System and method for NOx reduction optimization

• US 7,861,518 B2
• Filed: 01/19/2006
• Issued: 01/04/2011
• Est. Priority Date: 01/19/2006
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Federle, Ken R.
• Primary Examiner(s): NGUYEN, TU MINH
• Application Number:
  US11/334,735
• Publication Number:
  US 20070163244A1
• Time in Patent Office: 1,811 Days
• Field of Search: 602/74, 602/77, 602/85, 602/86, 701/123
• US Class Current: 60/286
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 2610/146 Control thereof, e.g. control of injectors or injection valves
• CPC Class Codes: F01N 2900/08 said parameters being related to the engine
• CPC Class Codes: F01N 2900/102 Travelling distance
• CPC Class Codes: F01N 2900/12 said parameters being related to the vehicle exterior
• CPC Class Codes: F01N 2900/1812 Flow rate
• CPC Class Codes: F01N 2900/1814 Tank level
• CPC Class Codes: F01N 3/208 Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
• CPC Class Codes: F02D 2200/0625 Fuel consumption, e.g. measured in fuel liters per 100 kms or miles per gallon
• CPC Class Codes: F02D 41/005 according to engine operating conditions
• CPC Class Codes: F02D 41/0235 in relation with the state of the exhaust gas treating apparatus control of exhaust gas treating apparatus per se F01N
• CPC Class Codes: F02D 41/1406 with use of a optimisation method, e.g. iteration
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

An engine controller determines the cost of operating a combustion engine and the cost of operating an emissions after-treatment device. Accordingly, the engine controller adjusts parameters for operation of the engine and the after-treatment device to ensure cost-effective use of the engine and the after-treatment device while complying with exhaust emissions requirements. In particular, the engine controller receives the price of fuel consumed by the engine and the price of reductant used by the after-treatment device to determine the respective cost of operation. Specifically, the fuel is diesel fuel used in a diesel engine; the reductant is urea use in a urea-based Selective Catalytic Reduction (SCR) system; and the regulated exhaust emissions is nitrogen oxide (NOx) emissions. The engine operating parameters may include cooled exhaust gas recirculation airflow, fuel injection timing, fuel injection pressure, and air-to-fuel ratio. The SCR system operating parameters may include the volume of urea injected.

Claims

1. A method for controlling exhaust emissions from a combustion engine, the method comprising:

determining a cost to operate a combustion engine including receiving a fuel price and a cost to operate an after-treatment device including receiving a reductant price;

comparing the cost to operate the combustion engine with the cost to operate the after-treatment device; and

at least one of adjusting one or more engine operating parameters and adjusting one or more after-treatment parameters, at least partially based on the comparison of the cost to operate the engine with the cost to operate the after-treatment device,

wherein the one or more engine operating parameters determine a first mixture of exhaust emissions after combustion of fuel by the combustion engine, said one or more engine operating parameters comprising at least one of a fuel injector timing, an air-to-fuel ratio, an injection pressure, and a cooled exhaust gas recirculation airflow, and

wherein the one or more after-treatment parameters determine a second mixture of exhaust emissions converted from the first exhaust emissions by the exhaust after-treatment device including a selective catalytic reduction device adapted to inject a reductant into the first exhaust emissions, said one or more after-treatment parameters comprising a reductant injection volume.

2. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the combustion engine is a diesel engine and the fuel is diesel fuel.

3. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the step of determining the cost to operate the engine includes receiving a fuel price through a manual input device.

4. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the step of determining the cost to operate the engine includes receiving a fuel price through an automated network.

5. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the reductant is urea.

6. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the step of determining the cost to operate the after-treatment device includes receiving a reductant price through a manual input device.

7. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the step of determining the cost to operate the after-treatment device includes receiving a reductant price through an automated network.

8. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein if the cost of operating the engine is greater than the cost to operate the after-treatment device, the step of at least one of adjusting the one or more engine operating parameters and adjusting the one or more after-treatment parameters includes at least one of advancing the fuel injector timing, increasing the air-to-fuel ratio, increasing the fuel injection pressure, decreasing the cooled exhaust gas recirculation airflow, and increasing the reductant injection volume.

9. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein if the cost of operating the engine is less than the cost to operate the after-treatment device, the step of at least one of adjusting the one or more engine operating parameters and adjusting the one or more after-treatment parameters includes at least one of retarding the fuel injector timing, decreasing the air-to-fuel ratio, decreasing the fuel injection pressure, increasing the cooled exhaust gas recirculation airflow, and decreasing from the reductant injection volume.

10. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the step of determining a cost to operate a combustion engine and a cost to operate an after-treatment device includes receiving sensor data from the engine and the after-treatment device.

11. The method for controlling exhaust emissions from a combustion engine according to claim 1, further comprising determining an optimal rate of reductant usage, and wherein the step of adjusting the one or more after-treatment parameters includes at least adjusting reductant usage to a rate not greater than the optimal rate of reductant usage.

12. The method for controlling exhaust emissions from a combustion engine according to claim 11, further comprising before the step of determining an optimal rate of reductant usage, receiving input data indicating a volume of available urea and a number of route miles to be driven using the engine.

13. The method for controlling exhaust emissions from a combustion engine according to claim 1, wherein the step of at least one of adjusting the one or more engine operating parameters and adjusting the one or more after-treatment parameters is based partially further on a limit for an amount of a part in the second mixture of exhaust emissions.

14. The method for controlling exhaust emissions from a combustion engine according to claim 13, wherein the part in the second mixture of exhaust emissions comprises nitrogen oxides.

15. A system for controlling exhaust emissions from a combustion engine, the system comprising:

a combustion engine adapted to produce a first mixture of exhaust emissions after combustion of fuel according to one or more engine operating parameters;

an exhaust after-treatment device including a selective catalytic reduction device adapted to convert the first exhaust emissions to a second mixture of exhaust emissions according to one or more after-treatment parameters, said selective catalytic reduction device adapted to inject a reductant into the first exhaust emissions; and

an engine controller adapted to control the engine and the after-treatment device,

wherein the engine controller receives a fuel price to determine a cost to operate the engine and receives a reductant price to determine a cost to operate the after-treatment device, compares the cost to operate the engine with the cost to operate the after-treatment device, and at least one of adjusts the one or more engine operating parameters and adjusts the one or more after-treatment parameters, at least partially based on the comparison of the cost to operate the engine with the cost to operate the after-treatment device, wherein the one or more engine operating parameters comprises at least one of a fuel injector timing, an air-to-fuel ratio, an injection pressure, and a cooled exhaust gas recirculation airflow, and the one or more after-treatment parameters comprises a reductant injection volume.

16. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the engine is a diesel engine and the fuel is diesel fuel.

17. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the reductant is urea.

18. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the reductant price is entered into the engine controller through a manual input device.

19. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the reductant price is entered into the engine controller through an automated network.

20. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein if the cost of operating the engine is greater than the cost to operate the after-treatment device, the engine controller at least one of adjusts the one or more engine operating parameters and adjusts the one or more after-treatment parameters by at least one of advancing the fuel injector timing, increasing the air-to-fuel ratio, increasing the fuel injection pressure, decreasing the cooled exhaust gas recirculation airflow, and increasing the reductant injection volume.

21. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein if the cost of operating the engine is less than the cost to operate the after-treatment device, the engine controller at least one of adjusts the one or more engine operating parameters and adjusts the one or more after-treatment parameters by at least one of retarding the fuel injector timing, decreasing the air-to-fuel ratio, decreasing the fuel injection pressure, increasing the cooled exhaust gas recirculation airflow, and decreasing from the reductant injection volume.

22. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the engine controller receives sensor data from the engine and the after-treatment device.

23. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the engine controller further determines an optimal rate of reductant usage, and wherein the engine controller adjusts the one or more after-treatment parameters by at least adjusting reductant usage to a rate not greater than the optimal rate of reductant usage.

24. The system for controlling exhaust emissions from a combustion engine according to claim 23, wherein the engine controller receives input data indicating a volume of available urea and a number of route miles to be driven by the system.

25. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the engine controller at least one of adjusts the one or more engine operating parameters and adjusts the one or more after-treatment parameters, based partially further on a limit for an amount of a part in the second mixture of exhaust emissions.

26. The system for controlling exhaust emissions from a combustion engine according to claim 25, wherein the part in the second mixture of exhaust emissions comprises nitrogen oxides.

27. The system for controlling exhaust emissions from a combustion engine according to claim 15, wherein the engine controller receives a fuel price to determine the cost to operate the engine.

28. The system for controlling exhaust emissions from a combustion engine according to claim 27, wherein the fuel price is entered into the engine controller through a manual input device.

29. The system for controlling exhaust emissions from a combustion engine according to claim 27, wherein the fuel price is entered into the engine controller through an automated network.