Apparatuses, methods, and systems for thermal management of hybrid vehicle SCR aftertreatment

• US 8,473,177 B2
• Filed: 08/15/2011
• Issued: 06/25/2013
• Est. Priority Date: 12/31/2010
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Madurai Kumar, Mahesh, Andreae, Morgan M., Currier, Neal W.
• Primary Examiner(s): Black, Thomas
• Assistant Examiner(s): Nolan, Peter D
• Application Number:
  US13/209,874
• Publication Number:
  US 20120173062A1
• Time in Patent Office: 680 Days
• Field of Search: 110/344, 110/345, 422/168, 422/169, 422/171, 422/172, 422/173, 422/174, 422/177, 423/213.2, 423/231.5, 602/73, 602/74, 602/76, 602/86, 603/00, 603/03, 701/101, 701/102, 701/103, 731/147.5
• US Class Current: 701/101
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/13 in order to stay within battery power input or output limits; in order to prevent overcharging or battery depletion
• CPC Class Codes: B60W 2510/085 Power
• CPC Class Codes: B60W 2510/244 Charge state
• CPC Class Codes: B60W 2510/246 Temperature
• CPC Class Codes: B60W 2710/0694 Engine exhaust temperature
• CPC Class Codes: B60W 30/18127 Regenerative braking
• CPC Class Codes: Y02T 10/40 Engine management systems
• CPC Class Codes: Y02T 10/62 Hybrid vehicles

Abstract

Some exemplary embodiments include hybrid vehicle systems including an engine operable to output exhaust, an exhaust aftertreatment system configured to receive the exhaust from the engine, the exhaust aftertreatment system including an SCR catalyst operable to reduce NOx in the exhaust and an electrical heater operable to heat the SCR catalyst, a motor/generator operable in a braking mode to receive torque to slow the vehicle and output electrical power, an energy storage device operable to output electrical power to drive the motor/generator and receive electrical power from the motor/generator, and a controller operable to control the electrical heater to heat the SCR catalyst using electrical power from the motor/generator in the braking mode.

Claims

1. A hybrid vehicle system comprising:

an engine operable to output exhaust;

an exhaust aftertreatment system configured to receive the exhaust from the engine, the exhaust aftertreatment system including an SCR catalyst operable to reduce NOx in the exhaust and an electrical heater operable to heat the SCR catalyst;

a motor/generator operable in a braking mode to receive torque to slow the vehicle and output electrical power;

an energy storage device operable to output electrical power to drive the motor/generator and receive electrical power from the motor/generator; and

a controller operable in the braking mode to control the electrical heater to heat the SCR catalyst using electrical power from the motor/generator in the braking mode simultaneously with electrical power from the energy storage device when the energy storage device is at a maximum charge threshold to reject energy generated in the braking mode as heat through the electrical heater to maintain consistent braking.

2. A hybrid vehicle system according to claim 1 wherein the controller is operable to determine a charge condition of the energy storage device and to control the electrical heater to heat the SCR catalyst using electrical power from the energy storage device based upon the charge condition of the energy storage device.

3. A hybrid vehicle system according to claim 2 wherein the motor/generator is operable in a generator mode to receive torque from the engine and output electrical power and wherein the controller is operable to control the electrical heater to heat the SCR catalyst using electrical power from the motor/generator in the generator mode in combination with electrical power from the energy storage device.

4. A hybrid vehicle system according to claim 1 wherein the controller is operable to determine a charge condition of the energy storage device and to control the electrical heater to heat the SCR catalyst using electrical power from the energy storage device or using electrical power from the motor/generator being driven by the engine based upon the charge condition of the energy storage device.

5. A hybrid vehicle system according to claim 4 wherein the controller is operable to determine an energy storage device derate condition and to control the electrical heater to heat the SCR catalyst using electrical power from the motor/generator being driven by the engine in combination with electrical power from the energy storage device based upon the energy storage device derate condition.

6. A hybrid vehicle system according to claim 5 wherein the energy storage device derate condition is based upon a temperature of the energy storage device.

7. A hybrid vehicle system according to claim 1 wherein the exhaust aftertreatment system includes a decomposition reactor and a doser operable to introduce reductant into the decomposition reactor at a location upstream of the SCR catalyst, and the electrical heater is operable to heat exhaust in the decomposition reactor at a location upstream of the doser effective to heat the SCR catalyst.

8. A hybrid vehicle system according to claim 7 wherein the controller is operable to determine a temperature condition of the SCR catalyst, determine a temperature condition of the decomposition reactor, and to control the electrical heater based upon the temperature condition of the SCR catalyst or the temperature condition of the decomposition reactor.

9. A hybrid vehicle system according to claim 1 wherein the controller is operable to determine an exhaust flow potential from the engine, determine an SCR temperature, determine a state of charge of the energy storage device, determine a regenerative braking event, and selectively power the electrical heater with the energy storage device, the motor/generator, or both based upon the exhaust flow potential, the SCR temperature, the state of charge of the energy storage device, and the regenerative braking event.

10. A hybrid vehicle system according to claim 9 wherein the controller is operable to control operation of the electrical heater in a low temperature operating mode when the SCR temperature is less than a minimum temperature threshold, in a temperature maintenance mode when the SCR temperature is greater than the minimum temperature threshold and less than a maximum temperature threshold, and in an inactive mode when the SCR temperature is greater than the maximum temperature threshold.

11. A method comprising:

providing a hybrid vehicle system including an internal combustion engine, a motor/generator, an SCR exhaust aftertreatment system including an SCR catalyst and an electrical heater, and an energy storage device;

determining a flow of exhaust gas from the internal combustion engine;

determining an SCR temperature of the SCR aftertreatment system;

determining a state of charge of the energy storage device,

determining a regenerative braking event; and

controlling the electrical heater to receive power simultaneously from the energy storage device and from the motor/generator during the regenerative braking event to heat the SCR catalyst when the state of charge of the energy storage device is at a maximum charge threshold to reject energy generated during the regenerative braking event as heat through the electrical heater to maintain consistent braking.

12. The method of claim 11 wherein the controlling the electrical heater includes operating the electrical heater in a low temperature operating mode when the SCR temperature is less than a minimum temperature threshold;

operating the electrical heater in a temperature maintenance mode when the SCR temperature is greater than the minimum temperature threshold and less than a maximum temperature threshold; and

deactivating the electrical heater when the SCR temperature is greater than the maximum temperature threshold.

13. The method of claim 12 wherein the low temperature operating mode powers the electrical heater in a first mode using power from the energy storage device, in a second mode using power from the motor/generator being driven by the engine, and in a third mode using power from both the energy storage device and the motor/generator being driven by the engine.

14. The method of claim 13 wherein operation in the first mode, the second mode or the third mode is controlled based upon the state of charge of the energy storage device and an energy storage device derate condition.

15. The method of claim 14 wherein the energy storage device includes a battery and the derate condition is determined based upon a temperature condition of the battery and a remaining life condition of the battery.

16. The method of claim 11 wherein the SCR exhaust aftertreatment system includes a decomposition reactor at a location upstream of the SCR catalyst and the electrical heater is operable to heat exhaust in the decomposition reactor based upon a temperature condition of the decomposition reactor.

17. A hybrid vehicle system comprising:

an engine operable to output exhaust;

an SCR exhaust aftertreatment system including an SCR catalyst and a decomposition reactor configured to receive exhaust from the engine and a doser upstream of the SCR catalyst operable to introduce reductant into the decomposition reactor;

an electrical heater operable to heat exhaust in the decomposition reactor, wherein the electrical heater is located in the decomposition reactor upstream of the doser;

a motor/generator operable as a motor to output torque and operable as a generator to output electrical power;

an energy storage device operable to provide electrical power to the motor/generator and receive electrical power from the motor/generator; and

a controller operable to determine a temperature condition of the exhaust entering the decomposition reactor and control the electrical heater to heat exhaust in the decomposition reactor using power from the energy storage device or power from the motor/generator based upon the temperature condition of the exhaust entering the decomposition reactor.

18. A system according to claim 17 wherein the motor/generator is operable in a braking mode to receive torque to slow the vehicle and output electrical power and in a generator mode to receive torque from the engine and output electrical power and the controller is operable to control the electrical heater to heat exhaust in the decomposition reactor using power from the motor/generator in the braking mode or power from the motor/generator in the generator mode.

19. A system according to claim 17 wherein the controller is operable to control the electrical heater to heat exhaust in the decomposition reactor using power from the energy storage device simultaneously with power from the motor/generator.

20. A system according to claim 17 wherein the controller is operable to control the electrical heater to heat exhaust in the decomposition reactor in a first mode using power from the energy storage device simultaneously with power from the motor/generator driven by the engine and in a second mode using power from the energy storage device simultaneously with power from the motor/generator driven by regenerative braking.