Abstract: Engine lubrication systems and methods of manufacturing and implementing engine lubrication systems and methods. In particular embodiments, an engine system includes an internal combustion engine lubrication system that utilizes a stacked configuration of a through-bolted engine to pattern around through-bolts and utilizes substantially hollow bulkheads to define a central high-pressure lubrication reservoir that minimizes lube system pressure while maintaining pressure at the extremities of the lubrication circuit. Available space is utilized within the bulkheads to provide a lubrication drainage restriction for reducing lubrication losses at engine shut-down.

Abstract: A method and system for mitigating a urea deposit within an SCR system that includes determining a mass of an accumulated urea deposit present within the SCR catalyst and SCR piping, comparing the mass of the accumulated urea deposit with a deposit upper threshold limit, and initiating an SCR regeneration event when the mass of the accumulated urea deposit is greater than the deposit upper threshold limit. The method further includes determining an amount of NH3 passing through the SCR catalyst downstream of the urea deposit, comparing the amount of NH3 passing through the SCR catalyst with an NH3 regeneration threshold limit, and terminating the SCR regeneration event when the level of NH3 passing through the SCR catalyst is less than the SCR NH3 regeneration threshold.

Abstract: An approach to tracking the engine off time of a system including an internal combustion engine. A timer apparatus may electrically couple to the engine control unit by way of a power connection that provides electrical power to the timer apparatus from the engine control unit. The timer apparatus may include a monitor module that monitors the power connection. A timer module may begin a time interval in response to the power connection transitioning from a powered state to an unpowered state. The timer module may end the time interval in response to the power connection transitioning from the unpowered state to the powered state. A communication module may communicate the time interval to the engine control unit by switching the power connection between the high state and the low state.

Abstract: A spark plug, and associated systems, for an internal combustion engine includes a central electrode that terminates at a first distal end surface defined about a central axis. The spark plug also includes at least one outer electrode that terminates at a second distal end surface. The at least one outer electrode at least partially laterally surrounds the central electrode such that the second distal end surface is radially offset relative to the central electrode and a lateral gap is defined between the central electrode and the at least one outer electrode. The spark plug include features that force or redirect movement of the flow of the fresh air-fuel mixture through the lateral gap to help to purge or move the residual exhaust gases left over from a previous combustion event out of the lateral gap.

Abstract: According to one embodiment, a sensor module includes a sensor probe that has at least two arms coupled together at a central location with each of the at least two arms extending radially outwardly away from the central location. Each of the at least two arms includes one of a plurality of openings and an elongate opening extending radially along the arm. The at least two arms define fluid flow channels therein. The sensor module also includes at least one extractor coupled to the probe. The at least one extractor includes a fluid flow channel that is communicable in fluid receiving communication with fluid flowing through the fluid flow channel of at least one of the at least two arms. Further, the sensor module includes at least one sensor that is communicable in fluid sensing communication with fluid flowing through the at least one extractor.

Abstract: According to one representative embodiment, an apparatus for determining the degradation of a selective catalytic reduction (SCR) catalyst of an engine exhaust aftertreatment system includes a system properties module configured to store at least one system dynamics property value of the exhaust system at a first time and receive the at least one system dynamics property value of the exhaust aftertreatment system at a second time subsequent to the first time. The apparatus also includes a system dynamics module configured to determine a storage capacity of the SCR catalyst based on a comparison between the at least one system dynamic property value at the first time and the at least one system dynamic property value at the second time. Additionally, the apparatus includes an SCR catalyst degradation factor module configured to determine an SCR catalyst degradation factor based at least partially on the storage capacity of the SCR catalyst.

Abstract: An apparatus, system, and method are disclosed for efficiently increasing exhaust flow temperature for an internal combustion engine. The method includes excepting a user input to disable an exhaust valve opening mechanism. The method further includes monitoring exhaust gas mass flows and temperatures, interpreting required exhaust temperatures for aftertreatment devices, and surveying a plurality of operating conditions for a combustion engine. The method includes determining a crankshaft angle for dynamically engaging an exhaust valve open mode based on the exhaust temperature, the required exhaust temperature, and the engine operating conditions. Dynamically engaging the exhaust valve open mode includes selecting a specific crankshaft angle for each combustion cycle of the engine.

Abstract: An apparatus, system, and method are disclosed for real-time diagnosis of a NOx-adsorption catalyst (NAC). The method includes verifying that a NAC temperature exceeds a threshold, determining that the NAC is in a steady-state operating condition, and surveying a first oxygen sensor upstream of the NAC and a second oxygen sensor downstream of the NAC. The method further includes calculating a lambda difference between the first and second oxygen sensors, and interpreting a NAC regeneration indicator. The method further includes determining a lean-to-rich transition and a rich-to-lean transition area based on the lambda difference and the regeneration indicator. The method concludes with setting a NAC function indicator according to the lean-to-rich transition area and the rich-to-lean transition area.

Abstract: According to one embodiment, described herein is an apparatus for mitigating on-board diagnostic (OBD) faults generated by an OBD system of an internal combustion engine (ICE) system having a selective catalytic reduction system with a diesel exhaust fluid (DEF) decomposition tube. The apparatus includes a fault mitigation module that is configured to monitor at least one OBD signal of the OBD system and issue a request for regenerating the DEF decomposition tube when a value of the at least one OBD signal reaches a predetermined regeneration threshold corresponding with the at least one OBD signal. The regeneration threshold is reachable prior to an OBD fault threshold corresponding with the at least one OBD signal. The apparatus also includes a regeneration module that is configured to regenerate the DEF decomposition tube according to the issued request.

Abstract: Described herein are various embodiments of a reductant decomposition system. According to one representative embodiment, the reductant decomposition system includes an exhaust gas chamber including an inlet and outlet. The system also includes a first exhaust gas distribution component positioned within the chamber and communicable in exhaust gas receiving communication with the outlet. The first exhaust gas distribution component causes swirling exhaust gas flow patterns within the exhaust gas chamber. Additionally, the system includes a second exhaust gas distribution component positioned within the chamber and communicable in exhaust gas providing communication with the inlet. The second exhaust gas distribution component includes features that cause a swirling exhaust gas flow pattern within a space defined by the second exhaust gas distribution component. Further, the system includes a reductant injector coupled to the exhaust gas chamber.

Abstract: According to one embodiment, described herein is an exhaust gas after-treatment system that is coupleable in exhaust gas stream receiving communication with an internal combustion engine. The exhaust gas after-treatment system includes a low temperature SCR catalyst configured to reduce NOx in exhaust gas having a temperature below a temperature threshold. The system also includes a normal-to-high temperature SCR catalyst configured to reduce NOx in exhaust gas having a temperature above the temperature threshold.

Abstract: According to one embodiment, an apparatus for controlling the heating of diesel exhaust fluid (DEF) in a DEF delivery system includes a temperature comparison module that compares a difference between a sensed ambient air temperature and a sensed DEF tank temperature with a predetermined temperature difference threshold. Additionally, the apparatus includes a DEF heating status module that is configured to generate a DEF heating command according to (i) the sensed ambient air temperature if the difference between the sensed ambient air temperature and sensed DEF tank temperature is less than the predetermined temperature threshold; and (ii) the sensed DEF tank temperature if the difference between the sensed ambient air temperature and sensed DEF tank temperature is more than the predetermined temperature threshold. The apparatus also includes a DEF heating control module that is configured to control the heating of the DEF according to the DEF heating command.

Abstract: According to one embodiment, an apparatus for controlling regeneration events on multiple diesel particulate filters (DPFs) of an exhaust after-treatment system includes a regeneration event synchronization module and regeneration event termination module. The regeneration event synchronization module is configured to simultaneously initiate a regeneration event on a first DPF and a regeneration event on a second DPF in response to a regeneration event request being triggered for one of the first and second DPFs. The regeneration event termination module is configured to terminate the regeneration event on the first DPF and the regeneration event on the second DPF. Under normal operating conditions, the termination of the regeneration event on the first DPF is performed independently of the termination of the regeneration event on the second DPF.

Abstract: In one embodiment, an apparatus for determining a deterioration of a NOx sensor response rate in an internal combustion engine system includes an engine control module configured to stop fueling to an internal combustion engine during motoring of the internal combustion engine. The apparatus also includes a signal monitoring module configured to monitor a NOx sensor signal after the engine control module stops fueling to the internal combustion engine during motoring of the engine and store NOx sensor signal data corresponding to the monitored NOx sensor signal. Additionally, the apparatus includes a time constant module that is configured to determine a time constant of the NOx sensor response after the engine control module stops fueling. The apparatus further includes a response rate deterioration module configured to determine a response rate deterioration value of the NOx sensor based at least partially on the determined time constant.

Abstract: An apparatus, system, and method are disclosed for determining a regeneration availability profile for an exhaust gas aftertreatment system. The method, in one embodiment, tracks historical attempts and success to determine the availability of regeneration for the system. In a further embodiment, the method divides the system operation into segments according to desired conditions which affect regeneration, for example the workload of an engine, and tracks separate success ratios for each operating condition. This allows prediction of success of a given regeneration based upon the current operating condition, as well as diagnostics of regeneration problems where an operating condition experiences trouble regenerating when historically it should not.

Abstract: Various embodiments of an apparatus, system, and method are disclosed for improving the tracking bandwidth of an air handling system of an internal combustion engine. For example, one embodiment of an apparatus includes an intake charge module configured to determine a desired air intake flow rate into the combustion chamber based at least partially on a desired oxygen concentration in the combustion chamber. The apparatus also includes an EGR system module configured to determine a desired EGR gas flow rate into the combustion chamber based at least partially on the desired oxygen concentration in the combustion chamber. Additionally, the apparatus includes a pre-filter module configured to modify the desired air intake flow rate and the desired EGR gas flow rate based at least partially on predetermined transient response characteristics of the air handling system.

Abstract: A method is disclosed for preventing an underspeed event of a turbocharger. The method includes interpreting a turbocharger speed, a compressor differential pressure (CDP) and a turbocharger differential pressure (TDP). The method further includes calculating a thrust load capacity (TLC) based on the turbocharger speed, and calculating a current thrust load (CTL) based on the CDP and the TDP. The method further includes calculating a thrust margin based on the TLC and the CTL, and controlling an actuator in response to the thrust margin. Controlling the actuator includes maintaining the thrust margin to a thrust margin target, which may be a function of the turbocharger speed. The actuator is a turbine bypass valve, a compressor bypass valve, a variable geometry turbocharger position, an exhaust throttle and/or an exhaust gas recirculation valve that controls the turbocharger speed.

Abstract: An apparatus, system, and method are disclosed for determining a catalyst bed temperature. The method may include receiving a current fluid mass flow within an exhaust pipe and a total amount of unburned fuel available for catalytic combustion. The method may further include determining a plurality of fluid enthalpy values corresponding to various locations within the exhaust pipe. The method may continue with calculating an amount of fuel burned on an upstream catalyst based on the plurality of fluid enthalpy values, and determining an amount of fuel remaining that is available for combustion on a downstream catalyst. The method may determine a combustion efficiency of the downstream catalyst based on the temperature rise across the downstream catalyst, and an amount of heat generated within the downstream catalyst based on the combustion efficiency and the amount of fuel remaining that is available for combustion on the downstream catalyst.

Abstract: An apparatus, system, and method are disclosed for predictive control of a turbocharger. The method includes interpreting a compressor performance model for a turbocharger, and interpreting at least one current operating parameter. The method further includes calculating a performance margin, calculating a performance margin derivative, and calculating a response value. The performance margin comprises a choke margin or a surge margin according to the position of an operating point in the compressor performance model. The performance margin is implemented in a first sigmoid function, and the performance margin derivative is implemented in a second sigmoid function. The response value is determined by applying a MIN function to the output of the product of the sigmoid functions in the choke margin case, and by applying a MAX function to the product of the sigmoid functions in the surge margin case.

Abstract: An apparatus, system, and method are disclosed for preventing turbocharger overspeed in a combustion engine. The method includes determining a turbocharger error term as a difference between a nominal turbocharger maximum speed and a current turbocharger speed. The method further includes determining a turbocharger speed derivative with respect to time. The method includes calculating a turbocharger control response based on the turbocharger error term and the turbocharger speed derivative with respect to time. The turbocharger control response may be a modified turbocharger maximum speed calculated by determining a reference speed multiplier based on the turbocharger error term and the turbocharger speed derivative with respect to time, and multiplying the reference speed multiplier by the nominal turbocharger maximum speed. The method thereby smoothly anticipates turbocharger transient events, and prevents an overspeed condition of the turbocharger.