to the user.

31. The apparatus of claim 30, wherein the set of emissions reduction features comprises at least one member selected from the group consisting of high pressure fuel injection, multiple fuel injections, exhaust gas recirculation (EGR), a diesel oxidation catalyst (DOC), a NO_x adsorption catalyst, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) system, a three-way catalyst, and a four-way catalyst, an ultra-low sulfur fuel requirement, and a low crankcase emissions requirement.

32. The apparatus of claim 30, wherein the set of secondary components comprises at least one member selected from the group consisting of an improved lubricity fuel filter, a fuel filter with improved fuel water separation, a fuel-borne catalyst additive filter, an acid-neutralizing lubrication filter, a micro-screen bypass lubrication filter, a centrifuge lubrication filter, an ultra-low ash oil specification, an open crankcase ventilation filter, a closed crankcase ventilation filter, and an enhanced air intake system.

33. A system for rapid design of an emissions component installation, the system comprising:

an internal combustion engine;

a user-specified emissions scheme comprising at least one emissions reduction feature;

a user-specified tube design input comprising point locations, bend criteria, and end conditions;

an emissions component installation design tool, the emissions component installation design tool comprising at least one member selected from the group consisting of a tube configuration tool and a secondary component selection tool;

wherein the tube configuration tool is configured to;

interpret the tube design input;

calculate a final tube design based on the tube design input;

display the final tube design to a user; and

wherein the secondary component selection tool is configured to;

interpret a user-specified emissions scheme comprising at least one emissions reduction feature; and

determine at least one secondary component that addresses at least one operational challenge corresponding to the at least one emissions reduction feature.

34. The system of claim 33, wherein the at least one emissions reduction feature comprises at least one member selected from the group consisting of wherein the set of emissions reduction features comprises at least one member selected from the group consisting of high pressure fuel injection, multiple fuel injections, exhaust gas recirculation (EGR), a diesel oxidation catalyst (DOC), a NO_x adsorption catalyst, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) system, a three-way catalyst, and a four-way catalyst, an ultra-low sulfur fuel requirement, and a low crankcase emissions requirement.

35. The system of claim 33, wherein the at least one secondary component comprises at least one member selected from the group consisting of an improved lubricity fuel filter, a fuel filter with improved fuel water separation, a fuel-borne catalyst additive filter, an acid-neutralizing lubrication filter, a micro-screen bypass lubrication filter, a centrifuge lubrication filter, an ultra-low ash oil specification, an open crankcase ventilation filter, a closed crankcase ventilation filter, and an enhanced air intake system.

36. A method to enhance an emissions component installation design, the method comprising:

executing an emissions component installation design tool, the emissions component installation design tool comprising at least one member selected from the group consisting of a tube configuration tool and a secondary component selection tool;

wherein the tube configuration tool is configured to;

interpret a tube design input comprising point locations, bend criteria, and end conditions;

calculate a final tube design based on the tube design input; and

display the final tube design to a user; and

wherein the secondary component selection tool is configured to;

interpret a user-specified emissions scheme comprising at least one emissions reduction feature;

determine at least one secondary component that addresses at least one operational challenge corresponding to the at least one emissions reduction feature; and

display the at least one secondary component to the user.

37. The method of claim 36, wherein the tube configuration tool is further configured to:

evaluate the final tube design for alternative embodiments of the tube design input;

generate a tube design input alternative such that the tube design input alternative costs less than the tube design input; and

display the tube design input alternative to the user.