Abstract: A system to detect the presence of a catalyst includes an exhaust gas tube, a first temperature sensing device, a second temperature sensing device, a flow rate measurement device, and a processing device. The first temperature sensing device measures a first temperature of exhaust gas upstream of the exhaust gas tube. The second temperature sensing device measures a second temperature of the exhaust gas downstream of the exhaust gas tube. The processing device estimates an expected time delay between the measured inlet and outlet exhaust gas temperatures corresponding to a system with a catalyst present. The processing device may also determine the presence of a catalyst by comparing the measured second temperature to the measured first temperature and comparing the measured second temperature to an estimated delayed first temperature associated with the expected time delay.

Abstract: An aftertreatment device for reducing NOx, PM, HC, and CO generated by a compression-ignition engine. In this device, lean exhaust air generated in the engine is enriched using a reactor together with an oxygen sorption device according to a target deNOx efficiency value, and heat energy is recovered. The enriched exhaust gas then passes through an oxidation catalyst, where NOx is reduced with CO and HC. PM in the exhaust gas is further trapped in a DPF. To lower energy cost, an heat exchanger is used for more effectively heating the DPF during regeneration, and an exhaust gas compressor positioned upstream from the DPF is employed to control engine back pressure. When exhaust gas temperature is low, to regenerate the DPF with minimum energy consumption, an electrical heater is used to heat dosing fuel before it is mixed with exhaust gas, and a regeneration heating process is then jump-started.

Abstract: A multi-functional apparatus and method for diagnosing issues in an engine system with a SCR exhaust gas processing system and controlling reductant delivery to the SCR system. The apparatus includes a Venturi exhaust passage device with a reductant injector positioned on a transition from a low pressure passage to a downstream high pressure passage. Temperature and pressures in the Venturi exhaust passage device are measured, and an exhaust flow rate value is calculated. The exhaust flow rate value can be used in controlling reductant delivery, and with a downstream lambda sensing value, the exhaust flow rate value, and a temperature sensing value, a variety of issues in the engine system and the SCR system can be detected. No engine operating parameter is required in the SCR controls and diagnostic algorithms, and less reductant deposit is introduced due to the elimination of stagnant area in the exhaust passage device.

Abstract: A system to detect the presence of a catalyst includes an exhaust gas tube, a first temperature sensing device, a second temperature sensing device, a flow rate measurement device, and a processing device. The first temperature sensing device measures a first temperature of exhaust gas upstream of the exhaust gas tube. The second temperature sensing device measures a second temperature of the exhaust gas downstream of the exhaust gas tube. The processing device estimates an expected time delay between the measured inlet and outlet exhaust gas temperatures corresponding to a system with a catalyst present. The processing device may also determine the presence of a catalyst by comparing the measured second temperature to the measured first temperature and comparing the measured second temperature to an estimated delayed first temperature associated with the expected time delay.

Abstract: An aftertreatment device for reducing nitrogen oxides (NOx), particulate matter (PM), hydrocarbon (HC), and carbon monoxide (CO) generated by a compression-ignition (CI) engine. In this device, lean exhaust air generated in the CI engine is converted to rich exhaust air, and energy used for the conversion is recycled using an energy recovery device. The result rich exhaust air then pass through an oxidation catalyst, where NOx is reduced with CO and HC.

Abstract: A DPF system including a Venturi exhaust passage device, in which a temperature and a pressure in a high pressure passage are measured, together with a difference of pressures in the high pressure passage and a low pressure passage, while a pressure drop across a DPF is monitored. A PM amount and an exhaust flow rate, which are key parameters in DPF control, can be calculated with the measured values. With the Venturi exhaust passage device, a two-stage bootstrapping heating device with two DOCs and an electrical heater can be used to heat exhaust gas at a temperature lower than a light-off temperature, while a flow-back passage fluidly connected to an outlet of the DPF can be used for increasing exhaust flow-rate and making PM distribution in the DPF more uniform. These technologies decrease risks of thermal runaways, and enable a DPF system controlled without using engine operating parameters.

Abstract: A multi-functional apparatus and method for diagnosing issues in an engine system with a SCR exhaust gas processing system and controlling reductant delivery to the SCR system. The apparatus includes a Venturi exhaust passage device with a reductant injector positioned on a transition from a low pressure passage to a downstream high pressure passage. Temperature and pressures in the Venturi exhaust passage device are measured, and an exhaust flow rate value is calculated. The exhaust flow rate value can be used in controlling reductant delivery, and with a downstream lambda sensing value, the exhaust flow rate value, and a temperature sensing value, a variety of issues in the engine system and the SCR system can be detected. No engine operating parameter is required in the SCR controls and diagnostic algorithms, and less reductant deposit is introduced due to the elimination of stagnant area in the exhaust passage device.

Abstract: A sensing apparatus for detecting fluid quality change using signals obtained from a fluid quality sensor for exposure to a fluid and a reference sensor positioned in a reference sensing means having a fluid trap section holding a part of the fluid. Sensing values obtained from the fluid quality sensor and the reference sensor are compared in determining an aging factor. An application of the sensing apparatus is an apparatus for detecting engine oil quality change in an engine system. With the sensing apparatus, a first aging factor can be calculated after an engine cold soak and a second one can be obtained during engine operation. With these two aging factors, in addition to oil quality change, failures in the engine system and sensors, and oil change events can also be detected. Additionally, since reference sensing values are provided by the reference sensor, power disconnections have least effects.

Abstract: A multifunctional fluid level and quality sensing device including a fluid level sensor and a capacitive sensor for detecting fluid level, fluid quality, errors in the sensing device, and issues in a fluid delivery system. In detecting fluid level, impedance of the capacitive sensor is used in improving sensing performance of the fluid level sensor, while in detecting fluid quality and errors in the sensing device, an expected impedance range with an upper boundary value and a lower boundary value is calculated, and a fault is generated when the measured impedance value is out of the expected impedance range. The fluid level and quality sensing device can also be used in a fluid delivery system for detecting system issues, and the results can be used for further isolating errors in the system. Operating status of higher level system provides more information for this purpose.

Abstract: A fluid delivery apparatus for delivering fluid according to a fluid delivery rate command including a fluid tank, a pump, a buffer, in which a pressure sensor is positioned, an injector, a pump controller, a fluid delivery controller, and a diagnostic controller. When a motor driven pump is used, the diagnostic controller is able to detect issues by comparing a measured pressure change with an expected value calculated using pressure sensing values and the power applied to the motor. If an air driven pump is employed, pressure sensing values, fluid delivery rate commands, and pump operating status can be used for calculating compressed air volume in the pump and trapped air volume in the buffer, and for further triggering pressing and suction strokes of the air driven pump, diagnosing issues in the fluid delivery apparatus, detecting fluid level in the fluid tank, and refilling trapped air in the buffer.

Abstract: A method includes raising a temperature of an SCR catalyst for a predetermined time period while dosing urea. The method further includes maintaining the temperature of the SCR catalyst without dosing urea for a second predetermined time period. The method further includes filtering out at least low frequency data from a first NOx sensor upstream of the SCR catalyst and from a second NOx sensor downstream of the SCR catalyst, and comparing the filtered data from the first NOx sensor and the second NOx sensor without dosing urea over a third predetermined time period. The method further includes providing a NOx sensor condition index for at least one of the first NOx sensor and the second NOx sensor in response to the comparing.

Abstract: An injector for delivering a working fluid into a working environment is disclosed. According to one embodiment of the present invention, the injector includes a pre-metering chamber and a swirl chamber. A high velocity partially atomized flow is produced in the pre-metering chamber through a first exit nozzle after impinging on an atomization element, and then a swirling flow is created in the swirl chamber with the atomization element. When the swirling flow is released through a second exit nozzle, atomization can be achieved at low injector pressure with centrifugal force and shearing of the working fluid. In another embodiment, the injector includes a swirl chamber and an atomization element with a bore, through which a control valve is positioned. The control valve forces a working fluid flow through the atomization element when the injector is energized to create a swirling flow. No flow-back is required for the injectors.

Abstract: A fluid delivery apparatus with a flow sensing means for delivering a first fluid into a second fluid. In a fluid delivery apparatus using a common rail method, which produces a pulsated flow, the flow sensing means generates sensing signals indicative of the flow rate and the temperature of the second fluid, the delivery rate of the first fluid, and the evaporating rate of the first fluid, while in a fluid delivery apparatus using a pump metering method, the flow sensing means is able to provide a sensing signal indicative of the delivery rate of the first fluid. The sensing signals can be used in a feedback control for controlling delivery rate, in limiting delivery rate according to the evaporation capability of the first fluid, and in a diagnostic system detecting failures and abnormalities in the fluid delivery apparatus.

Abstract: Systems and methods are disclosed for determining or diagnosing a reagent dosing system failure to provide sufficient reagent to an exhaust aftertreatment system that includes an SCR catalyst to satisfy a reagent dosing command.

Abstract: A multi-stage SCR control system including a front reductant dosing device, a front SCR device, a back reductant dosing device, a back SCR device, and a dosing controller. In normal control cycles, a NSR of the front SCR device is controlled below a stoichiometric reaction ratio to decrease system sensitivity to catalyst aging. In a diagnostic cycle, the NSR of the front or the back SCR device is controlled lower than the stoichiometric reaction ratio, and a reductant quality ratio, which is indicative of reductant quality and dosing accuracy, is calculated. In another diagnostic cycle, the NSR is controlled above the stoichiometric reaction ratio, and an average deNOx efficiency is calculated. The reductant quality ratio and the average deNOx efficiency values are further used in SCR feedback control and permanent catalyst damages can also be isolated from temporary catalyst poisons with these values after a thermal recovery event is completed.

Abstract: A sensing apparatus for detecting fluid quality change using signals obtained from a fluid quality sensor for exposure to a fluid and a reference sensor positioned in a reference sensing means having a fluid trap section holding a part of the fluid. Sensing values obtained from the fluid quality sensor and the reference sensor are compared in determining an aging factor. An application of the sensing apparatus is an apparatus for detecting engine oil quality change in an engine system. With the sensing apparatus, a first aging factor can be calculated after an engine cold soak and a second one can be obtained during engine operation. With these two aging factors, in addition to oil quality change, failures in the engine system and sensors, and oil change events can also be detected. Additionally, since reference sensing values are provided by the reference sensor, power disconnections have least effects.

Abstract: An ammonia generating and delivery apparatus generating ammonia by heating a precursor material with a heating device controlled by a temperature pulse controller which receives commands from a pressure controller, and delivering ammonia with a flow rate controlled by a three-stage PWM controller. The temperature pulse controller is used in a first feedback loop to create a temperature pulse sequence at a surface of the heating device. A pressure controller in a second feedback loop provides duty-cycle commands to the temperature pulse controller, while in delivering ammonia, effects of pressure variation to delivery accuracy are compensated in the three-stage PWM controller, which includes a flow-rate feedback loop. The ammonia generating and delivery apparatus can also include two containers, in which the precursor material in one container is charged and discharged according to the capability of the other container in generating ammonia.

Abstract: A multi-stage SCR system including a front reductant injecting device, a front mixer, a front SCR catalyst, a back reductant injecting device, a back mixer, a back SCR catalyst, and a DCU. The front and back reductant injecting devices receives reductant from an air-driven pump, which includes a liquid supply tank, a pressure tank, and solenoids control valves. Under pressure provided by a compress air source, reductant is pressed into the front and back reductant injecting devices from the air-driven pump. The front and back reductant devices also have flow-back paths fluidly connected to a reductant tank. And in purging or maintenance heating, the flow-back paths can be energized open. In the multi-stage SCR system, a DOC can be further positioned in between the two SCR devices for increasing the deNOx efficiency in the back SCR catalyst, so that the system is less sensitive to catalyst aging.

Abstract: A multifunctional fluid level and quality sensing device including a fluid level sensor and a capacitive sensor for detecting fluid level, fluid quality, errors in the sensing device, and issues in a fluid delivery system. In detecting fluid level, impedance of the capacitive sensor is used in improving sensing performance of the fluid level sensor, while in detecting fluid quality and errors in the sensing device, an expected impedance range with an upper boundary value and a lower boundary value is calculated, and a fault is generated when the measured impedance value is out of the expected impedance range. The fluid level and quality sensing device can also be used in a fluid delivery system for detecting system issues, and the results can be used for further isolating errors in the system. Operating status of higher level system provides more information for this purpose.

Abstract: A dosing apparatus with purging means for delivering reductant into an exhaust gas treatment system of an internal combustion engine. The apparatus includes a first Venturi T connector with two high pressure ports and a low pressure port, and a purge control valve for switching from normal dosing to purging by controlling flow through the two high pressure ports. The apparatus may also include a second Venturi T connector and a reductant supply chamber for purging reductant residue in its pump and reductant passage lines. The apparatus may further include a purging controller that triggers a purging event according to engine oil or coolant temperature and controls the purging process after a dosing process completes.