Aftertreatment system with gas sensor downstream of a heater

Patent metadata

Field	Value
Publication number	US-11591949-B2
Application number	US-202217682606-A
Country	US
Kind code	B2
Filing date	Feb 28, 2022
Priority date	Mar 2, 2021
Publication date	Feb 28, 2023
Grant date	Feb 28, 2023

Abstract

An aftertreatment system for treating constituents of an exhaust gas produced by an engine includes a heater configured to selectively heat the exhaust gas entering the aftertreatment system. An aftertreatment component is disposed downstream of the heater. A gas sensor is disposed downstream of the heater and upstream of the aftertreatment component. The gas sensor comprises a sensing element, and a heating element configured to selectively heat the sensing element to an operating temperature of the sensing element.

First claim

What is claimed is:

1. An aftertreatment system for treating an exhaust gas produced by an engine, the aftertreatment system comprising:
a heater configured to selectively heat the exhaust gas entering the aftertreatment system;
an aftertreatment component disposed downstream of the heater;
a gas sensor disposed downstream of the heater and upstream of the aftertreatment component, the gas sensor comprising:
a sensing element, and
a heating element configured to selectively heat the sensing element to an operating temperature of the sensing element; and

a controller configured to:
determine an upstream exhaust gas temperature of the exhaust gas upstream of the heater,
in response to the upstream exhaust gas temperature being less than a first threshold, cause activation of the heater,
determine a downstream exhaust gas temperature of the exhaust gas downstream of the heater, and
in response to the downstream exhaust gas temperature being equal to or greater than the first threshold, cause activation of the heating element of the gas sensor.

2. The aftertreatment system of claim 1 , further comprising:
a housing, the aftertreatment component and the gas sensor being disposed in the housing.

3. The aftertreatment system of claim 1 , wherein the first threshold is 100 degrees Celsius.

4. The aftertreatment system of claim 1 , wherein:
the controller is further configured to:
in response to the downstream exhaust gas temperature being less than a second threshold that is greater than the first threshold, maintain the heater and the heating element in their respective activated states until the downstream exhaust gas temperature reaches the second threshold.

5. The aftertreatment system of claim 4 , wherein the controller is further configured to modulate a power of the heater and a power of the sensing element to maintain the sensing element at the second threshold.

6. The aftertreatment system of claim 1 , wherein:
the controller is further configured to:
activate the sensing element simultaneously with or subsequent to activating the heating element, and
determine an amount of exhaust gas constituents in the exhaust gas based on a signal received from the sensing element.

7. The aftertreatment system of claim 1 , wherein the aftertreatment component comprises at least one of an oxidation catalyst, a filter, a selective catalytic reduction system, or a two-way catalyst.

8. The aftertreatment system of claim 7 , wherein the aftertreatment component comprises the oxidation catalyst, the gas sensor being disposed between the heater and the oxidation catalyst.

9. The aftertreatment system of claim 1 , wherein the heater comprises an electrical heater.

10. A controller for an aftertreatment system that comprises an aftertreatment component, a heater disposed upstream of the aftertreatment component, and a gas sensor comprising a sensing element and a heating element disposed downstream of the heater and upstream of the aftertreatment component, the controller configured to:
determine an upstream exhaust gas temperature of the exhaust gas upstream of the heater;
in response to the upstream exhaust gas temperature being less than a first threshold, cause activation of the heater;
determine a downstream exhaust gas temperature of the exhaust gas downstream of the heater; and
in response to the downstream exhaust gas temperature being equal to or greater than the first threshold, cause activation of the heating element of the gas sensor.

11. The controller of claim 10 , wherein the first threshold is 100 degrees Celsius.

12. The controller of claim 10 , wherein the controller is further configured to:
in response to the downstream exhaust gas temperature being less than a second threshold that is greater than the first threshold, maintain the heater and the heating element in their respective activated states until the downstream exhaust gas temperature reaches the second threshold.

13. The controller of claim 12 , wherein the controller is further configured to modulate a power of the heater and a power of the sensing element to maintain the sensing element at the second threshold.

14. The controller of claim 10 , wherein the controller is further configured to:
activate the sensing element simultaneously with or subsequent to activating the heating element; and
determine an amount of exhaust gas constituents in the exhaust gas based on a signal received from the sensing element.

15. A method for treating an exhaust gas produced by an engine, the method comprising:
determining, by a controller, an upstream exhaust gas temperature of an exhaust gas flowing through an aftertreatment system upstream of a heater of the aftertreatment system, the aftertreatment system comprising a gas sensor comprising a sensing element and a heating element disposed downstream of the heater and upstream of an aftertreatment component of the aftertreatment system;
in response to the upstream exhaust gas temperature being less than a first threshold, causing, by the controller, activation of the heater;
determining, by the controller, a downstream exhaust gas temperature of the exhaust gas downstream of the heater; and
in response to the downstream exhaust gas temperature being equal to or greater than the first threshold, causing, by the controller, activation of the heating element of the gas sensor.

16. The method of claim 15 , further comprising:
in response to the downstream exhaust gas temperature being less than a second threshold that is greater than the first threshold, maintaining, by the controller, the heater and the heating element in their respective activated states until the downstream exhaust gas temperature reaches the second threshold.

17. The method of claim 16 , further comprising:
modulating, by the controller, a power of the heater and a power of the sensing element to maintain the sensing element at the second threshold.

18. The method of claim 15 , further comprising:
activating, by the controller, the sensing element simultaneously with or subsequent to activating the heating element; and
determining, by the controller, an amount of exhaust gas constituents in the exhaust gas based on a signal received from the sensing element.

Assignees

• Cummins Emission Solutions Inc

Inventors

• Norris Colin L
• Osburn Andrew W
• Johnson Ryan M
• Corbet Todd A
• Fath Kyle Robert
• Henry Lindsey R
• Faalzada Baseer

Classifications

• Y02T10/12

  Improving ICE efficiencies · CPC title

• F01N9/00

  Electrical control of exhaust gas treating apparatus (monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00) · CPC title

• F01N13/008 Primary

  Mounting or arrangement of exhaust sensors in or on exhaust apparatus (sensor arrangements for engine control F02D41/1439) · CPC title

• F01N2560/02

  the means being an exhaust gas sensor · CPC title

• F01N2560/026

  for measuring or detecting NOx · CPC title