Method and apparatus for monitoring ash accumulation in a particulate filter of an emission abatement assembly

• US 7,581,389 B2
• Filed: 08/31/2004
• Issued: 09/01/2009
• Est. Priority Date: 01/13/2004
• Status: Expired due to Fees

• Current Assignee: ET US Holdings LLC
• Original Assignee: EMCON Technologies LLC (Forvia SE)
• Inventors: Johnson, Randall J., Crawley, Wilbur H.
• Primary Examiner(s): Tran; Binh Q.
• Application Number:
  US10/931,010
• Publication Number:
  US 20050150214A1
• Time in Patent Office: 1,827 Days
• Field of Search: 602/74, 602/86, 602/95, 602/97, 603/00, 603/03, 603/11
• US Class Current: 60/297
• CPC Class Codes: F01N 11/002 the diagnostic devices measuring or estimating temperature or pressure in, or downstream of the exhaust apparatus
• CPC Class Codes: F01N 2240/14 a fuel burner
• CPC Class Codes: F01N 2550/04 Filtering activity of particulate filters
• CPC Class Codes: F01N 2900/1406 Exhaust gas pressure
• 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 3/025 using fuel burner or by adding fuel to exhaust
• CPC Class Codes: F01N 9/002 of filter regeneration, e.g. detection of clogging
• CPC Class Codes: F23Q 3/008 Structurally associated with fluid-fuel burners
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A method of monitoring ash buildup in a particulate filter includes determining particulate accumulation in the filters subsequent to filter regeneration to determine when the filter is in need of servicing to remove ash there from. An emission abatement assembly is also disclosed.

Claims

1. A method of monitoring ash buildup in a particulate filter of an emission abatement assembly, the method comprising the steps of:

providing an emission abatement assembly comprising a fuel-fired burner positioned upstream of a particulate filter,

determining a pressure drop across the particulate filter as a function of exhaust mass flow from an engine to trigger filter regeneration, experimentally generating a data table by mapping pressure drops across the particulate filter as a function of exhaust mass flow at various particulate loading, storing the data table in an electronic controller, determining a current pressure drop across the particulate filter, determining a current mass flow, querying the data table to retrieve an experimentally created limit value that corresponds to the current exhaust mass flow, comparing the current pressure drop to the limit value, and commencing a regenerating cycle if the current pressure drop exceeds the limit value,

selectively operating the fuel-fired burner to regenerate the particulate filter to remove soot accumulated therein,

generating a control signal subsequent to the regenerating step, and

determining a level of ash accumulation in the particulate filter in response to generation of the control signal.

2. The method of claim 1, further comprising the step of generating an error signal if the level of ash accumulation in the particulate filter exceeds a predetermined limit.

3. The method of claim 2, further comprising the step of communicating the error signal to an engine control unit of an engine.

4. The method of claim 1, wherein determining the level of ash accumulation comprises determining a pressure drop across the particulate filter.

5. The method of claim 4, further comprising the step of generating an error signal if the pressure drop across the particulate filter exceeds a predetermined limit.

6. The method of claim 5, further comprising the step of communicating the error signal to an engine control unit of an engine.

7. The method of claim 1, wherein determining the level of ash accumulation comprises monitoring output from a pressure sensor.

8. The method of claim 1, including generating the control signal in response to an end of a regeneration cycle, wherein determining the end of the regeneration cycle comprises determining when fuel ceases to be supplied to the fuel-fired burner.

9. The method of claim 1, including supplying fuel to the fuel-fired burner through a fuel inlet nozzle, supplying power to a pair of electrodes to generate a spark in a gap between the pair of electrodes, and advancing the fuel through the gap to be ignited by the spark.

10. The method of claim 9, including enclosing a combustion chamber within a burner housing of the fuel-fired burner, directing exhaust gas from an engine to an exhaust gas inlet port formed within the housing, and igniting the fuel within the combustion chamber.

11. The method of claim 10, generating a flow of pressurized air, and advancing the flow of pressurized air to a combustion air inlet of the fuel-fired burner to provide additional oxygen to sustain a combustion of the fuel.

12. The method of claim 11, wherein the particulate filter comprises a filter substrate positioned within a filter housing, and including securing the filter housing to the burner housing, directing exhaust gas flow from an outlet of the burner housing into an inlet of the filter housing to remove particulates, and exhausting treated exhaust gas into the atmosphere through an exhaust pipe.

13. The method of claim 12, including securing a collector housing of a collector to the filter housing and advancing the treated exhaust gas through the collector prior to being exhausted to the atmosphere.

14. The method of claim 1, providing a control unit including a control unit housing defining an interior chamber, and including positioning the electronic controller within the control unit housing, and controlling activation of the fuel-fired burners via control signals generated by the electronic controller.

15. The method of claim 14, including positioning an air pump within the interior chamber such that a pump air inlet is in fluid communication with the interior chamber, controlling the air pump via control signals generated by the control unit to selectively supply pressurized air to a combustion air inlet of the fuel-fired burner, and drawing filtered air into the interior chamber through a housing air inlet.

16. A method of monitoring ash buildup in a particulate filter of an emission abatement assembly, the method comprising the steps of:

providing an emission abatement assembly comprising a fuel-fired burner operable to generate heat which oxidizes soot trapped in a particulate filter,

determining a pressure drop across the particulate fitter as a function of exhaust mass flow from an engine to trigger filter regeneration, experimentally generating a data table by mapping pressure drops across the particulate filter as a function of exhaust mass flow at various particulate loadings, storing the data table in an electronic controller, determining a current pressure drop across the particulate filter. determining a current mass flow, querying the data table to retrieve an experimentally created limit value that corresponds to the current exhaust mass flow, comparing the current pressure drop to the limit value, and commencing a regenerating cycle if the current pressure drop exceeds the limit value,

determining an end of a regeneration cycle of the particulate filter which comprises determining when fuel ceases to be supplied to the fuel-fired burner, and generating a control signal in response thereto, and

determining a level of ash accumulation in the particulate filter in response to generation of the control signal.

17. The method of claim 16, wherein the step of determining the level of ash accumulation in the particulate filter comprises determining a pressure drop across the particulate filter.

18. The method of claim 16, further comprising the step of generating an error signal if the level of ash accumulation in the particulate filter exceeds a predetermined limit.

19. The method of claim 18, further comprising the step of communicating the error signal to an engine control unit of an engine.

20. The method of claim 16, including supplying fuel to the fuel-fired burner through a fuel inlet nozzle, supplying power to a pair of electrodes to generate a spark in a gap between the pair of electrodes, and advancing the fuel through the gap to be ignited by the spark.

21. The method of claim 20, including enclosing a combustion chamber within a burner housing of the fuel-fired burner, directing exhaust gas from an engine to an exhaust gas inlet port formed within the housing, igniting the fuel within the combustion chamber, generating a flow of pressurized air, and advancing the flow of pressurized air to a combustion air inlet of the fuel-fired burner to provide additional oxygen to sustain a combustion of the fuel.

22. The method of claim 21, wherein the particulate filter comprises a filter substrate positioned within a filter housing, and including securing the filter housing to the burner housing, directing exhaust gas flow from an outlet of the burner housing into an inlet of the filter housing to remove particulates, and exhausting treated exhaust gas into the atmosphere through an exhaust pipe.

23. The method of claim 16, providing a control unit including a control unit housing defining an interior chamber, and including positioning the electronic controller within the control unit housing, and controlling activation of the fuel-fired burner with the electronic controller.

24. The method of claim 23, including positioning an air pump within the interior chamber such that a pump air inlet is in fluid communication with the interior chamber, controlling the air pump via control signals generated by the control unit to selectively supply pressurized air to a combustion air inlet of the fuel-fired burner, and drawing filtered air into the interior chamber through a housing air inlet.