Systems and methods for maintaining aftertreatment capability during vehicle life

Patent metadata

Field	Value
Publication number	US-11933213-B2
Application number	US-202117552029-A
Country	US
Kind code	B2
Filing date	Dec 15, 2021
Priority date	Dec 15, 2021
Publication date	Mar 19, 2024
Grant date	Mar 19, 2024

Abstract

Methods and systems are provided for regenerating an after-treatment system of a vehicle. A first operational parameter of a first component of the after-treatment system is monitored and a second operational parameter, different to the first operational parameter, of a second component of the after-treatment system is monitored. It is determined if the first operational parameter of the first component is outside a first threshold range and if the second operational parameter is approaching a second threshold and, in response to the first operational parameter being outside the first threshold range and the second operational parameter being within the second threshold range, a regeneration sequence of the after-treatment system configured to regenerate at least the first component of the after-treatment system is initiated.

First claim

The invention claimed is:

1. A method for regenerating an after-treatment system of a vehicle, the method comprising:
monitoring a first operational parameter of a first component of the after-treatment system;
monitoring a second operational parameter, different to the first operational parameter, of a second component of the after-treatment system;
determining if the first operational parameter of the first component is outside a first threshold range;
determining if the second operational parameter is approaching a second threshold range;
in response to the first operational parameter being outside the first threshold range and the second operational parameter being within the second threshold range, initiating a regeneration sequence of the after-treatment system configured to regenerate at least the first component of the after-treatment system;
determining if the first operational parameter of the first component is outside of a third threshold range, larger than the first threshold range; and
in response to the first operational parameter not being outside of the third threshold range, initiating a regeneration sequence configured to regenerate the first component and a second component.

2. The method of claim 1 , wherein determining if the second operational parameter is within the second threshold range is carried out in response to the first operational parameter being outside the first threshold range.

3. The method of claim 1 , further comprising:
initiating a first regeneration sequence comprising a first regeneration cycle of the first component of the after-treatment system; and
wherein the second component is not regenerated as a part of the first regeneration sequence.

4. The method of claim 1 , further comprising:
determining if a current vehicle usage allows for a regeneration sequence of the after-treatment system configured to regenerate the first component and second component of the after-treatment system; and
in response to the vehicle usage not allowing regeneration of the first and second component, initiating a second regeneration sequence comprising the first regeneration cycle of the first component for a first time period; and
after expiry of the first time period, initiating a first regeneration cycle of the second component.

5. The method of claim 1 , further comprising:
in response to the first operational parameter being outside of the third threshold range, initiating another regeneration sequence configured to regenerate the first component and the second component.

6. The method of claim 1 , further comprising:
wherein the first component is an electrically heated catalyst; and
wherein the second component is a particular filter.

7. The method of claim 1 , wherein the operational parameter is at least one of: a resistance; a temperature; a power draw; emissions output; or a current draw.

8. The method of claim 1 , wherein the threshold of the operational parameter is configurable.

9. The method of claim 1 , wherein the regeneration sequence is carried out during low-flow conditions in the after-treatment system.

10. An after-treatment system of a vehicle comprising:
an electrically heated catalyst, electrically coupled to a power source;
a particulate filer; and
a controller, communicatively coupled to the electrically heated catalyst, the particulate filter, and the power source, the controller configured to:
monitor a first operational parameter of the electrically heated catalyst;
monitor a second operational parameter, different to the first operational parameter, of the particulate filter;
determine if the first operational parameter is outside a first threshold range;
determine if the second operational parameter is approaching a second threshold range;
in response to the first operational parameter being outside the first threshold range and the second operational parameter being within the second threshold range, initiate a regeneration sequence of the after-treatment system configured to regenerate at least the electrically heated catalyst;
determine if the first operational parameter of the electrically heated catalyst is outside of a third threshold range, larger than the first threshold range; and
in response to the first operational parameter not being outside of the third threshold range, initiating a regeneration sequence configured to regenerate the electrically heated catalyst and the particulate filter.

11. The after-treatment system of claim 10 , wherein determining if the second operational parameter is within the second threshold range is carried out in response to the first operational parameter being outside the first threshold range.

12. The after-treatment system of claim 10 , the controller further configured to:
initiate a first regeneration sequence comprising a first regeneration cycle of the electrically heated catalyst; and
wherein the particulate filter is not regenerated as a part of the first regeneration sequence.

13. The after-treatment system of claim 10 , the controller further configured to:
determine if a current vehicle usage allows for a regeneration sequence of the after-treatment system configured to regenerate the first component and second component of the after-treatment system; and
in response to the vehicle usage not allowing regeneration of the first and second component, initiating a second regeneration sequence comprising the first regeneration cycle of the first component for a first time period; and
after expiry of the first time period, initiating a first regeneration cycle of the particulate filter.

14. The after-treatment system of claim 10 , the controller further configured to:
in response to the first operational parameter being outside of the third threshold range, initiating another regeneration sequence configured to regenerate the electrically heated catalyst and the particulate filter.

15. The after-treatment system of claim 10 , wherein the operational parameter is at least one of: a resistance; a temperature; a power draw; emissions output; or a current draw.

16. The after-treatment system of claim 10 , wherein:
the threshold of the operational parameter is configurable;
the regeneration sequence comprises increasing a power delivered to the electrically heated catalyst; and
the regeneration sequence is carried out during low-flow conditions in the after-treatment system.

17. A vehicle comprising the after-treatment system of claim 10 .

18. A non-transitory computer-readable medium having instructions encoded thereon for carrying out method for regenerating an after-treatment system of a vehicle, the method comprising:
monitoring a first operational parameter of a first component of the after-treatment system;
monitoring a second operational parameter, different to the first operational parameter, of a second component of the after-treatment system;
determining if the first operational parameter of the first component is outside a first threshold range;
determining if the second operational parameter is approaching a second threshold range;
in response to the first operational parameter being outside the first threshold range and the second operational parameter being within the second threshold range, initiating a regeneration sequence of the after-treatment system configured to regenerate at least the first component of the after-treatment system;
determining if the first operational parameter of the first component is outside of a third threshold range, larger than the first threshold range; a

Assignees

• Ford Global Tech Llc

Inventors

• Cox David
• Balenović Mario
• Ponter Christopher
• Rogosin Larry
• Peacock Craig

Classifications

• F01N9/002 Primary

  of filter regeneration · CPC title

• F01N3/035

  with catalytic reactors · CPC title

• F01N3/2013

  using electric or magnetic heating means · CPC title

• F01N2240/16

  an electric heater, i.e. a resistance heater · CPC title

• F01N2250/02

  filtering and catalytic conversion · CPC title