System and method for controlling temperature of exhaust gas at inlet of selective catalytic reduction system

Patent metadata

Field	Value
Publication number	US-11674422-B2
Application number	US-202217707072-A
Country	US
Kind code	B2
Filing date	Mar 29, 2022
Priority date	Mar 31, 2021
Publication date	Jun 13, 2023
Grant date	Jun 13, 2023

Abstract

An aftertreatment system includes a selective catalytic reduction (SCR) system, a heater, and a controller that determines a rise in temperature of exhaust gas at an outlet of the heater for a plurality of power levels, predicts a first temperature of the exhaust gas at the outlet of the heater based on the rise in temperature, predicts a second temperature of the exhaust gas at a location of the SCR system based on the first temperature, compares the second temperature for each of the plurality of power levels with a target temperature of the exhaust gas at the inlet of the SCR system, selects one of the plurality of power levels based on the comparison, and adjusts operation of the heater based on the selected one of the plurality of power levels to achieve the target temperature of the exhaust gas at the inlet of the SCR system.

First claim

What is claimed is:

1. An aftertreatment system comprising:
a selective catalytic reduction (SCR) system;
a heater; and
a controller comprising a processor programmed to execute computer-readable instructions stored in a memory to:
determine a rise in temperature of exhaust gas at an outlet of the heater for a plurality of power levels of the heater;
predict a first temperature of the exhaust gas at an outlet of the heater based on the rise in temperature for each of the plurality of power levels;
predict a second temperature of the exhaust gas at a location of the SCR system based on the first temperature for each of the plurality of power levels, wherein the location of the SCR system comprises an inlet of the SCR system or a defined axial location of the SCR system;
compare the second temperature for each of the plurality of power levels with a target temperature of the exhaust gas at the location of the SCR system by computing a sum-of-squares error value between the second temperature of each of the plurality of power levels and the target temperature of the exhaust gas at the location of the SCR system;
select one of the plurality of power levels based on the comparison; and
adjust operation of the heater based on the selected one of the plurality of power levels to achieve the target temperature of the exhaust gas at the location of the SCR system.

2. The aftertreatment system of claim 1 , wherein the processor is further programmed to execute computer-readable instructions to:
select one of the plurality of power levels by:
determining a minimum value from the sum-of-squares error values corresponding to the plurality of power levels, and
selecting a power level corresponding to the minimum value as the selected one of the plurality of power levels.

3. The aftertreatment system of claim 2 , wherein the processor is further programmed to execute computer-readable instructions to:
determine that more than one value of the sum-of squares error values corresponds to the minimum value;
compute a difference between the second temperature corresponding to each of the more than one value of the sum-of squares error values that corresponds to the minimum value and the target temperature; and
select the power level of the heater corresponding to a minimum difference between the second temperature and the target temperature.

4. The aftertreatment system of claim 1 , wherein the rise in temperature of the exhaust gas at the outlet of the heater is based on a power level of the heater, a mass flow rate of the exhaust gas, and a heat capacity of the exhaust gas.

5. The aftertreatment system of claim 1 , wherein the determination of the rise in temperature of exhaust gas at the outlet of the heater, the prediction of the first temperature, the prediction of the second temperature, the comparison of the second temperature with the target temperature, the selection one of the plurality of power levels, and the adjustment of the operation of the heater is repeated in each of a plurality of steps to make predictions for a forecast window.

6. The aftertreatment system of claim 1 , further comprising
an oxidation catalyst, wherein the
processor is further programmed to execute computer-readable instructions to:
determine a third temperature of the exhaust gas at an outlet of the oxidation catalyst;
compare the second temperature with the target temperature of the exhaust gas at the location of the SCR system; and
insert hydrocarbons into the oxidation catalyst based on the comparison and the third temperature to achieve the target temperature of the exhaust gas at the location of the SCR system.

7. The aftertreatment system of claim 1 , wherein the heater is an electric heater.

8. An aftertreatment system comprising:
a selective catalytic reduction (SCR) system;
a heater; and
a controller comprising a processor programmed to execute computer-readable instructions stored in a memory to:
determine a first temperature of exhaust gas at a location of the SCR system, wherein the location of the SCR system comprises an inlet of the SCR system or a defined axial location of the SCR system;
determine a second temperature of the exhaust gas at an outlet of the heater;
compare the first temperature with a target temperature of the exhaust gas at the location of the SCR system by computing a sum-of-squares error value between the first temperature of each of the plurality of power levels and the target temperature of the exhaust gas at the location of the SCR system; and
adjust operation of the heater based on the comparison and the second temperature to achieve the target temperature of the exhaust gas at the location of the SCR system.

9. The aftertreatment system of claim 8 , wherein the controller is a feedforward controller, and wherein the processor is further programmed to execute computer-readable instructions to:
predict the second temperature of the exhaust gas at the outlet of the heater based on a rise in temperature of the exhaust gas at the outlet of the heater for a plurality of power levels; and
predict the first temperature of the exhaust gas at the location of the SCR system based on the second temperature for each of the plurality of power levels.

10. The aftertreatment system of claim 9 , wherein the processor is further programmed to execute computer-readable instructions to predict the rise in temperature of the exhaust gas at the outlet of the heater based on a power level of the heater, a mass flow rate of the exhaust gas, and a heat capacity of the exhaust gas.

11. The aftertreatment system of claim 8 , wherein the processor is further programmed to execute computer-readable instructions to:
select one of the plurality of power levels to adjust the operation of the heater by:
determining a minimum value from the sum-of-squares error values corresponding to the plurality of power levels, and
selecting a power level corresponding to the minimum value as the selected one of the plurality of power levels.

12. The aftertreatment system of claim 11 , wherein the processor is further programmed to execute computer-readable instructions to:
determine that more than one value of the sum-of squares error values corresponds to the minimum value;
compute a difference between the second temperature corresponding to each of the more than one value of the sum-of squares error values that corresponds to the minimum value and the target temperature; and
select the power level of the heater corresponding to a minimum difference between the second temperature and the target temperature.

13. The aftertreatment system of claim 8 , wherein the determination of the first temperature, the determination of the second temperature, the comparison of the first temperature with the target temperature, and the adjustment of the operation of the heater is repeated in each of a plurality of steps to make predictions for a forecast window.

Assignees

• Cummins Emission Solutions Inc

Inventors

• Norris Colin L
• Staebler Bryon D
• Abraham Jeffrey Diwakar
• Nelson Thomas R
• Pettem Santhosh Kumar
• Schneider Dylan Lawrence

Classifications

• F01N3/106

  Auxiliary oxidation catalysts · CPC title

• F01N2900/0602

  Electrical exhaust heater signals · CPC title

• F01N2900/1631

  Heat amount provided to exhaust apparatus · CPC title

• F01N3/2033

  using a fuel burner or introducing fuel into exhaust duct · CPC title

• F01N3/2066 Primary

  Selective catalytic reduction [SCR] · CPC title