Methods for estimating particulate load in a particulate filter, and related systems

• US 8,069,658 B2
• Filed: 11/26/2008
• Issued: 12/06/2011
• Est. Priority Date: 11/26/2008
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: He, Suhao, Heibel, Achim Karl-Erich, Tandon, Pushkar
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): Shanske, Jason
• Application Number:
  US12/324,090
• Publication Number:
  US 20100126145A1
• Time in Patent Office: 1,105 Days
• Field of Search: 602/95, 552/823, 554/281, 55D/IG.10, 952/83
• US Class Current: 60/295
• CPC Class Codes: F01N 2900/0601 being estimated
• CPC Class Codes: F01N 2900/1606 Particle filter loading or soot amount
• CPC Class Codes: F01N 2900/1611 Particle filter ash amount
• CPC Class Codes: F01N 9/002 of filter regeneration, e.g. detection of clogging
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A method for regenerating a particulate filter may comprise calculating a first estimated soot load of a particulate filter based on a pressure drop of an exhaust gas flowing through the particulate filter, and calculating a second estimated soot load of the particulate filter based on a mass balance of soot in the particulate filter. The method may further comprise calculating a hybrid estimated soot load based on the first estimated soot load and the second estimated soot load, wherein calculating the hybrid estimated soot load comprises applying at least one gate so as to weight a relative contribution of each of the first estimated soot load and the second estimated soot load to the hybrid estimated soot load, and causing regeneration of the particulate filter when the hybrid estimated soot load is greater than or equal to a threshold value.

Claims

1. A method for regenerating a particulate filter, comprising:

calculating a first estimated soot load of a particulate filter based on a pressure drop of an exhaust gas flowing through the particulate filter;

calculating a second estimated soot load of the particulate filter based on a mass balance of soot in the particulate filter;

calculating a hybrid estimated soot load based on the first estimated soot load and the second estimated soot load, wherein calculating the hybrid estimated soot load comprises selectively applying at least one gate to the first estimated soot load and the second estimated soot load depending on periods of accuracy of calculating each of the first estimated soot load and the second estimated soot load, so as to weight a relative contribution of each of the first estimated soot load and the second estimated soot load to the hybrid estimated soot load; and

causing regeneration of the particulate filter when the hybrid estimated soot load is greater than or equal to a threshold value.

2. The method of claim 1, wherein the at least one gate is selected from at least one of exhaust temperature, exhaust flow rate, bed temperature, soot uniformity, pressure drop, oxidation rate, soot load rate, flow stability, pressure stability, filter history, and regeneration conditions.

3. The method of claim 1, wherein calculating the first estimated soot load comprises determining a temperature, a flow rate, and a pressure drop of the exhaust gas flowing through the particulate filter.

4. The method of claim 3, wherein determining the pressure drop of the exhaust gas comprises determining a total pressure drop of the exhaust gas.

5. The method of claim 4, wherein determining the total pressure drop of the exhaust gas comprises determining inlet contraction losses, outlet expansion losses, inlet channel losses, outlet channel losses and permeable layer losses of the exhaust gas.

6. The method of claim 3, wherein calculating the first estimated soot load further comprises determining a corrected soot layer permeability.

7. The method of claim 6, wherein determining the corrected soot layer permeability comprises determining a Stokes-Cunningham correction factor to soot layer permeability.

8. The method of claim 1, wherein calculating the second estimated soot load comprises calculating an amount of soot mass change in the particulate filter based on soot influx and soot burnout by regeneration.

9. The method of claim 1, further comprising calculating an estimated ash load of the particulate filter.

10. The method of claim 9, wherein calculating an estimated ash load comprises:

calculating a first estimated ash load of the particulate filter based on a pressure drop in the particulate filter;

calculating a second estimated ash load of the particulate filter based on a mass balance of soot in the particulate filter; and

calculating a hybrid estimated ash load based on the first estimated ash load and the second estimated ash load, wherein calculating the hybrid estimated ash load comprises applying at least one gate to weight a relative contribution of each of the first estimated ash load and the second estimated ash load to the hybrid estimated ash load.

11. The method of claim 1, further comprising applying one or more filters to filter dynamic fluctuations corresponding to the hybrid estimated soot load.

12. The method of claim 1, wherein the at least one gate is selected such that the relative contribution of each of the first estimated soot load and the second estimated soot load respectively ranges from 0 to 100 percent of the hybrid soot load.

13. A system for estimating soot load in a particulate filter, comprising:

a temperature sensor, a pressure drop sensor, and at least one engine sensor; and

at least one controller configured to receive signals from the temperature sensor, the pressure drop sensor, and the at least one engine sensor, and dynamically calculate both a pressure drop based soot load estimate and a mass balance based soot load estimate based on the signals, wherein the controller is configured to selectively apply at least one gate to the pressure drop based soot load estimate and the mass balance based soot load estimate depending on periods of accuracy of calculating each of the pressure drop-based soot load estimate and the mass balance-based soot load estimate to weight a relative contribution of each of the pressure drop based soot load estimate and the mass balance based soot load estimate to determine a hybrid soot load estimate.

14. The system of claim 13, wherein the controller is configured to apply the at least one gate to suppress one of the pressure drop based soot load estimate and the mass balance based soot load estimate to determine the hybrid soot load estimate.

15. The system of claim 13, wherein the at least one gate is selected such that the relative contribution of each of the pressure drop based soot load estimate and the mass balance based soot load estimate ranges from 0 to 100 percent of the hybrid soot load estimate.

16. The system of claim 13, wherein the at least one controller is configured to estimate an ash load in the particulate filter.

17. The system of claim 13, wherein the at least one controller is configured to apply at least one filter to filter dynamic fluctuations corresponding to the hybrid soot load estimate.

18. The system of claim 17, wherein the at least one controller is configured to generate at least one response signal causing regeneration of the particulate filter when the hybrid soot load estimate is greater than or equal to a threshold value.

19. A method for regenerating a particulate filter used for treating exhaust gas from a combustion engine, the method comprising:

calculating a pressure drop based soot load estimate and a mass balance based soot load estimate;

weighting each of the pressure drop based soot load estimate and the mass balance based soot load estimate based on an accuracy of calculating the pressure drop-based soot load estimate and an accuracy of calculating the mass balance-based soot load estimate during periods of engine operation, the weighting yielding a weighted pressure drop based soot load estimate and a weighted mass balance based soot load estimate;

calculating a soot load estimate based on the weighted pressure drop based soot load estimate and the weighted mass balance based soot load estimate; and

causing regeneration of the particulate filter when the hybrid estimated soot load is greater than or equal to a threshold value.

20. The method of claim 19, wherein the weighting comprises applying at least one gate to each of the pressure drop based soot load estimate and the mass balance based soot load estimate.

21. The method of claim 20, wherein the at least one gate is selected such that a relative contribution of each of the pressure drop based soot load estimate and the mass balance based soot load estimate to the calculated soot load estimate respectively ranges from 0 to 100 percent.

22. A method for regenerating a particulate filter, comprising:

calculating a first estimated soot load of a particulate filter based on a pressure drop of an exhaust gas flowing through the particulate filter;

calculating a second estimated soot load of the particulate filter based on a mass balance of soot in the particulate filter;

calculating a hybrid estimated soot load based on the first estimated soot load and the second estimated soot load, wherein calculating the hybrid estimated soot load comprises;

selectively applying a gate to the first estimated soot load and the second estimated soot load, depending on periods of accuracy of calculating each of the first estimated soot load and the second estimated soot load, so as to weight a relative contribution of each of the first estimated soot load and the second estimated soot load to the hybrid estimated soot load; and

applying a filter to filter dynamic fluctuations corresponding to the hybrid estimated soot load;

wherein the gate is based on one or more of exhaust temperature, exhaust flow rate, bed temperature, soot uniformity, pressure drop, oxidation rate, soot load rate, flow stability, pressure stability, filter history, and regeneration conditions; and

causing regeneration of the particulate filter when the hybrid estimated soot load is greater than or equal to a threshold value.