Patent ID: 12196117

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the figures, and more particularly toFIG.1, shown therein and designated by the reference numeral100is an embodiment of a particulate filter regeneration system that is shown coupled to an engine exhaust system110. The engine exhaust system shown includes an exhaust pipe3that extends from an engine1(e.g., a diesel engine) through a turbo charger2and through various modules for removing pollutants from the exhaust gas. In the embodiment shown, a diesel oxidation catalyst (DOC)4is in fluid communication with the exhaust pipe3and is disposed on the downstream side of the turbo charger2. Similarly, a selective catalytic reduction system (SCR)5is in fluid communication with the exhaust pipe3on the downstream side of the DOC4, and a particulate filter7is in fluid communication with the exhaust pipe3and is disposed on the downstream side of the SCR5. To facilitate cleaning of the particulate filter with a regeneration system100, the exhaust system110comprises an adapter fitting6disposed on the downstream side of the SCR5and either the upstream or downstream side of the particulate filter7. The adapter fitting6is shown coupled to a particulate filter regeneration system100.

The regeneration system100comprises a first supply line101and a second supply line102configured to provide one or more fuels and, if needed, an oxidizer, to the exhaust pipe3either upstream or downstream of the particulate filter7. The system100further comprises a connector8that is configured to couple with an access port30of the exhaust pipe3(such as at adapter fitting6) such that the first and second supply lines101,102are in fluid communication with the exhaust pipe3. The connector8is configured to releasably couple with the access port of the exhaust pipe3so that the regeneration system100can be selectively coupled to and decoupled from the exhaust system, such as through a quick-release mechanism. The access port to the exhaust pipe3is located either upstream or downstream of a particulate filter7so that when the fuel fed to the exhaust pipe3is combusted, the soot or particulate matter on the particulate filter7is oxidized, e.g., converted to a harmless gas(es). With such system, the particulate filter can be selectively regenerated or cleaned.

Referring now toFIG.2, a particulate filter regeneration system100ais shown and is a more detailed schematic of the particulate filter regeneration system that is shown inFIG.1. Regeneration system100acomprises supply line101(which is shown coupled to a fuel reservoir20via valve21) and supply line102(which is shown coupled to an oxidizer source22). Each supply line101,102can be coupled to a connector8that is configured to couple to the access port of an exhaust pipe3so that the supply lines101,102are in fluid communication with the exhaust pipe3.

Supply line101defines a conduit having a first end103and a second end104and is configured to transport fuel through the conduit. The supply line101is coupled to connector8, and during use, e.g., when connector8is coupled to an access port of the exhaust pipe3, the conduit is in fluid communication with the exhaust pipe3at the first end103. Second end104is coupled to a fuel source, e.g., reservoir20. Reservoir20can contain a fuel with a relatively low boiling point and high BTU content as compared to other fuel options. For example, in some embodiments, reservoir20can contain butane, propane, methane and/or any combination thereof.

Along the length of the supply line101are several modules for controlling flow and measuring pressure within the supply line101. In the embodiment shown, a pressure switch is disposed on the downstream side of reservoir20. The pressure switch10can be configured to output a signal to indicate whether the reservoir valve is open and/or to indicate whether the pressure within the reservoir20is adequate. A fuel pressure regulator12is located on the downstream side of the pressure switch10and can be configured to reduce the pressure of the fuel flowing from reservoir20to a predetermined pressure. A fuel supply valve11is located on the upstream side of the fuel pressure regulator12and can be configured to block or permit flow through the supply line conduit101. A pressure sensor13is disposed on the downstream side of the fuel supply valve11and can be configured to measure the pressure within the supply line101. Another fuel supply valve14can be located on the downstream side of the pressure sensor13, and another pressure sensor15is located downstream of the fuel supply valve14.

Supply line102also defines a conduit having a first end105and a second end106and is configured to transport a gas, such as air or other oxygen-containing gas. The supply line102is coupled to connector8, and during use, e.g., when connector8is coupled to an access port of the exhaust pipe3, the conduit is in fluid communication with the exhaust pipe3at the first end105. On the other end (second end106), supply line102is in fluid communication with the output of an oxidizer gas source, shown here as a compressor22outputting compressed air. But it is understood that a reservoir of a pressurized oxygen-containing gas, such as air, could also be used.

Along the length of the supply line102are modules for controlling flow and measuring pressure within the supply line102. In the embodiment shown, a pressure switch16is disposed on the downstream side of the compressor22and can be configured to output a signal to indicate whether the compressed air source is supplying an adequate air pressure through the conduit. A pressure regulator17is disposed on the downstream side of the pressure switch16and is configured to reduce the pressure of the air flowing from the compressor22to a predetermined pressure. A compressed air supply valve18is located on the downstream side of the pressure regulator17and can be configured to block or permit flow through the supply line conduit102. A pressure sensor19is located downstream of the compressed air valve18and can be configured to measure the pressure within the supply line102.

In some embodiments, supply lines101,102can be coupled to connector8by way of one or more nozzles23, which can be coupled to or integrated with the connector8. The two supply line ends103,105coupled to the connector8are in sufficient proximity to each other so that at least a portion of the fuel and the oxygen-containing gas can mix and combustion of the fuel can occur.

In addition to the supply lines, system100acomprises an igniter24configured to generate a spark within the exhaust pipe3in proximity of the fuel and the oxidizer when exiting the first and second supply lines101,102. In an embodiment, the spark-generating portion of the igniter24can be coupled to the connector8such that the igniter24is downstream from nozzle23when connected to the exhaust system110, i.e., closer to the particulate filter than nozzle23is.

Also coupled to connector8can be a temperature sensor25. This sensor25is configured to measure the temperature, particularly in the exhaust pipe when the connector8is coupled to the exhaust pipe. This temperature sensor25is disposed relative to the nozzle23and igniter24so that the sensor can detect a temperature rise in the proximity of the fuel source and/or igniter24, indicating whether the fuel injected into the exhaust system110actually combusted during an ignition cycle.

Referring now toFIGS.3A and3B, shown therein and designated by the reference numeral100bis a second embodiment of the present regeneration system. This embodiment is similar to that shown inFIG.2except that it further comprises a system controller9and the modules of supply line101and102and those coupled to connector8are configured to communicate with controller9. For example, the pressure sensors13,15, and19are configured to output a signal indicating pressure to the controller9. Similarly, temperature sensor25is configured to output a signal indicating pressure to the controller9. Valves11,14,18, and/or21can be configured to close and open via communications from the controller9. Controller9can also be configured to cycle on and off air compressor22. The igniter24can be configured to actuate via communication from the controller9. In the embodiment shown, igniter24comprises an ignition coil24aand an ignition plug24b. Ignition plug24b(e.g., spark plug) is coupled to connector8and in proximity of nozzle23. Other devices for creating the necessary heat to cause ignition of the fuel include a glow plug

System controller9can be provided with a data-processing system comprising a microprocessor9dconfigured to transmit instructions or receive readings from the various modules of the system100bfor implementation of a valve safety verification process and/or a filter regeneration process. The system100bcan further be equipped with a memory9e, especially a non-volatile memory, allowing it to load and store a software program, that, when executed in the microprocessor9d, allows the valve safety verification process and/or the filter regeneration process to be implemented. This non-volatile memory9ecan be, for example, a ROM (read-only memory). Furthermore, the system controller9comprises a memory9f, especially a volatile memory, allowing data to be stored during the execution of the software package and the implementation of the process. This volatile memory9fmay be, for example, a RAM or EEPROM (“random access memory” or “electrically erasable programmable read-only memory”, respectively).

In some embodiments, the system controller9can be configured to selectively and independently open and close valves (e.g.,11,14, and/or18)(module9cinFIG.3B). In some embodiments, the system controller9can be configured to execute a safety verification process (module9ainFIG.3B) and/or a regeneration process (module9binFIG.3B).

FIG.4Adepicts an embodiment of a safety verification process with system controller9configured to executing one or more steps of this process. Beginning at a step S1, a sensor function verification process of all of the system's sensors will be performed. This process comprises validating pressure switches10,16are above a threshold value, e.g., above psi, determining if pressure sensors13,15,19are within threshold values, e.g., less than 0.5 psi, and determining if temperature sensor25is within a threshold value, e.g., less than 75° C. If the sensors do not relay an appropriate value, an error code with information pinpointing a failure can be generated. Such error code and/or information pinpointing the failure can be displayed on a screen, which is part of a user interface system40.

If the sensors are verified to be operational, at a step2, a valve interlock test is initiated to determine the integrity of the valves. Specifically, at a step S3, the fuel supply valve14is cycled open to relieve any pressure that may be contained between valves11and14during start up and then is cycled closed. At a step S4, a pressure reading is obtained by the pressure sensor13to determine if fuel supply valve11is leaking. For example, if the pressure rises above atmospheric, the test fails (e.g., valve11may be leaking) and an error code is generated. At a step S5, the fuel supply valve11is cycled open to pressurize the conduit of supply line101between fuel supply valves11and14and then is cycled closed. At a step S6, a pressure reading is obtained from pressure sensor13to determine if fuel valve14is leaking. If the pressure drops below a threshold value, the test fails. In some embodiments, this threshold value is the actual pressure of the regulator12or within a certain percentage thereof (e.g., 5% of the regulated pressure). If the test fails, the controller9can communicate with the user interface system40, generating and displaying an error code and/or returning to a start menu.

At a step S7, the fuel supply valves11and14are both cycled open. At a step S8, a pressure reading is obtained from pressure sensors13and15to determine the integrity of the fuel pressure regulator12is within the threshold values. This threshold value can be the same as the previous value, e.g., the actual reservoir pressure or a minimum acceptable pressure for the reservoir. If the pressure is below or above the threshold value, the test fails and returns to the start menu with an error code.

At a step S9, the fuel supply valves11and14are cycled closed. At a step S10, the compressed air supply valve18is opened and the air compressor22is cycled on. At a step S11, a pressure reading is obtained from pressure sensor19to determine the integrity of the compressed air pressure regulator17is within a threshold value. If the pressure is below or above the threshold value, the test fails and returns to the start menu with an error code.

At a step S12, the compressed air supply valve18is closed and air compressor22is cycled off. At a step S13, if all of the above test complete without setting errors, the safety verification process is complete. In some embodiments, the system may then move on to the start of the regeneration process.

FIG.4Bdepicts an embodiment of a filter regeneration process with processor9configured to execute one or more steps of this process. the filter regeneration process can begin at a step S14where the compressed air valve18opens and the air compressor22is actuated to initiate the purge cycle for a predetermined amount of time (e.g., 5 seconds to 10 minutes), and the compressed air valve will remain open through step S15. At a step S15, the fuel supply valves11and14are opened. Moreover, pressure sensors15,19and temperature sensor25will be monitored, and the igniter24will be actuated for a predetermined amount of time. At a step S16, a continuous measurement of the temperature sensor25is obtained to determine if the temperature within the exhaust pipe is above a threshold value or increased a certain amount within a set interval of time. The temperature reading helps determine combustion throughout the entire regeneration period. If temperature drops below a threshold value, the regeneration process fails and returns to the purge sequence, step S14. The system can attempt to reignite again (up to 3 times in some embodiments) before generating an error code and/or returning to the start menu. At a step S17, the regeneration process is allowed to run for a predetermined amount of time. The amount of time can depend on a number of factors that can be taken into account when determining the time, such factors can include, e.g., the vehicle make, vehicle model, vehicle year, the engine make, the engine model, the engine year, the filter type, the amount of particulates in the particulate filter, the amount of time since the filter was previously regenerated, size or mass of the filter to be regenerated; the BTUs generated by the system100, and the moisture content in the exhaust system. In some embodiments, the regeneration process can run from 2 minutes to 3 hours or more (e.g., 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180 minutes, or any time therebetween). In some embodiments, the air to fuel ratio dispensed can be between 20:1 and 10:1 (e.g., 10:1, 11:1, 12:1, 13:1, 14:1, 15:1, 16:1, 17:1, 18:1, 19:1 20:1, or any range therein). System100can be configured to provide either a variable or constant output of BTUs. A variable BTU system would allow for comparable burn times despite differences in the filters to be cleaned. A variable system can comprise electronic regulators or electronic switching valves for regulators12and17. In some embodiments, the electronic switching valves can be driven by a pulse width modulation from the controller9,9c. The variable BTU system could be configured to generate a higher amount of BTUs at the beginning and reduce the amount of BTUs once the filter reached a desired regeneration temperature. Such temperature can be estimated from temperature sensor25.

To terminate the combustion cycle, at a step S18, the fuel supply valves11and14closed. At a step S19, the post purge process begins. The compressed air supply valve18remains open and air compressor22remains on for a predetermined amount of time (e.g., 5 seconds to 10 minutes), thus completing the filter regeneration process.

Referring now toFIGS.5and6, shown therein and designated by the reference numeral6ais an embodiment of an adapter fitting.FIG.5shows a perspective view of only adapter fitting6a, andFIG.6shows a cross-section schematic of adapter fitting6acoupled to connector8. Adapter fitting6ais a clamp-style adapter fitting. Fitting6acomprises a sidewall31ahaving a first end32aand a second end33aand defining at least a portion of a conduit34aextending between the two ends32a,33a. The sidewall31acomprises an opening/access port disposed between the two ends32a,33athat is in fluid communication with the conduit34a. The clamp-style adapter fitting6ais configured to clamp around an exhaust pipe (e.g., exhaust pipe3) such that the exhaust pipe extends through the conduit34a. The fitting6acan comprise clamp lock35acoupled to the sidewall31aand configured to maintain the sidewall in a cinched/compressed position around the exhaust pipe.

In some embodiments, the adapter fitting6amay comprise a releasable lock36athat is adjacent to or defines at least a portion of the access port30a. Locking mechanism36acan be coupled to or integral with the sidewall31aand is configured to couple with the connector8of filter regeneration system100a,110a(FIGS.2and3A). Releasable locking mechanism36acan be any variety of devices for securing two objects together, such as a screw-threaded type; bayonet-type mount, or a breech-lock type (friction type).

In some embodiments, the adapter fitting6acan comprise a cover (not shown) rotatably or slideably coupled to the sidewall so that it can move between a closed position and an open position to selectively cover and uncover the access port. In some embodiments, the cover can be biased toward the closed position. For example, in some embodiments, the cover is coupled to the sidewall via a hinge that is biased toward the closed position.

Referring now toFIG.7, shown therein and designated by the reference numeral6bis another embodiment of an adapter fitting. Adapter6bis a flanged-type adapter fitting. Adapter6bis the same as adapter fitting6aexcept the structure used to couple with exhaust pipe is a flanged end33band does not have a clamping mechanism or a releasable locking mechanism.

Referring now toFIG.8, shown therein and designated by the reference numeral6cis another embodiment of an adapter fitting. Adapter fitting6cis a clamp-style adapter fitting similar to that shown inFIG.5except that a sidewall31cdefines only a portion of conduit34cand chain40cis coupled to sidewall31cto define another portion of the conduit. A portion of lock35c, namely pin39c, also defines a portion of conduit34c. The sidewall31ccomprises an opening/access port30cdisposed between the two ends32c,33cof sidewall31cthat is in fluid communication with the conduit34c. The clamp-style adapter fitting6cis configured to clamp around an exhaust pipe (e.g., exhaust pipe3) such that the exhaust pipe extends through the conduit34c. The fitting6ccan comprise clamp lock35ccoupled to the sidewall31cand configured to maintain the sidewall31cand chain40cin a cinched/compressed position. In the embodiment shown, clamp lock35ccomprises a knob38cdefining a threaded receptacle configured to engage a threaded pin39cthat is coupled to chain40cat an end opposite from where the chain is coupled to sidewall31c.

In some embodiments, the adapter fitting6cmay comprise a releasable lock36cthat is adjacent to or defines at least a portion of the access port30c. Lock36ccan be coupled to or integral with the sidewall31cand is configured to couple with the connector8of filter regeneration system100a,110a(FIGS.2and3A). Releasable lock36ccan be any variety of devices for securing two objects together, such as a screw-threaded type; bayonet-type mount, or a breech-lock type (friction type). In the embodiment shown, lock36ccomprises a resilient tab mounted to sidewall31c. An end of tab31cis disposed above opening30cand is configured to fit into a notch of, e.g., connector8, when the connector extends through the opening and slidably release from the notch when the connector8is intentionally pulled from the opening.

Some embodiments include a method of testing a particulate filter regeneration system. Referring toFIG.2, valve14can be cycled opened and closed. (This cycling of valve14may occur after both valves11and14have been cycled open and closed.) After closing, the pressure at sensor13in the region between the two valves11,14is compared to atmospheric pressure. If this pressure is substantially equal to atmospheric pressure, the functioning of valve11is verified.

To verify the function of valve14, valve11is opened (while valve14remains closed) and the pressure between valve11and valve14is compared to a second threshold value. In some embodiments, the second threshold value is the pressure at which regulator12is configured to dispense the fuel in reservoir20. If this pressure remains above or maintains a pressure substantially the same as the second threshold value, the valve14is verified to be functioning properly.

To verify the function of regulator12, both valves11,14are cycled open and the pressure between valves11,14or after valve14is compared to a third threshold value. In some embodiments, the third threshold value is the pressure at which regulator12is configured to dispense the fuel in reservoir20. In some embodiments, the third threshold value is equal to the second threshold value. If the difference between this pressure and the third threshold value is between 1% to 25% (e.g., 1%, 5%, 10%, 15%, 20%, or 25%), the regulator12is verified to be functioning properly.

To verify the function of gas pressure regulator17, valve18upstream of pressure sensor19and downstream of air compressor22and regulator17is opened, and the pressure downstream of valve18(e.g., at sensor19) is compared to a fourth threshold value. In some embodiments, the fourth threshold value is the pressure at which regulator17is configured to dispense the oxygen-containing gas from compressor22. If the difference between this pressure and the fourth threshold value is between 1% to 25% (e.g., 1%, 5%, 10%, 15%, 20%, or 25%), the regulator17is verified to be functioning properly. (The compressor22is in communication with the atmosphere, which is a reservoir for the purpose of this disclosure.)

The regeneration cycle can then be initiated. In some embodiments, a particulate filter can be regenerated without removing it from the exhaust system. In other embodiments, the particulate filter can be removed from the exhaust system and placed in housing configured to contain a gaseous substance and withstand the combustion reaction. The housing is also configured to couple to connector8.

To execute a particulate regeneration cycle, after supply lines101,102are coupled to a housing containing a particulate filter or to an engine exhaust pipe at a location either upstream or downstream of a particulate filter (such as through an access port), a fuel is dispensed through supply line101and into the housing or the exhaust pipe, and an oxygen-containing gas is dispensed through supply line102. The fuel (e.g., butane, propane, methane, or some combination thereof) and the oxygen-containing gas can be dispensed for a predetermined amount of time to fill the housing or exhaust system in the vicinity of the filter. After such time, the fuel can be ignited, such as by generating a spark with igniter24in the vicinity of dispensed fuel. This causes the fuel to combust, thereby regenerating the particulate filter. As stated previously, the fuel to gas ratio can be between 20:1 and 10:1. This combustion reaction can be maintained (e.g., by maintaining a flow of fuel and gas) for 2 minutes to 3 hours or more (e.g., 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180 minutes, or any time therebetween).

In order to verify that combustion has occurred, the temperature within the engine exhaust system is measured. If the temperature is above a threshold, such as 100° C., combustion is confirmed.

The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.