Abstract: An aftertreatment system comprises a housing defining an internal volume. The housing includes an inlet, an outlet and a first sidewall. A sleeve is positioned within the internal volume and protrudes through the first sidewall. An inner shell is positioned within an inner region defined by the sleeve and defines a recess therein. The inner shell spaced apart from the sleeve so as to define a channel therebetween. A base is positioned within the recess and includes an injection port which is in communication with the internal volume. An injector is disposed on the base and is disposed completely within the recess. The injector is in fluidic communication with the internal volume via the injection port. The injector is configured to inject an exhaust reductant into the internal volume via the opening. A cover plate can be disposed over the recess and structured to prevent objects from impacting the injector.

Abstract: An aftertreatment system comprises a first SCR system, a second SCR system positioned downstream of the SCR system and a reductant storage tank. At least one reductant insertion assembly is fluidly coupled to the reductant storage tank. The at least one reductant insertion assembly is also fluidly coupled to the first SCR system and the SCR system. A controller is communicatively coupled to the reductant insertion assembly. The controller is configured to instruct the reductant insertion assembly to asynchronously insert the reductant into the first SCR system and the second SCR system.

Abstract: An aftertreatment system comprises a reductant storage tank and a SCR system fluidly coupled thereto. A reductant physical level sensor and a tank temperature sensor are operatively coupled to the reductant storage tank. A controller is communicatively coupled with each of the sensors and configured to: interpret a first level output value from the physical level sensor and a first temperature output value from the tank temperature sensor. If the first level output value is below a first threshold, the controller determines if the first temperature output value is below a second threshold. If the first level output value is below the first threshold and the first temperature output value is below the second threshold, the controller determines a virtual reductant level in the reductant storage tank and indicates the virtual reductant level in lieu of a physical reductant level in the reductant storage tank to a user.

Abstract: An apparatus comprises a housing including a housing first portion having a first joint portion configured to overlap a second joint portion of a housing second portion so as to form a housing joint. A primary clamp is positioned at a primary location of the housing joint which abuts at least a portion of the first and the second joint portion. A mounting bracket is positioned on and contacts the primary clamp. A plurality of secondary clamps are positioned at secondary locations, each of which is different than the primary location, of the housing joint. A band is operatively coupled to the mounting bracket by positioning around and contacting each of the plurality of secondary clamps. The band is tightened to urge the mounting bracket and thereby the primary clamp, and the plurality of secondary clamps towards the housing joint to secure the housing joint.

Abstract: A liquid reductant injector nozzle includes a first portion defining a hollow cylindrical static chamber, in fluid communication with second portion defining a hollow frustoconical converging section, which is in turn in fluid communication with a sharp edged type discharge orifice. The hollow cylindrical static chamber is in reductant receiving communication with a reductant source, and has a first and second circular opening having equal diameters. The second circular opening is downstream of the first circular opening. The hollow frustoconical converging section is in reductant receiving communication with the hollow cylindrical static chamber via the second circular opening. Reductant received from the reductant source is discharged through the discharge orifice. A sidewall of the hollow cylindrical static chamber and a frustum side of the frustoconical converging section define an angle of convergence of the liquid reductant injector nozzle relative to a plane of the second circular opening.

Abstract: Implementations described herein relate to features for a single module aftertreatment system. The single module aftertreatment system includes a casing, a catalyst within the casing, and a sensor mount coupled to the casing. The sensor mount is angled relative to a portion of the casing at a position where the sensor mount is coupled to the casing. The sensor mount includes a first attachment leg, a second attachment leg, and an angled mounting portion. The angled mounting portion connects the first attachment leg to the second attachment leg. The sensor mount is coupled to the casing by the first attachment leg and the second attachment leg such that the first attachment leg, the second attachment leg, and the angled mounting portion form an air gap relative to the casing.

Abstract: Implementations described herein relate to utilizing discrete transient local state space models to modify an output from a steady state NOx estimation model to provide a final estimated NOx value. An engine operating space, defined by a speed and injection quantity map, is subdivided into several discrete local state spaces and a transient model is developed for each discrete state space to output a NOx estimation correction value. The transient models may be a regression model or the transient model may be an empirical map of data values. The NOx estimation correction value modifies a steady state NOx value to calculate the final NOx estimated value. The final NOx estimated value is then output to another component, such as a controller as an input for controlling one or more components of an engine, an aftertreatment system, and/or a diagnostic system.

Abstract: Systems and methods to selectively control plurality of dosing modules may include receiving data indicative of an exhaust flow rate. An amount of reductant to be dosed may be determined based, at least in part, on the data indicative of the exhaust flow rate. A decomposition delay time may also be determined and a first dosing module and a second dosing module may be selectively activated. The first dosing module may be selectively activated at a first time and the second dosing module is selectively activated at a second time. The second time is based on the first time and the determined decomposition delay time.

Abstract: An aftertreatment system comprises an SCR system and at least one reductant insertion assembly fluidly coupled thereto. The reductant insertion assembly includes an injector and reductant storage tank. The injector includes a first fluid connector and a second fluid connector. A first fluid connector marking is defined on the first fluid connector and a second fluid connector marking is defined on the second fluid connector. The reductant storage tank includes a first fluid conduit fluidly coupled to the first fluid connector and a second fluid conduit fluidly coupled to the second fluid connector. A first fluid conduit marking is defined on the first fluid conduit, and a second fluid conduit marking is defined on the second fluid conduit. The first fluid conduit marking corresponds to the first fluid connector marking, and the second fluid conduit marking corresponds to the second fluid connector marking, thereby identifying a coupling relationship therebetween.

Abstract: Exhaust aftertreatment assemblies and methods of manufacturing and operating exhaust aftertreatment assemblies. The exhaust aftertreatment assembly includes a reductant delivery device, a reductant source fluidly coupled to the reductant delivery device, a mixing chamber positioned between the reductant delivery device and the reductant source and thereby fluidly coupling the reductant source to the reductant delivery device, and a compressed air source fluidly coupled to the mixing chamber upstream of the mixing chamber with respect to the reductant delivery device. The compressed air source provides compressed air to mix with reductant in the mixing chamber.

Abstract: An aftertreatment system comprises a first bank to receive a first portion of an exhaust gas and a second bank to receive a second portion of the exhaust gas. A first reductant insertion assembly is fluidly coupled to the first bank and a parent controller is communicatively coupled thereto. A second reductant insertion assembly is fluidly coupled to the second bank and a first child controller is communicatively coupled thereto. A third reductant insertion assembly is fluidly coupled to the first bank and a second child controller is communicatively coupled thereto. The parent controller instructs the first reductant insertion assembly to insert reductant into the first bank. The parent controller also instructs the first child controller to command the second reductant insertion assembly to insert reductant into the second bank, and instructs the second child controller to command the third reductant insertion assembly to insert reductant into the first bank.

Abstract: A reductant delivery system is provided for delivery of reductant to an engine exhaust aftertreatment system that is heated during cold temperature conditions. A heat exchange fluid flows through a heat exchange circuit that provides a flow path from the heat source to the doser, from the doser to the reductant storage tank, and from the reductant storage tank to the heat source. A control valve controls the flow of the heat exchange fluid in the heat exchange circuit so that at least one heat exchange cycle includes a circulation period that increases the temperature of the reductant in the doser and storage tank and a termination period where circulation is stopped until reductant temperature in the doser reaches a lower limit.

Abstract: Catalyst diagnostic limit parts and methods for making catalyst diagnostic limit parts are disclosed. An exemplary catalyst diagnostic limit part includes a substrate and a washcoat coating the substrate. The washcoat includes an active catalyst and an inactive catalyst at a predetermined ratio of active catalyst to inactive catalyst so as to control the performance of the catalyst diagnostic limit part.

Abstract: One form of the present application is an apparatus including an internal combustion engine structured to produce an exhaust flow, an exhaust system structured to receive the exhaust flow, and a reductant injector structured to inject reductant into a primary passage of the exhaust system upstream of a catalyst. The apparatus further includes an injector passage structured to receive a portion of exhaust upstream of the injector and further structured to flow the exhaust into the primary passage around the injector in a manner such that deposit formation is reduced.

Abstract: An aftertreatment system comprises a first passageway to receive a first portion and a second passageway to receive a second portion of the exhaust gas from the engine. The first and second passageways can have the same length. A first selective catalytic reduction system is fluidly coupled to the first passageway to receive and treat the first portion. A second selective catalytic reduction system is fluidly coupled to the second passageway to receive and treat the second portion. A plurality of sensors are disposed on the first passageway and/or the first selective catalytic reduction system to sense operational parameters of the first portion of the exhaust gas. A controller is in electronic communication with the plurality of sensors to determine the operational parameters of the first portion and to determine operational parameters of the second portion of the exhaust gas based upon the first operational parameters.

Abstract: A system may include a NOx sensor and a controller. The controller may be configured to interpret a value of a first parameter indicative of an amount of NOx measured by the NOx sensor and interpret a value of a second parameter for a NOx value from a look-up table. The controller may be further configured to determine a correction factor based on the value of the first parameter and the value of the second parameter and generate a dosing command based, at least in part, on the determined correction factor. In some implementations, the NOx value from the look-up table may be based on one or more operating conditions of an engine. In some implementations, the controller may be further configured to update a NOx value of the look-up table based on the determined correction factor.

Abstract: An aftertreatment system comprises a housing including a sidewall and defining an internal volume. The housing is sized and configured to house at least one aftertreatment component within the internal volume. A sensor mounting table is coupled to the sidewall. The sensor mounting table includes a base and a plurality of legs extending from the base. Each leg of the plurality of legs includes a first portion and a second portion. The first portion extends orthogonally from the base towards the housing. The second portion extends outwardly relative to the base at a non-zero angle from an end of the first portion located distal from the base. The second portion is coupled to the sidewall of the housing, thereby coupling the sensor mounting table to the housing. At least one electronic module is removably coupled to the sensor mounting table.

Abstract: An aftertreatment system comprises a housing having an inlet, an outlet and a sidewall. The housing defines an internal volume structured to receive an exhaust gas via the inlet. The sidewall defines an access opening. An access panel is operatively coupled to the sidewall and covers the access opening. The access panel defines a plurality of throughholes. Each of the plurality of throughholes are configured to receive a fastener therethrough for removably coupling the access panel to the sidewall. An injection port is also defined in the access panel. An injector is positioned on the access panel. The injector is removably coupled to the access panel via a coupling assembly so that the injector is in fluidic communication with the internal volume via the injection port. A SCR system is disposed in the internal volume and includes at least one catalyst formulated to decompose constituents of the exhaust gas.

Abstract: An exhaust elbow includes an upstream sidewall defining an upstream portion of the exhaust elbow, a downstream sidewall defining a downstream portion of the exhaust elbow, and a deflector. The upstream portion is configured to receive an upstream exhaust gas. The deflector is coupled to the upstream sidewall of the exhaust elbow upstream and is configured to deflect a portion of the upstream exhaust gas received by the upstream portion of the exhaust elbow away from a region of an interior of the exhaust elbow into which an injected reductant from a dosing module is injected. The deflector may reduce and/or prevent formation of reductant deposits on a downstream sidewall. In some implementations, an exhaust assisted flow separator may also be included to direct a portion of the upstream exhaust gas received by the upstream portion of the exhaust elbow through a dosing opening.

Abstract: Reductant delivery systems are disclosed that include a dry reductant source and a liquid reductant source which are operable to selectively provide gaseous reductant and liquid reductant to an exhaust aftertreatment system for treatment and reduction of NOx emissions. The gaseous reductant is provided to the exhaust aftertreatment system for treatment of NOx emissions under a first temperature condition associated with the exhaust system and the liquid reductant for treatment of NOx emissions under a second temperature condition associated with the exhaust system.