Abstract:
An apparatus and system for monitoring and communicating emissions data for a diesel engine. An exhaust gas analyzer uses infrared light to measure the quantity of trace gases and particulates in an exhaust gas outlet from a diesel engine. The gas analyzer preferably includes a logic processor to interpret the measured data and a memory device to store the measured data. A radio transmitter, cellular data transmitter, or Smartphone transmits the measurement data. In a diagnostic and monitoring system for a diesel engine, the exhaust gas analyzer is in contact with the exhaust gases from the diesel engine, preferably in the tailpipe. A data receiver receives the measurement data transmitted by the radio transmitter, cellular data transmitter, or Smartphone.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to diesel engine emissions. More particularly, the present invention relates to an apparatus and system for monitoring emissions from diesel engines. 
       BACKGROUND OF THE INVENTION 
       [0002]    Diesel engines are widely used in a huge array of applications. Generally, diesel engines are classified as being either stationary or mobile. Stationary diesel engines include those used to generate power or compress air and other fluids. Hotels, casinos, and hospitals use large stationary diesel engines to generate power in the event of a power grid failure. Large industrial compressors are used in applications like construction, excavation and mining, or in mechanized assembly lines. Mobile diesel engines are even more ubiquitous. Mobile diesel engines can be found in: personal automobiles, commercial shipping trucks, aircraft, marine vessels (personal boats, commercial ships, tankers, tug boats, etc.), and locomotive engines used in rail transport. It is likely that an average person is affected, at least tangentially, by a diesel engine several times in any given day. 
         [0003]    Diesel engines are extremely powerful, but they are also extremely dirty. Diesel engines run on diesel fuel, and diesel fuel emits a range of pollutants when it burns. Diesel fumes generally contain: carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOx), methane, and hydrocarbon particulates, among other pollutants. These gases and particulates are created as the diesel fuel burns, and are then expelled from the diesel engine as exhaust. Diesel exhaust is particularly problematic in that all the various gases contained therein cause an increase in the atmosphere&#39;s ability to trap infrared energy. This eventually creates holes in the ozone layer of the atmosphere and negatively effects global climates. 
         [0004]    Diesel fumes cause another environmental problem called smog. Smog is a thick layer of pollution that can blanket entire geographical regions depending on the climate and weather patterns. Smog limits visibility (even on a clear day) and is very harmful if inhaled. When pollution is trapped in the atmosphere as described, it can also cause acid rain. Acid rain occurs when harmful pollutants dissolve into water droplets before they fall to the earth as rain. The resulting rain drops have a high pH level, which is why they are known as ‘acid rain’. Acid rain damages crops and landscaping, and can even cause the paint on buildings, signs and cars to blister and peel. It has only been within the last few decades that the eye-opening effects of diesel engine fumes have been studied. Because of the detrimental nature of the pollution created by diesel engines, the government has stepped in to regulate the sources of diesel pollution. 
         [0005]    The main governmental arm that deals with environmental regulations is the Environmental Protection Agency (EPA). The main function of the EPA is to write and enforce regulations based on the laws passed by Congress dealing with the environment. In the face of the environmental damage caused by diesel engine pollution, the EPA has enforced a whole host of regulations in an attempt to limit these harmful effects. The EPA currently regulates oil refinement, vehicle manufacturing, car sales across state borders, fuel sales, and almost every other aspect of fuel production and use. The EPA specifically regulates engine fuel systems and how much pollution any given engine can emit. With each passing year, these regulations become more and more strict. It is usually up to engine manufacturers to figure out how to stay in compliance with these emissions regulations. If the regulations are not met, engine manufacturers and users may be sanctioned. 
         [0006]    One of the most logistically problematic areas of most EPA regulation schemes in this area is in monitoring engine emissions. For example, locomotive engines found in freight trains produce several thousand horsepower. Often, these engines are daisy-chained together in order to move tons of freight across the country. These engine use a large amount of fuel on initial start-up, so when they are awaiting assignment to the proper cargo, they are often left idling in train yards across the country. The EPA currently has regulations that seek to control the emissions of an idling locomotive, but these regulations simply state that an idling locomotive can emit no more than a given amount of particulates, CO2, etc. per hour. No two engines, even of the same type, pollute at the same rate. Thus, train yards seeking to follow EPA regulations generally do not know which engines are the worst offenders and need to be shut off. As a result, a train yard operator may be forced to turn off every idling engine every 15 minutes or so in an attempt to ensure that the restricted level of emissions is not reached. But later, when the engine is turned on again, it uses more fuel on startup than it would have used had it been left idling. This means that the train yard is losing money. On the other side of the this problem, enforcement of the regulations on train yards not seeking to stay in line with the EPA mandate is almost logistically impossible. All the EPA can reasonably do is random inspections of idling locomotive engines in hopes of catching a polluter off-guard. 
         [0007]    This same problem presents itself in several other venues as well. For example, trucking companies are subject to EPA regulations but truck engines may pollute differently depending on driving conditions (mountain roads, hot climates, high altitudes). So the trucking company may end up making expensive and unnecessary engine modifications in an attempt to satisfy EPA regulations. Conversely, the EPA has no effective way of monitoring emissions of truck engines while they are traveling from point A to point B. This same problem occurs with every other type of engine emission that the EPA seeks to regulate. 
         [0008]    Accordingly, there is a need for a system and apparatus for monitoring diesel engine emissions in real time and presenting emissions data to engine owners or government regulators. The present invention fulfills these needs and provides other related advantages. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention is directed to an exhaust gas analyzer comprising an analysis chamber having an exhaust intake and an exhaust outlet, the analysis chamber being transparent to light. An infrared light source is disposed adjacent to the analysis chamber and an infrared light detector is disposed adjacent to the analysis chamber generally opposite the light source. The light source and light detector are configured such that the light from the light source passing through the analysis chamber is received by the light detector. The light detector is configured to measure the amount of infrared light passing through the analysis chamber. A logic processor is in electronic communication with the light detector and programmed to receive data of the measured infrared light passing through the analysis chamber. A memory device is in electronic communication with the logic processor and configured to store the data of the measured infrared light. 
         [0010]    The logic processor is preferably configured to determine an amount of trace gases and particulates in exhaust gases passing through the analysis chamber based upon the amount of measured infrared light. The data stored in the memory device represents the amount of trace gases and particulates in the exhaust gases passing through the analysis chamber. 
         [0011]    A data output device is preferably included and in electronic communication with the memory device. The data output device may comprise a radio transmitter or a cellular data transmitter. The cellular data transmitter may comprise a Smartphone including a computer processor. The Smartphone may be in electronic communication with the infrared light source, the infrared light detector, and the logic processor and be configured to operate the exhaust gas analyzer or its components individually. 
         [0012]    The exhaust gas analyzer preferably includes an external power supply or an internal battery electrically connected to the logic processor and memory device. The trace gases and particulates measured by the exhaust gas analyzer preferably include carbon monoxide, carbon dioxide, nitrous oxide, methane, and hydrocarbon particulates. 
         [0013]    A diagnostic and monitoring system for a diesel engine preferably comprises an exhaust gas analyzer as described above. The exhaust gas analyzer is in fluid communication with an exhaust gas outlet on the diesel engine. A data receiver is included and configured to receive measurement data from the exhaust gas analyzer. 
         [0014]    The exhaust gas analyzer is preferably disposed in a tailpipe attached to the exhaust gas outlet such that exhaust gases from the diesel engine enter the exhaust intake on the exhaust gas analyzer. The exhaust gas analyzer is preferably electrically connected to a battery or an alternator associated with the diesel engine. 
         [0015]    The data receiver is either a fixed device mounted proximate to the diesel engine or a handheld mobile device. The handheld mobile device is preferably configured to receive measurement data from exhaust gas analyzers in a plurality of diagnostic and monitoring systems for a plurality of diesel engines. 
         [0016]    Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The accompanying drawings illustrate the invention. In such drawings: 
           [0018]      FIG. 1  is a perspective view of a truck with a diesel engine and the present invention installed in the smoke stack; 
           [0019]      FIG. 2  is a cross-sectional view of a diesel engine illustrating the various stages of the combustion cycle along with the intake and exhaust flows; 
           [0020]      FIG. 3  is a schematic diagram of the gas analyzer of the present invention illustrating the data path and logic; and 
           [0021]      FIG. 4  is a schematic diagram of the present invention illustrating how the receiver interacts with the gas analyzer. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0022]    The present invention is a diagnostics system and apparatus for monitoring emissions from diesel engines. Specifically, the apparatus is a gas analyzer which is installed in a diesel engine at a location where it comes in contact with engine exhaust fumes. The gas analyzer reads the levels of different pollutants in the exhaust and is able to communicate this data in one of several ways, as will be described. The system of the current invention utilizes the pollutant readings from the engine to enable engine owners and environmental regulators to effectively marshal their resources in a timely and cost effective way. The diagnostics system for diesel engines of the present invention is generally referred to in the illustrations by the number 10. 
         [0023]    In  FIG. 1 , the diagnostics system  10  is illustrated as installed in a large diesel truck  18 . The engine  12  of the truck  18  runs on diesel fuel and produces exhaust that exits the engine through the exhaust pipes  20 . The engine exhaust of a diesel engine is very dirty and contains pollutants and noxious gases as described above. A gas analyzer  14  is placed in the exhaust pipes  20  of the engine  12  such that the analyzer  14  comes in direct contact with the exhaust fumes produced by the engine  12 . In this way, the analyzer  14  can give accurate readings for the pollutants contained within the exhaust. 
         [0024]    The combustion cycle that produces exhaust fumes is illustrated in the cross-sectional view of an engine  12  in  FIG. 2 . The process starts with the engine intake  22 . Here, fuel and air are mixed and fed into the engine  12 . The fuel/air mixture is fed past the intake valve  26  into the combustion chamber  24 . At this point the intake valve  26  seals the combustion chamber  24  and the piston  30  moves upward creating a tremendous amount of pressure in the combustion chamber  24 . When the pressure in the combustion chamber  24  is sufficient, the fuel/air mixture combusts, creating an explosion that forces the piston  30  away from the combustion chamber  24 . At this point, the exhaust valve  28  opens to evacuate any unburned fuel through the engine exhaust port  32 . The combustion of the diesel fuel in the combustion chamber  24  is not perfect. This means that there is often unburned fuel left behind. Additionally, diesel fuel is not a very efficient fuel, so rather than burning completely upon ignition, it leaves behind many polluting by-products. All of this is evacuated out of the engine exhaust at this point in the cycle. It is this exhaust that the diagnostics system  10  seeks to analyze and monitor. 
         [0025]    The diagnostics system  10  includes a gas analyzer  14  that is placed in an engine  12  such that it comes in direct contact with the exhaust produced by that engine  12 . The gas analyzer  14  is illustrated in a schematic diagram in  FIG. 3 . The gas analyzer  14  is a standard five gas analyzer with specific modifications. A five gas analyzer measures trace amounts of various gases by determining the absorption of an emitted infrared light source through a certain air sample. In  FIG. 3 , the gas analyzer  14  has an infrared source  48  that passes infrared energy through an analysis chamber  44 . The infrared energy is received by a detector  50  directly opposite. The detector  50  reads the amount of infrared energy that passes through the exhaust sample in the analysis chamber  44  and determines the amount of trace gases that reside in the exhaust sample. The exhaust sample enters the analysis chamber  44  via an exhaust intake  42 . Once analysis is complete, the exhaust sample is pushed out the exhaust evacuation port  46 . 
         [0026]    The gas analyzer  12  is small and can run off a battery  36  or a constant power source  34  outside the gas analyzer  12 . This outside power source  34  could be the engine battery. The gas analyzer  14  is capable of detecting trace amounts of the following: CO, CO2, NOx, Methane, and hydrocarbon particulates. Prior art gas analyzers typically feature an analog or digital readout that allows an operator to read the results of the analysis. The gas analyzer  14  is modified in order to be able to store and communicate the results of the gas analysis. As such, the gas analyzer has computer logic  38  that is powered by either the battery  36  or the external power source  34 . The computer logic  38  receives the results of the exhaust gas analysis from the detector  50 . The computer logic  38  can determine whether preset limits have been reached or exceeded and can also send the results of the exhaust analysis to the computer memory  40 . The computer memory  40  may be long-term memory or short-term memory or a combination of both. Once the results and analysis have been stored, they are broadcast via the data output  52 . The data output  52  varies in two embodiments of the gas analyzer  12  as discussed below. 
         [0027]    In the first embodiment, the gas analyzer  12  is configured to include computer logic  38  and memory  40  for storing and communicating the analysis results, as described above. In this first embodiment, the data output  52  is a radio transmitter. The radio transmitter continuously broadcasts the gas analysis results. The radio signal can be picked up by a handheld receiver outside the engine (see  FIG. 4 ). This embodiment is useful if, for example, a train yard owner wishes to take readings from all the engines currently operating in the train yard. He only has to walk around the yard with the hand-held receiver and take readings from the analyzers currently installed. If the radio transmitters in the gas analyzers are strong enough, the train yard owner may be able to take emissions readings without leaving the main office of the yard. This embodiment is also useful for government regulators making surprise inspections. The regulator only has to stand near the engine being inspected. The gas analyzer  12  and transmitter of this embodiment are small enough to fit within the exhaust pipe  20  of an engine  12  and are preferably powered by the engine battery (not shown). A supplemental on-board back up battery  36  may also be provided within the gas analyzer  12 . 
         [0028]    The second embodiment is more sophisticated than the first and includes a gas analyzer  12  where the data output  52  is a specially programmed Smartphone. A Smartphone is a mobile phone built on a mobile operating system. This device has more computing capability and connectivity than a standard phone. It basically combines a personal computer with a telephone. Smartphone&#39;s typically feature relatively fast microprocessors, memory storage, Wi-Fi and data network connectivity, Global Positioning Satellite (GPS) navigation, and a high resolution display. The Smartphone is connected to the gas analyzer  12  such that the smartphone can operate the analyzer and store the analysis results. In this embodiment of the gas analyzer  12 , the power source  34  is preferably the engine battery, but the gas analyzer  12  may also include an on-board back up battery  36 . 
         [0029]    The programmable smartphone enables this embodiment of the gas analyzer  12  to be utilized at virtually any distance. For example, a shipping company with a fleet of 800 trucks can install this embodiment of the gas analyzer  12  into each truck. From the shipping company&#39;s headquarters, emissions data can be gathered from any truck at any time. The analyzer&#39;s Smartphone may be programmed to only answer calls from the shipping company&#39;s headquarters. Once the call is connected an analysis computer at the shipping company&#39;s headquarters pulls all the emissions data stored on the Smartphone. Alternately, the Smartphone can be pre-programmed to activate the gas analyzer, collect an emissions sample and call the company headquarters with the results. This can happen at any time interval desired. The Smartphone attached to the gas analyzer may also be equipped with a Global Positioning Satellite (GPS) locator. This means that along with being able to collect emissions data from any engine at any time, the shipping company can also know the exact location of every truck in their fleet at any time. 
         [0030]    Government regulators may also use the second embodiment to great advantage. For example, a law may be passed requiring all shipping fleets to install gas analyzers in a certain percentage of their engines. Regulators would then be able to view emissions data at any time from any shipping company. Emissions data could be collected automatically, or could be requested on a case by case basis. The programmable smart phone in the gas analyzer  12  distributed by the regulators may optionally be included with a connection to the internal engine startup mechanism (not shown). Then for example, if the engine is polluting above a given level after repeated warnings, the engine may be shut down remotely by the regulators. This system would provide government regulators with the ability to test engine owners for emissions compliance easily at any time. This could also provide the EPA and other regulators with a vehicle to generate a substantial amount of residual income from fees/fines. Monies generated by this process could be managed by a phone company who administers the cellular phone lines utilized by the smart phone in the gas analyzer  12 . Alternately, monies may be managed by a third party. 
         [0031]    The system of the present invention is collecting emissions data from diesel engines, as described above and illustrated in  FIG. 4 . Here, an overview is illustrated wherein an engine  12  creates exhaust  56  which is then analyzed by a gas analyzer  14 . The analysis results  54  are broadcast to a receiver  16 , as in one of the embodiments described above. This system also provides engine owners with a unique opportunity for monetizing the cleanliness of their engines. The United States has a program that allows over-polluters to buy “carbon credits” from under-polluters. A carbon credit is equivalent to a certain amount of pollution over a given time. The EPA assigns carbon credits to companies based on the type of industry the company is in. It is possible for a company to under-pollute; that is, to produce less pollution than their assigned amount of carbon credits allows them to pollute. This carbon credit surplus can be very valuable to another company that produces more pollution than their allotment of carbon credits allows for. With the system of the present invention in place, and under-polluter will be able to more accurately determine at any time exactly how much pollution it is producing and exactly how much carbon credit surplus it has or needs. 
         [0032]    Although several embodiments have been described in detail for purposes of illustration, various modifications may be made to each without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.