US20110041482A1 - Method and apparatus for exhaust aftertreatment of an internal combustion engine - Google Patents
Method and apparatus for exhaust aftertreatment of an internal combustion engine Download PDFInfo
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- US20110041482A1 US20110041482A1 US12/544,532 US54453209A US2011041482A1 US 20110041482 A1 US20110041482 A1 US 20110041482A1 US 54453209 A US54453209 A US 54453209A US 2011041482 A1 US2011041482 A1 US 2011041482A1
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- exhaust gas
- substrate portion
- flow
- substrate
- aftertreatment device
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2053—By-passing catalytic reactors, e.g. to prevent overheating
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/011—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more purifying devices arranged in parallel
- F01N13/017—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more purifying devices arranged in parallel the purifying devices are arranged in a single housing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2892—Exhaust flow directors or the like, e.g. upstream of catalytic device
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2410/00—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
Definitions
- This disclosure is related to exhaust aftertreatment systems for internal combustion engines.
- Known combustion by-products ejected into an exhaust gas feedstream include carbon monoxide (CO), nitrides of oxygen (NOx), and particulate matter (PM), among others.
- Unburned hydrocarbons (HC) are also present in engine-out emissions. Operating the engine at varying air/fuel ratios including rich, lean and stoichiometric ratios produces different proportions of the by-products and the unburned HC.
- Known aftertreatment systems can include multiple aftertreatment devices.
- Each aftertreatment device includes a coated substrate and/or particulate filter to oxidize, adsorb, desorb, reduce, and combust elements of the exhaust gas feedstream.
- Each aftertreatment device processes different by-products and different proportions of the by-products produced at various air/fuel ratios.
- Aftertreatment systems including multiple aftertreatment devices may be disadvantaged by requirements for additional space in the underbody and engine compartment devices, thermal inefficiencies associated with the additional thermal mass and surface area for thermal dissipation, and engine torque losses attributable to forcing the exhaust gas feedstream through the devices in the form of back pressure.
- An exhaust gas aftertreatment device includes a single intake path for an exhaust gas feedstream from an internal combustion engine and a coated substrate including a first substrate portion fluidly in parallel with a second substrate portion.
- a flow modification device selectively restricts flow of the exhaust gas feedstream exclusively to the first substrate portion, exclusively to the second substrate portion, and concurrently to the first substrate portion and the second substrate portion in controllably variable proportions.
- FIG. 2 is a is a schematic drawing of a first exemplary aftertreatment device with a control valve, in accordance with the present disclosure
- FIG. 3 is a cross-sectional view of a first exemplary substrate device, in accordance with the present disclosure
- FIG. 4 is a schematic drawing of the first exemplary aftertreatment device the control valve in a first position, in accordance with the present disclosure
- FIG. 5 is a schematic drawing of the first exemplary aftertreatment device the control valve in a second position, in accordance with the present disclosure
- FIG. 6 is a schematic drawing of the first exemplary aftertreatment device the control valve in a third position, in accordance with the present disclosure
- FIG. 7 is a schematic drawing of a second exemplary aftertreatment device with a control valve, in accordance with the present disclosure.
- FIG. 8 is a cross-sectional view of an alternate embodiment of a second exemplary substrate device, in accordance with the present disclosure.
- FIG. 1 schematically shows an exemplary spark-ignition direct-injection internal combustion engine 10 , an accompanying control module 5 , and an exhaust aftertreatment system 70 that have been constructed in accordance with embodiments of the disclosure.
- the exemplary engine 10 may be selectively operative in a plurality of combustion modes, including a controlled auto-ignition combustion mode, a homogeneous spark-ignition combustion mode, a stratified-charge spark-ignition combustion mode, and a compression ignition mode.
- the exemplary engine 10 is selectively operative at an air/fuel ratio that is primarily lean of stoichiometry.
- the disclosure can be applied to various combustion cycles and internal combustion engine systems including homogeneous-charge compression-ignition, diesel, pre-mixed charge compression ignition, and stratified-charge spark-ignition direct-injection and is not limited thereby.
- the exemplary engine 10 includes a multi-cylinder direct-injection four-stroke internal combustion engine having reciprocating pistons slidably movable in cylinders which define variable volume combustion chambers. Each piston is connected to a rotating crankshaft by which their linear reciprocating motion is translated to rotational motion.
- An air intake system provides intake air to an intake manifold which directs and distributes air into an intake runner to each combustion chamber.
- the air intake system includes airflow ductwork and devices for monitoring and controlling the air flow.
- the air intake devices preferably include a mass airflow sensor for monitoring mass airflow and intake air temperature.
- a throttle valve preferably includes an electronically controlled device which controls air flow to the engine in response to a control signal from the control module 5 .
- a pressure sensor in the manifold is adapted to monitor manifold absolute pressure and barometric pressure.
- An external flow passage recirculates exhaust gases from engine exhaust to the intake manifold, having a flow control valve, referred to as an exhaust gas recirculation valve.
- the control module 5 is operative to control mass flow of exhaust gas to the intake manifold by controlling opening of the exhaust gas recirculation valve.
- At least one intake valve and one exhaust valve corresponds to each cylinder and combustion chamber. There is preferably one valve actuator for each one of the intake and exhaust valves.
- Each intake valve can allow inflow of air and fuel to the corresponding combustion chamber when open.
- Each exhaust valve can allow flow combustion by-products out of the corresponding combustion chamber to the aftertreatment system 70 when open.
- the engine can include a fuel injection system, including a plurality of high-pressure fuel injectors each adapted to directly inject a mass of fuel into one of the combustion chambers, in response to a signal from the control module 5 .
- the fuel injectors are supplied pressurized fuel from a fuel distribution system.
- the engine can include a spark-ignition system by which spark energy is provided to a spark plug for igniting or assisting in igniting cylinder charges in each of the combustion chambers in response to a signal from the control module 5 .
- the exemplary engine 10 is preferably equipped with various sensing devices for monitoring engine operation and exhaust gases, e.g., air/fuel ratio sensor.
- An exhaust gas sensor monitors the exhaust gas feedstream, and can include an air/fuel ratio sensor in one embodiment.
- the control module 5 executes algorithmic code stored therein to control actuators to control engine operation, including throttle position, spark timing, fuel injection mass and timing, intake and/or exhaust valve timing and phasing, and exhaust gas recirculation valve position to control flow of recirculated exhaust gases.
- Valve timing and phasing may include negative valve overlap and lift of exhaust valve reopening (in an exhaust re-breathing strategy).
- the control module 5 is configured to receive input signals from an operator (e.g., a throttle pedal position and a brake pedal position) to determine an operator torque request and input from the sensors indicating the engine speed and intake air temperature, and coolant temperature and other ambient conditions.
- the control module 5 is preferably a general-purpose digital computer generally including a microprocessor or central processing unit, storage mediums including non-volatile memory including read only memory and electrically programmable read only memory, random access memory, a high speed clock, analog to digital and digital to analog circuitry, and input/output circuitry and devices and appropriate signal conditioning and buffer circuitry.
- the control module 5 has a set of control algorithms, including resident program instructions and calibrations stored in the non-volatile memory and executed to provide desired functions.
- the algorithms are preferably executed during preset loop cycles. Algorithms are executed by the central processing unit and are operable to monitor inputs from the aforementioned sensing devices and execute control and diagnostic routines to control operation of the actuators, using preset calibrations. Loop cycles may be executed at regular intervals, for example each 3.125, 6.25, 12.5, 25 and 100 milliseconds during ongoing engine and vehicle operation. Alternatively, algorithms may be executed in response to occurrence of an event.
- the exhaust aftertreatment system 70 is fluidly connected to the exhaust manifold 39 and includes catalytic and/or trap substrates operative to oxidize, adsorb, desorb, reduce, and combust elements of the exhaust gas feedstream.
- the exhaust aftertreatment system 70 includes one or more exhaust aftertreatment device(s) 48 that are preferably closely coupled to the exhaust manifold 39 of the exemplary engine 10 .
- FIGS. 2 and 3 show the exhaust aftertreatment device 48 constructed in accordance with the present disclosure.
- the exhaust aftertreatment device 48 includes a single intake end 100 fluidly connected to the exhaust manifold 39 and an outlet end 200 for containing the exhaust gas feedstream.
- the exhaust aftertreatment device 48 includes a housing 130 attached to the single intake end 100 and the outlet end 200 .
- the housing 130 in one embodiment is a cylindrical shape constructed from stainless steel or other material.
- the single intake end 100 of the housing 130 divides into two flow paths including a first exhaust gas path 110 and a second exhaust gas path 120 .
- a flow modification mechanism e.g., a control valve 102 , is signally connected to the control module 5 and configured to modify the exhaust gas feedstream flowing to the first and second exhaust gas paths 110 and 120 .
- the first exhaust gas path 110 is configured to channel exhaust gas flow to a first substrate portion 140 of a substrate device 145 and the second exhaust gas path 120 is configured to channel exhaust gas flow to a second substrate portion 150 of the substrate device 145 .
- the exhaust aftertreatment device 48 includes the substrate device 145 including the first and second substrate portions 140 and 150 .
- the first and second substrate portions 140 and 150 are fluidly parallel in relationship to the exhaust gas feedstream, and each has a multiplicity of parallel flow passages through which exhaust gas can flow. Fluidly parallel portions are understood to mean that an exhaust gas flowing through one portion does not also flow through the other portion.
- the substrate 145 is formed from ceramic material, e.g., cordierite, and having flow-through passages at a density of about 62 to 96 cells per square centimeter (400-600 cells per square inch), and a wall thickness between the flow passages of about three to seven mils.
- the substrate 145 is formed from corrugated stainless steel.
- the flow passages for the first and second substrate portions 140 and 150 of the substrate 145 can be individually coated with differing washcoat materials, e.g., alumina and zeolite, and differing densities and masses of active materials, i.e., platinum-group metals and other metals.
- exemplary catalytically active metals can include platinum group metals including platinum (Pt), palladium (Pd), and rhodium (Rh) and non-platinum group metals including iron (Fe), copper (Cu) thallium (Tl) and vanadium (Va).
- one of the first and second substrate portions 140 and 150 includes a washcoat and catalytically active materials to process oxygen-rich exhaust gas at lower temperatures and the other includes a washcoat and catalytically active materials to process exhaust gas at higher temperatures.
- FIG. 3 shows a cross-sectional view of one embodiment of the substrate device 145 having the first and second fluidly parallel substrate portions 140 and 150 .
- the cross-sectional view shows the substrate 145 having a substantially circular cross-section.
- the second substrate portion 150 has a circular cross-section of a diameter less than the diameter of the substrate device 145 , and the second substrate portion 150 has an annular cross-section that circumscribes the first substrate portion 140 .
- the control valve 102 is positioned in the single intake end 100 of the exhaust aftertreatment device 48 , although the control valve 102 may alternatively be suitably positioned elsewhere within the exhaust aftertreatment device 48 , e.g., in the outlet end 200 .
- the control valve 102 includes a flow control valve configured to direct flow of the exhaust gas feedstream via flow diffusing, flow diverting and/or flow blocking mechanisms or devices.
- the control valve 102 is preferably centrally positioned within the exhaust aftertreatment device 48 .
- the control valve 102 is configured to prohibit exhaust gas flow through one of the first and second substrate portions 140 and 150 .
- the control valve 102 may be actuated or otherwise controlled by, for example, a solenoid or other actuation device known in the art configured to receive actuation commands from the control module 5 .
- the control valve 102 may be implemented in the exhaust aftertreatment device 48 using any one of multiple flow modification devices and this disclosure is not limited thereby.
- the control valve 102 is controllable to any one of a first position, a second position and a third position to effect a desired exhaust gas flow.
- the first position permits exhaust gas flow through the first substrate portion 140 while prohibiting exhaust gas flow through the second substrate portion 150 .
- the second position permits exhaust gas flow through the second substrate portion 150 while prohibiting exhaust gas flow through the first substrate portion 140 .
- the third position permits simultaneous exhaust gas flow through both the first and second substrate portions 140 and 150 .
- FIG. 2 illustrates an embodiment of the control valve 102 including a hollow tube structure 105 having a porous end 106 connected to a member 107 including a capped end 108 .
- the engine 10 generates an exhaust gas feedstream containing constituent elements including hydrocarbons (HC), carbon monoxide (CO), nitrides of oxygen (NOx), and particulate matter (PM), among others.
- HC hydrocarbons
- CO carbon monoxide
- NOx nitrides of oxygen
- PM particulate matter
- the exhaust aftertreatment device 48 is configured to process the different proportions of the constituent elements produced by the varying air/fuel ratios.
- Engine operation can include transitions between combustion modes and variations in engine-out air/fuel ratios.
- the control valve 102 can direct the exhaust gas feedstream to flow to one of the first exhaust gas path 110 , the second exhaust gas path 120 , and both the first and second exhaust gas paths 110 and 120 concurrently.
- the exhaust gas feedstream may be directed through the second exhaust path 120 during lean engine operation and directed through the first exhaust path 110 during stoichiometric or rich engine operation.
- FIGS. 4-6 show the control valve 102 in multiple positions within the exhaust aftertreatment device 48 .
- the hollow tube structure 105 permits exhaust flow to the first exhaust path 110 , thereby incrementally increasing exhaust gas flow through the first substrate portion 140 and incrementally decreasing exhaust gas flow through the second substrate portion 150 .
- the member 107 and the capped end 108 incrementally inhibit exhaust gas flow through the second substrate portion 150 .
- the control valve 102 is controlled to a first position (shown in FIG. 4 )
- the capped end substantially prohibits exhaust gas flow to the second substrate portion 150 and the hollow tube structure 105 permits exhaust gas flow to the first substrate portion 140 .
- the hollow tube structure 105 inhibits exhaust flow to the first exhaust path 110 , thereby incrementally increasing exhaust flow through the second substrate portion 150 and incrementally decreasing exhaust flow through the first substrate portion 140 .
- the control valve 102 is controlled to a second position (shown in FIG. 6 )
- the hollow tube structure 105 substantially prohibits exhaust gas flow to the first substrate portion 140
- the capped end 108 of the member 107 permits exhaust gas flow to the second substrate portion 150 .
- FIG. 4 shows the exhaust aftertreatment device 48 with the control valve 102 in a first position whereby the exhaust gas feedstream is controlled through the first exhaust path 110 .
- the exhaust gas feedstream is prohibited from going through the second exhaust path 120 .
- the first substrate portion 140 oxidizes, adsorbs, reduces, and combusts elements in the exhaust gas feedstream.
- FIG. 5 shows the exhaust aftertreatment device 48 with the control valve 102 in a second position whereby the exhaust gas feedstream is controlled through the second exhaust path 120 .
- the exhaust gas feedstream is prohibited from going through the first exhaust path 110 .
- the second substrate portion 150 oxidizes, adsorbs, reduces, and combusts elements in the exhaust gas feedstream.
- FIG. 6 shows the exhaust aftertreatment device 48 with the control valve 102 in a third position intermediate the first and second positions whereby the exhaust gas feedstream is permitted to concurrently flow through both the first and second exhaust paths 110 and 120 .
- Both the first and second substrate portions 140 and 150 oxidize, adsorb, reduce, and combust elements in the exhaust gas feedstream.
- FIG. 7 shows an alternate embodiment of the exhaust aftertreatment device 48 .
- the substrate 145 includes first substrate portion 140 contiguous to the second substrate portion 150 .
- the control valve 102 is signally connected to the control module 5 and configured to control the exhaust gas feedstream flow to the first and second substrate portions 140 and 150 .
- the control valve 102 When the control valve 102 is in a first position, the exhaust gas flows through the first exhaust gas path 110 to the first substrate portion 140 and prohibits exhaust gas flow to the second substrate portion 150 .
- the control valve 102 is in a second position, the exhaust gas flows through the second exhaust gas path 120 to the second substrate portion 150 and prohibits exhaust gas flow to the first substrate portion 140 .
- the control valve 102 is in a third position intermediate the first and second positions, exhaust gas flows through the first and second exhaust gas paths 110 and 120 to both the first and second substrate portions 140 and 150 .
- FIG. 8 shows a cross sectional view of an the substrate described with reference to FIG. 7 , with the first substrate portion 140 contiguous to the second substrate portion 150 .
Abstract
Description
- This disclosure is related to exhaust aftertreatment systems for internal combustion engines.
- The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
- Known combustion by-products ejected into an exhaust gas feedstream include carbon monoxide (CO), nitrides of oxygen (NOx), and particulate matter (PM), among others. Unburned hydrocarbons (HC) are also present in engine-out emissions. Operating the engine at varying air/fuel ratios including rich, lean and stoichiometric ratios produces different proportions of the by-products and the unburned HC.
- Known aftertreatment systems can include multiple aftertreatment devices. Each aftertreatment device includes a coated substrate and/or particulate filter to oxidize, adsorb, desorb, reduce, and combust elements of the exhaust gas feedstream. Each aftertreatment device processes different by-products and different proportions of the by-products produced at various air/fuel ratios. Aftertreatment systems including multiple aftertreatment devices may be disadvantaged by requirements for additional space in the underbody and engine compartment devices, thermal inefficiencies associated with the additional thermal mass and surface area for thermal dissipation, and engine torque losses attributable to forcing the exhaust gas feedstream through the devices in the form of back pressure.
- An exhaust gas aftertreatment device includes a single intake path for an exhaust gas feedstream from an internal combustion engine and a coated substrate including a first substrate portion fluidly in parallel with a second substrate portion. A flow modification device selectively restricts flow of the exhaust gas feedstream exclusively to the first substrate portion, exclusively to the second substrate portion, and concurrently to the first substrate portion and the second substrate portion in controllably variable proportions.
- One or more embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:
-
FIG. 1 is a schematic drawing of an exemplary engine system, in accordance with the present disclosure; -
FIG. 2 is a is a schematic drawing of a first exemplary aftertreatment device with a control valve, in accordance with the present disclosure; -
FIG. 3 is a cross-sectional view of a first exemplary substrate device, in accordance with the present disclosure; -
FIG. 4 is a schematic drawing of the first exemplary aftertreatment device the control valve in a first position, in accordance with the present disclosure; -
FIG. 5 is a schematic drawing of the first exemplary aftertreatment device the control valve in a second position, in accordance with the present disclosure; -
FIG. 6 is a schematic drawing of the first exemplary aftertreatment device the control valve in a third position, in accordance with the present disclosure; -
FIG. 7 is a schematic drawing of a second exemplary aftertreatment device with a control valve, in accordance with the present disclosure; and -
FIG. 8 is a cross-sectional view of an alternate embodiment of a second exemplary substrate device, in accordance with the present disclosure. - Referring now to the drawings, wherein the showings are for the purpose of illustrating certain exemplary embodiments only and not for the purpose of limiting the same,
FIG. 1 schematically shows an exemplary spark-ignition direct-injectioninternal combustion engine 10, an accompanyingcontrol module 5, and anexhaust aftertreatment system 70 that have been constructed in accordance with embodiments of the disclosure. Like numerals refer to like elements in the embodiments. Theexemplary engine 10 may be selectively operative in a plurality of combustion modes, including a controlled auto-ignition combustion mode, a homogeneous spark-ignition combustion mode, a stratified-charge spark-ignition combustion mode, and a compression ignition mode. Theexemplary engine 10 is selectively operative at an air/fuel ratio that is primarily lean of stoichiometry. The disclosure can be applied to various combustion cycles and internal combustion engine systems including homogeneous-charge compression-ignition, diesel, pre-mixed charge compression ignition, and stratified-charge spark-ignition direct-injection and is not limited thereby. - The
exemplary engine 10 includes a multi-cylinder direct-injection four-stroke internal combustion engine having reciprocating pistons slidably movable in cylinders which define variable volume combustion chambers. Each piston is connected to a rotating crankshaft by which their linear reciprocating motion is translated to rotational motion. An air intake system provides intake air to an intake manifold which directs and distributes air into an intake runner to each combustion chamber. The air intake system includes airflow ductwork and devices for monitoring and controlling the air flow. The air intake devices preferably include a mass airflow sensor for monitoring mass airflow and intake air temperature. A throttle valve preferably includes an electronically controlled device which controls air flow to the engine in response to a control signal from thecontrol module 5. A pressure sensor in the manifold is adapted to monitor manifold absolute pressure and barometric pressure. An external flow passage recirculates exhaust gases from engine exhaust to the intake manifold, having a flow control valve, referred to as an exhaust gas recirculation valve. Thecontrol module 5 is operative to control mass flow of exhaust gas to the intake manifold by controlling opening of the exhaust gas recirculation valve. - At least one intake valve and one exhaust valve corresponds to each cylinder and combustion chamber. There is preferably one valve actuator for each one of the intake and exhaust valves. Each intake valve can allow inflow of air and fuel to the corresponding combustion chamber when open. Each exhaust valve can allow flow combustion by-products out of the corresponding combustion chamber to the
aftertreatment system 70 when open. - The engine can include a fuel injection system, including a plurality of high-pressure fuel injectors each adapted to directly inject a mass of fuel into one of the combustion chambers, in response to a signal from the
control module 5. The fuel injectors are supplied pressurized fuel from a fuel distribution system. The engine can include a spark-ignition system by which spark energy is provided to a spark plug for igniting or assisting in igniting cylinder charges in each of the combustion chambers in response to a signal from thecontrol module 5. - The
exemplary engine 10 is preferably equipped with various sensing devices for monitoring engine operation and exhaust gases, e.g., air/fuel ratio sensor. An exhaust gas sensor monitors the exhaust gas feedstream, and can include an air/fuel ratio sensor in one embodiment. - The
control module 5 executes algorithmic code stored therein to control actuators to control engine operation, including throttle position, spark timing, fuel injection mass and timing, intake and/or exhaust valve timing and phasing, and exhaust gas recirculation valve position to control flow of recirculated exhaust gases. Valve timing and phasing may include negative valve overlap and lift of exhaust valve reopening (in an exhaust re-breathing strategy). Thecontrol module 5 is configured to receive input signals from an operator (e.g., a throttle pedal position and a brake pedal position) to determine an operator torque request and input from the sensors indicating the engine speed and intake air temperature, and coolant temperature and other ambient conditions. - The
control module 5 is preferably a general-purpose digital computer generally including a microprocessor or central processing unit, storage mediums including non-volatile memory including read only memory and electrically programmable read only memory, random access memory, a high speed clock, analog to digital and digital to analog circuitry, and input/output circuitry and devices and appropriate signal conditioning and buffer circuitry. Thecontrol module 5 has a set of control algorithms, including resident program instructions and calibrations stored in the non-volatile memory and executed to provide desired functions. The algorithms are preferably executed during preset loop cycles. Algorithms are executed by the central processing unit and are operable to monitor inputs from the aforementioned sensing devices and execute control and diagnostic routines to control operation of the actuators, using preset calibrations. Loop cycles may be executed at regular intervals, for example each 3.125, 6.25, 12.5, 25 and 100 milliseconds during ongoing engine and vehicle operation. Alternatively, algorithms may be executed in response to occurrence of an event. - The
exhaust aftertreatment system 70 is fluidly connected to theexhaust manifold 39 and includes catalytic and/or trap substrates operative to oxidize, adsorb, desorb, reduce, and combust elements of the exhaust gas feedstream. Theexhaust aftertreatment system 70 includes one or more exhaust aftertreatment device(s) 48 that are preferably closely coupled to theexhaust manifold 39 of theexemplary engine 10. -
FIGS. 2 and 3 show theexhaust aftertreatment device 48 constructed in accordance with the present disclosure. Theexhaust aftertreatment device 48 includes asingle intake end 100 fluidly connected to theexhaust manifold 39 and anoutlet end 200 for containing the exhaust gas feedstream. Theexhaust aftertreatment device 48 includes ahousing 130 attached to thesingle intake end 100 and theoutlet end 200. Thehousing 130 in one embodiment is a cylindrical shape constructed from stainless steel or other material. Thesingle intake end 100 of thehousing 130 divides into two flow paths including a firstexhaust gas path 110 and a secondexhaust gas path 120. A flow modification mechanism, e.g., acontrol valve 102, is signally connected to thecontrol module 5 and configured to modify the exhaust gas feedstream flowing to the first and secondexhaust gas paths exhaust gas path 110 is configured to channel exhaust gas flow to afirst substrate portion 140 of asubstrate device 145 and the secondexhaust gas path 120 is configured to channel exhaust gas flow to asecond substrate portion 150 of thesubstrate device 145. - The
exhaust aftertreatment device 48 includes thesubstrate device 145 including the first andsecond substrate portions second substrate portions substrate 145 is formed from ceramic material, e.g., cordierite, and having flow-through passages at a density of about 62 to 96 cells per square centimeter (400-600 cells per square inch), and a wall thickness between the flow passages of about three to seven mils. In one embodiment, thesubstrate 145 is formed from corrugated stainless steel. The flow passages for the first andsecond substrate portions substrate 145 can be individually coated with differing washcoat materials, e.g., alumina and zeolite, and differing densities and masses of active materials, i.e., platinum-group metals and other metals. Exemplary catalytically active metals can include platinum group metals including platinum (Pt), palladium (Pd), and rhodium (Rh) and non-platinum group metals including iron (Fe), copper (Cu) thallium (Tl) and vanadium (Va). In one embodiment, one of the first andsecond substrate portions -
FIG. 3 shows a cross-sectional view of one embodiment of thesubstrate device 145 having the first and second fluidlyparallel substrate portions substrate 145 having a substantially circular cross-section. Thesecond substrate portion 150 has a circular cross-section of a diameter less than the diameter of thesubstrate device 145, and thesecond substrate portion 150 has an annular cross-section that circumscribes thefirst substrate portion 140. - The
control valve 102 is positioned in thesingle intake end 100 of theexhaust aftertreatment device 48, although thecontrol valve 102 may alternatively be suitably positioned elsewhere within theexhaust aftertreatment device 48, e.g., in theoutlet end 200. Thecontrol valve 102 includes a flow control valve configured to direct flow of the exhaust gas feedstream via flow diffusing, flow diverting and/or flow blocking mechanisms or devices. Thecontrol valve 102 is preferably centrally positioned within theexhaust aftertreatment device 48. Thecontrol valve 102 is configured to prohibit exhaust gas flow through one of the first andsecond substrate portions control valve 102 may be actuated or otherwise controlled by, for example, a solenoid or other actuation device known in the art configured to receive actuation commands from thecontrol module 5. As one skilled in the art will recognize, thecontrol valve 102 may be implemented in theexhaust aftertreatment device 48 using any one of multiple flow modification devices and this disclosure is not limited thereby. - The
control valve 102 is controllable to any one of a first position, a second position and a third position to effect a desired exhaust gas flow. The first position permits exhaust gas flow through thefirst substrate portion 140 while prohibiting exhaust gas flow through thesecond substrate portion 150. The second position permits exhaust gas flow through thesecond substrate portion 150 while prohibiting exhaust gas flow through thefirst substrate portion 140. The third position permits simultaneous exhaust gas flow through both the first andsecond substrate portions -
FIG. 2 illustrates an embodiment of thecontrol valve 102 including ahollow tube structure 105 having aporous end 106 connected to amember 107 including a cappedend 108. During engine operation, theengine 10 generates an exhaust gas feedstream containing constituent elements including hydrocarbons (HC), carbon monoxide (CO), nitrides of oxygen (NOx), and particulate matter (PM), among others. Operating theengine 10 at varying air/fuel ratios including rich, lean and stoichiometric ratios produce different proportions of the constituent elements and therefore result in different aftertreatment considerations, e.g., different catalysts for NOx emissions during lean engine operation. Preferably, theexhaust aftertreatment device 48 is configured to process the different proportions of the constituent elements produced by the varying air/fuel ratios. - Engine operation can include transitions between combustion modes and variations in engine-out air/fuel ratios. The
control valve 102 can direct the exhaust gas feedstream to flow to one of the firstexhaust gas path 110, the secondexhaust gas path 120, and both the first and secondexhaust gas paths second exhaust path 120 during lean engine operation and directed through thefirst exhaust path 110 during stoichiometric or rich engine operation. -
FIGS. 4-6 show thecontrol valve 102 in multiple positions within theexhaust aftertreatment device 48. As thecontrol valve 102 is controlled away from the first andsecond substrate portions hollow tube structure 105 permits exhaust flow to thefirst exhaust path 110, thereby incrementally increasing exhaust gas flow through thefirst substrate portion 140 and incrementally decreasing exhaust gas flow through thesecond substrate portion 150. Themember 107 and the cappedend 108 incrementally inhibit exhaust gas flow through thesecond substrate portion 150. When thecontrol valve 102 is controlled to a first position (shown inFIG. 4 ), the capped end substantially prohibits exhaust gas flow to thesecond substrate portion 150 and thehollow tube structure 105 permits exhaust gas flow to thefirst substrate portion 140. As thecontrol valve 102 is controlled towards the first andsecond substrate portions hollow tube structure 105 inhibits exhaust flow to thefirst exhaust path 110, thereby incrementally increasing exhaust flow through thesecond substrate portion 150 and incrementally decreasing exhaust flow through thefirst substrate portion 140. When thecontrol valve 102 is controlled to a second position (shown inFIG. 6 ), thehollow tube structure 105 substantially prohibits exhaust gas flow to thefirst substrate portion 140, and the cappedend 108 of themember 107 permits exhaust gas flow to thesecond substrate portion 150. -
FIG. 4 shows theexhaust aftertreatment device 48 with thecontrol valve 102 in a first position whereby the exhaust gas feedstream is controlled through thefirst exhaust path 110. The exhaust gas feedstream is prohibited from going through thesecond exhaust path 120. Thus, thefirst substrate portion 140 oxidizes, adsorbs, reduces, and combusts elements in the exhaust gas feedstream. -
FIG. 5 shows theexhaust aftertreatment device 48 with thecontrol valve 102 in a second position whereby the exhaust gas feedstream is controlled through thesecond exhaust path 120. The exhaust gas feedstream is prohibited from going through thefirst exhaust path 110. Thus, thesecond substrate portion 150 oxidizes, adsorbs, reduces, and combusts elements in the exhaust gas feedstream. -
FIG. 6 shows theexhaust aftertreatment device 48 with thecontrol valve 102 in a third position intermediate the first and second positions whereby the exhaust gas feedstream is permitted to concurrently flow through both the first andsecond exhaust paths second substrate portions -
FIG. 7 shows an alternate embodiment of theexhaust aftertreatment device 48. In the alternate embodiment, thesubstrate 145 includesfirst substrate portion 140 contiguous to thesecond substrate portion 150. Thecontrol valve 102 is signally connected to thecontrol module 5 and configured to control the exhaust gas feedstream flow to the first andsecond substrate portions control valve 102 is in a first position, the exhaust gas flows through the firstexhaust gas path 110 to thefirst substrate portion 140 and prohibits exhaust gas flow to thesecond substrate portion 150. When thecontrol valve 102 is in a second position, the exhaust gas flows through the secondexhaust gas path 120 to thesecond substrate portion 150 and prohibits exhaust gas flow to thefirst substrate portion 140. When thecontrol valve 102 is in a third position intermediate the first and second positions, exhaust gas flows through the first and secondexhaust gas paths second substrate portions -
FIG. 8 shows a cross sectional view of an the substrate described with reference toFIG. 7 , with thefirst substrate portion 140 contiguous to thesecond substrate portion 150. - The disclosure has described certain preferred embodiments and modifications thereto. Further modifications and alterations may occur to others upon reading and understanding the specification. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.
Claims (17)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/544,532 US20110041482A1 (en) | 2009-08-20 | 2009-08-20 | Method and apparatus for exhaust aftertreatment of an internal combustion engine |
DE102010034104A DE102010034104A1 (en) | 2009-08-20 | 2010-08-12 | Method and device for exhaust aftertreatment of an internal combustion engine |
CN2010102608136A CN101994549A (en) | 2009-08-20 | 2010-08-20 | Method and apparatus for exhaust aftertreatment of internal combustion engine |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US12/544,532 US20110041482A1 (en) | 2009-08-20 | 2009-08-20 | Method and apparatus for exhaust aftertreatment of an internal combustion engine |
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Publication Number | Publication Date |
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US20110041482A1 true US20110041482A1 (en) | 2011-02-24 |
Family
ID=43604179
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/544,532 Abandoned US20110041482A1 (en) | 2009-08-20 | 2009-08-20 | Method and apparatus for exhaust aftertreatment of an internal combustion engine |
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US (1) | US20110041482A1 (en) |
CN (1) | CN101994549A (en) |
DE (1) | DE102010034104A1 (en) |
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WO2013004914A1 (en) * | 2011-07-07 | 2013-01-10 | Ecocat Oy | New purifying apparatus |
EP2693011A1 (en) * | 2012-07-30 | 2014-02-05 | Benteler Automobiltechnik GmbH | Exhaust gas valve assembly with integrated bypass |
GB2554379A (en) * | 2016-09-23 | 2018-04-04 | Ford Global Tech Llc | Improving warm-up of a catalytic aftertreatment device |
US10738674B2 (en) | 2016-09-21 | 2020-08-11 | Ford Global Technologies, Llc | Warm-up of a catalytic aftertreatment device |
US11371412B2 (en) * | 2020-07-09 | 2022-06-28 | Hyundai Motor Company | Exhaust heat recovery apparatus for vehicle having a longitudinal valve separating two parallel exhaust flow paths |
US11719147B2 (en) * | 2021-11-16 | 2023-08-08 | Man Energy Solutions Se | Exhaust gas after-treatment system of an engine designed as gas engine or dual-fuel engine, engine and method for operating the same |
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US10344642B2 (en) * | 2017-06-02 | 2019-07-09 | GM Global Technology Operations LLC | Systems and methods for controlling exhaust flow through dual after treatment device |
AT520807B1 (en) | 2017-12-28 | 2020-10-15 | Avl List Gmbh | EXHAUST GAS AFTER-TREATMENT DEVICE FOR A COMBUSTION ENGINE |
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CN101994549A (en) | 2011-03-30 |
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