Engine health and oil consumption rate diagnostic using back pressure

Patent metadata

Field	Value
Publication number	US-12460568-B2
Application number	US-202118577143-A
Country	US
Kind code	B2
Filing date	Jul 8, 2021
Priority date	Jul 8, 2021
Publication date	Nov 4, 2025
Grant date	Nov 4, 2025

Abstract

An aftertreatment system includes a particulate filter configured to receive exhaust gas from an engine and a controller that measures an actual pressure drop across the particulate filter, determines an expected total ash accumulation rate in the particulate filter based on a current duty cycle of the engine, determines an expected pressure drop across the particulate filter based on the expected total ash accumulation rate, compares the expected pressure drop with the actual pressure drop, and determines whether an oil consumption rate in the engine is abnormal based on the comparison.

First claim

What is claimed is:

1 . An aftertreatment system comprising:
a particulate filter configured to receive exhaust gas from an engine; and a controller that executes computer-readable instructions stored on a memory to:
determine an actual pressure drop across the particulate filter based on pressure measurements across the particulate filter;
determine an expected total ash accumulation rate in the particulate filter based on a first calibration table comprising a plurality of pressure drops across a test particulate filter and a corresponding first ash accumulation rate or a soot and ash accumulation rate in the test particulate filter at each of the plurality of pressure drops and a second calibration table comprising a plurality of duty cycles and a corresponding estimated oil consumption rate at each of the plurality of duty cycles;
determine an expected pressure drop across the particulate filter based on the expected total ash accumulation rate;
compare the expected pressure drop with the actual pressure drop;
determine whether an oil consumption rate of the engine is abnormal based on the comparison; and
responsive to determining the oil consumption rate of the engine is abnormal, raising an alert to indicate abnormal oil consumption rate.

2 . The aftertreatment system of claim 1 , wherein the controller executes the computer-readable instructions to determine the expected pressure drop based on the first calibration table.

3 . The aftertreatment system of claim 1 , wherein the second calibration table further comprises an additional calibration table comprising a corresponding second ash accumulation rate corresponding to the estimated oil consumption rate at each of the plurality of duty cycles.

4 . The aftertreatment system of claim 1 , wherein the controller executes the computer-readable instructions to determine that the oil consumption rate in the engine is abnormal based on the actual pressure drop being greater than the expected pressure drop, and that the oil consumption rate in the engine is not abnormal based on the actual pressure drop being less than or equal to the expected pressure drop.

5 . A method comprising:
determining, by a controller of an aftertreatment system, an actual pressure drop across a particulate filter configured to receive exhaust gas from an engine based on pressure measurements across the particulate filter; determining, by the controller, an expected total ash accumulation rate in the particulate filter based on a first calibration table comprising a plurality of pressure drops across a test particulate filter and a corresponding first ash accumulation rate or a soot and ash accumulation rate in the test particulate filter at each of the plurality of pressure drops and a second calibration table comprising a plurality of duty cycles and a corresponding estimated oil consumption rate at each of the plurality of duty cycles; determining, by the controller, an expected pressure drop across the particulate filter based on the total ash accumulation rate; comparing, by the controller, the expected pressure drop with the actual pressure drop; determining, by the controller, whether an oil consumption rate in the engine is abnormal based on the comparison; and responsive to determining the oil consumption rate of the engine is abnormal, raising, by the controller, an alert to indicate abnormal oil consumption rate.

6 . The method of claim 5 , further comprising determining, by the controller, the expected pressure drop based on the first calibration table.

7 . The method of claim 5 , wherein the second calibration table further comprises an additional calibration table comprising a corresponding second ash accumulation rate corresponding to the estimated oil consumption rate at each of the plurality of duty cycles.

8 . The method of claim 5 , further comprising determining, by the controller, that the oil consumption rate in the engine is abnormal based on the actual pressure drop being greater than the expected pressure drop, and that the oil consumption rate in the engine is not abnormal based on the actual pressure drop being less than or equal to the expected pressure drop.

9 . A non-transitory computer-readable media comprising computer-readable instructions stored thereon that when executed by a controller of an aftertreatment system causes the controller to perform a process comprising:
determining an actual pressure drop across a particulate filter configured to receive exhaust gas from an engine based on pressure measurements across the particulate filter; determining an expected total ash accumulation rate in the particulate filter based on a first calibration table comprising a plurality of pressure drops across a test particulate filter and a corresponding first ash accumulation rate or a soot and ash accumulation rate in the test particulate filter at each of the plurality of pressure drops and a second calibration table comprising a plurality of duty cycles and a corresponding estimated oil consumption rate at each of the plurality of duty cycles; determining an expected pressure drop across the particulate filter based on the expected total ash accumulation rate; comparing the expected pressure drop with the actual pressure drop; determining whether an oil consumption rate in the engine is abnormal based on the comparison; and responsive to determining the oil consumption rate of the engine is abnormal, raising an alert to indicate abnormal oil consumption rate.

10 . The non-transitory computer-readable media of claim 9 , wherein the controller executes the computer-readable instructions to determine the expected pressure drop based on the first calibration table.

11 . The non-transitory computer-readable media of claim 9 , wherein the second calibration table further comprises an additional calibration table comprising a corresponding second ash accumulation rate corresponding to the estimated oil consumption rate at each of the plurality of duty cycles.

12 . The non-transitory computer-readable media of claim 9 , wherein the controller further executes computer-readable instructions for determining that the oil consumption rate in the engine is abnormal based on the actual pressure drop being greater than the expected pressure drop, and that the oil consumption rate in the engine is not abnormal based on the actual pressure drop being less than or equal to the expected pressure drop.

Assignees

• Cummins Emission Solutions Inc

Inventors

• Zokoe Jr James
• Punde Shirish S
• Staebler Bryon D
• Dabhoiwala Rayomand

Classifications

• F01N2900/1611

  Particle filter ash amount · CPC title

• F01N2900/1606

  Particle filter loading or soot amount · CPC title

• F01N11/002

  the diagnostic devices measuring or estimating temperature or pressure in, or downstream of the exhaust apparatus · CPC title

• Y02T10/40

  Engine management systems · CPC title

• F01N2560/08

  the means being a pressure sensor · CPC title