Feedback control in selective catalytic reduction

• US 8,034,291 B2
• Filed: 01/23/2008
• Issued: 10/11/2011
• Est. Priority Date: 01/23/2008
• Status: Active Grant

• Current Assignee: Cummins Filtration Incorporated (Cummins Incorporated)
• Original Assignee: Cummins Filtration Incorporated (Cummins Incorporated)
• Inventors: Ma, Hongbin, McDaniel, Mickey R., Xi, Clyde, Qi, Baohua, Ogunleye, Hakeem
• Primary Examiner(s): Ramdhanie; Bobby
• Application Number:
  US12/018,583
• Publication Number:
  US 20090185954A1
• Time in Patent Office: 1,357 Days
• Field of Search: 422/62
• US Class Current: 422/62
• CPC Class Codes: F01N 2560/026 for measuring or detecting NOx
• CPC Class Codes: F01N 2560/06 the means being a temperature sensor
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 2900/0408 using a feed-back loop
• CPC Class Codes: F01N 2900/0411 using a feed-forward control
• CPC Class Codes: F01N 2900/0412 using pre-calibrated maps, tables or charts
• CPC Class Codes: F01N 2900/14 said parameters being related to the exhaust gas
• CPC Class Codes: F01N 3/208 Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An apparatus for introducing a reductant into an exhaust system is described. The apparatus includes a controller that generates a resulting dosing command used as an instruction to release an amount of reductant into the exhaust system. The controller includes a feedback control module that generates a weighing factor. The weighing factor is configured to be applied to a lower limit dosing command and configured to be applied to an upper limit dosing command, where the lower and upper limit dosing commands converted by the weighing factor are used by the controller to generate the resulting dosing command.

Claims

1. An apparatus for generating a dosing command for introducing a reductant into an exhaust system comprising:

at least one sensor configured to detect NO_x produced during engine combustion; and

a controller operatively connected with the at least one sensor, the controller configured to receive an output of the at least one sensor based on the NO_x detected by the at least one sensor, the controller configured to process the output from the at least one sensor and generate a resulting dosing command having an instruction to introduce a reductant into the exhaust system, the resulting dosing command including a lower limit dosing command, an upper limit dosing command, and a weighing factor, the weighing factor configured to be applied to the lower and upper limit dosing commands in a calculation to provide the resulting dosing command, such that the resulting dosing command is a value within end values of the lower and upper limit dosing commands.

2. The apparatus of claim 1, wherein the at least one sensor is operatively connected to an outlet of the exhaust system.

3. The apparatus of claim 1, wherein the controller comprises a feedback control module configured to receive the output from the at least one sensor and generate the weighing factor.

4. The apparatus of claim 3, wherein the feedback control module is configured to adjust the weighing factor and apply the weighing factor to the lower and upper limit dosing commands.

5. The apparatus of claim 3, wherein the feedback control module is a proportional-integral-derivative controller.

6. The apparatus of claim 1, wherein the controller is configured to periodically update the resulting dosing command.

7. The apparatus of claim 1, wherein the controller further comprising at least one look-up table as an input for generating the weighing factor when the at least one sensor fails or when the resulting dosing command is not updated for a period of time.

8. The apparatus of claim 7, wherein the look-up table comprising an engine speed input and a total fueling input.

9. The apparatus of claim 1, wherein the weighing factor, a value of which varies between 0 and 1, applied to the upper limit dosing command comprising a product of the upper limit dosing command (limit cmd) and the weighing factor (factor), according to the formula:

limit cmd*factor, and

the weighing factor applied to the lower limit dosing command comprising a product of the lower limit dosing command (feedforward cmd) and the difference of 1 and the weighing factor (1−

factor), according to the formula;

feed-forward cmd*(1−

factor).

10. The apparatus of claim 1, wherein the lower limit dosing command comprising a calculation based on an emission target for the exhaust system, and the upper limit dosing command comprising a calculation based on a maximum allowed ammonia slip.

11. The apparatus of claim 10, wherein the maximum allowed ammonia slip is about 25 ppm or less.

12. The apparatus of claim 1, wherein the upper limit dosing command is generated based on linear calculations of at least one ammonia to NO_x ratio.

13. The apparatus of claim 12, wherein the upper limit dosing command is generated based on a result examination process configured to examine whether the linear calculations are valid, and configured to select a valid linear calculation result as the upper limit dosing command.

24. An exhaust system comprising the apparatus of claim 1;

a selective catalyst reduction device that includes an inlet and an outlet, where the at least one sensor is connected to the outlet; and

a doser operatively connected to the controller and connected to the selective catalyst reduction device, the doser is configured to receive the resulting dosing command and is configured to introduce the reductant into the inlet of the selective catalyst reduction device and based on the resulting dosing command.

14. A method of generating a dosing command to introduce a reductant into an exhaust system comprising:

detecting NO_x produced during engine combustion with a sensor;

receiving an output of the NO_x detected by the sensor with a controller;

processing the output with the controller to generate a dosing command that comprises;

calculating a lower limit dosing command with the controller, the lower limit dosing command comprising a calculation based on a maximum allowed NO_x emission for the exhaust system;

calculating an upper limit dosing command with the controller, the upper limit dosing command comprising a calculation based on a maximum allowed ammonia slip;

generating a weighing factor with the controller, the weighing factor comprising a calculation based on a detected NO_x output;

processing the lower limit and upper limit dosing commands with the controller using the weighing factor; and

generating a resulting dosing command with the controller based on a calculation of the processed lower limit and upper limit dosing commands, the resulting dosing command being a value within end values of the lower and upper limit dosing commands.

15. The method of claim 14, wherein generating the weighing factor comprising receiving an output from the sensor using a feedback control module, calculating the weighing factor using the output from the sensor, and delivering the weighing factor to the controller to process the lower limit and upper limit dosing commands using the weighing factor.

16. The method of claim 14, wherein generating the resulting dosing command comprises periodically updating the resulting dosing command.

17. The method of claim 14, wherein generating the resulting dosing command comprises using at least one look-up table as an input for generating the weighing factor when the sensor fails or when the resulting dosing command is not updated for a period of time.

18. The method of claim 17, wherein the look-up table comprising an engine speed input and a total fueling input.

19. The method of claim 14, wherein the lower limit dosing command comprising a calculation based on an emission target for the exhaust system, and the upper limit dosing command comprising a calculation based on a maximum allowed ammonia slip.

20. The method of claim 19, wherein the maximum allowed ammonia slip is about 25 ppm or less.

21. The method of claim 14, wherein calculating the upper limit dosing command further comprises performing linear calculations of at least one ammonia to NO_x ratio.

22. The method of claim 21, further comprising examining the validity of assumptions for the linear calculations, and selecting a valid linear calculation result as the upper limit dosing command.

23. A selective catalyst reduction exhaust system comprising:

a selective catalyst reduction device including an inlet and an outlet;

at least one sensor operatively connected to the outlet of the selective catalyst reduction device, the at least one sensor configured to detect NO_x produced during engine combustion;

a controller operatively connected with the at least one sensor, the controller configured to receive an output of the at least one sensor based on the NO_x detected by the at least one sensor, the controller configured to process the output from the at least one sensor and generate a resulting dosing command having an instruction to introduce a reductant into the exhaust system, the resulting dosing command including a lower limit dosing command, an upper limit dosing command, and a weighing factor, the weighing factor configured to be applied to the lower and upper limit dosing commands, the weighing factor configured to convert the lower and upper limit dosing commands to end values of the resulting dosing command; and

a doser operatively connected to the controller and connected to the selective catalyst reduction device, the doser configured to receive the resulting dosing command and configured to introduce the reductant into the exhaust system at the inlet of the selective catalyst reduction device and based on the resulting dosing command.