Abstract: An exhaust gas heat recovery system includes a housing, a heat exchanger and a valve assembly. The valve assembly is disposed within the housing and includes a monolithic valve body, a moveable valve plate and a rotatable valve shaft. The valve body includes a bore, a valve seat surrounding the bore and trunnions integrally formed with the valve seat. The trunnions are diametrically opposed to each other and laterally extending outside of the housing. The valve plate coupled for rotation with the valve shaft between a first position allowing exhaust gas flow through the bore and the first exhaust gas passageway, and a second position allowing exhaust gas flow through the second exhaust gas passageway and preventing exhaust gas flow through the bore and the first exhaust gas passageway. The valve shaft being supported for rotation by the trunnions.

Abstract: An exhaust gas heat recovery system includes a housing assembly, a valve assembly and a heat exchanger. The valve assembly is disposed within the housing assembly and includes a shaft and a plate. The plate is rotatable between a first position whereat exhaust gas flow through a first fluid passageway is allowed and exhaust gas flow through a second exhaust gas passageway is prevented, and a second position whereat exhaust gas flow through the second fluid passageway is allowed and exhaust gas flow through the first gas passageway is prevented. The heat exchanger assembly includes a heater core having a working fluid circulating therein. The working fluid is in thermal communication with fluid in the heater core. The housing assembly includes first and second shells attached to each other at a joint. An axis of the shaft being at the joint of the first and second shells.

Abstract: An exhaust gas heat recovery system includes a housing assembly, a valve assembly and a heat exchanger. The valve assembly is disposed within the housing assembly and includes a shaft and a plate. The plate is rotatable between a first position whereat exhaust gas flow through a first fluid passageway is allowed and exhaust gas flow through a second exhaust gas passageway is prevented, and a second position whereat exhaust gas flow through the second fluid passageway is allowed and exhaust gas flow through the first gas passageway is prevented. The heat exchanger assembly includes a heater core having a working fluid circulating therein. The working fluid is in thermal communication with fluid in the heater core. The housing assembly includes first and second shells attached to each other at a joint. An axis of the shaft being at the joint of the first and second shells.

Abstract: An exhaust gas heat recovery system includes a housing, a heat exchanger and a valve assembly. The valve assembly is disposed within the housing and includes a monolithic valve body, a moveable valve plate and a rotatable valve shaft. The valve body includes a bore, a valve seat surrounding the bore and trunnions integrally formed with the valve seat. The trunnions are diametrically opposed to each other and laterally extending outside of the housing. The valve plate coupled for rotation with the valve shaft between a first position allowing exhaust gas flow through the bore and the first exhaust gas passageway, and a second position allowing exhaust gas flow through the second exhaust gas passageway and preventing exhaust gas flow through the bore and the first exhaust gas passageway. The valve shaft being supported for rotation by the trunnions.

Abstract: An exhaust aftertreatment system includes a burner in heat transfer relation with exhaust gas in an exhaust gas passageway. The burner includes a housing assembly and a nozzle assembly, the housing assembly at least partially defining a combustion chamber. The nozzle assembly is at least partially received in the housing assembly and includes a nozzle body and an electric heating element. The heating element is disposed within the nozzle body and operable to heat fuel flowing through the nozzle body. A control module is in communication with the heating element and controls the heating element in a first mode in which the heating element heats fuel for combustion in the combustion chamber, and a second mode in which the heating element burns deposits off of the nozzle body when fuel is not supplied to the nozzle body.

Abstract: A burner for an exhaust aftertreatment system may include a housing assembly and an ignition device. The housing assembly may include an inner shell surrounded by intermediate and outer shells. The inner shell may at least partially define a combustion chamber. The housing assembly may include an airflow passage having an opening extending through the outer shell. The airflow passage may extend between the outer shell and the intermediate shell as well as between the intermediate shell and the inner shell. The airflow passage may provide fluid communication between the opening and the combustion chamber. The ignition device may be at least partially disposed within the housing assembly and may ignite fuel received from a fuel source and air received from the airflow passage to produce a flame in the combustion chamber. The airflow passage may be in a heat transfer relationship with the flame in the combustion chamber.

Abstract: An exhaust treatment system may include a burner, a flame sensor assembly and a control module. The flame sensor assembly may be at least partially disposed within the burner and may include an insulator and an electric heating element in heat transfer relation with the insulator. The control module may be in communication with the flame sensor assembly. The control module may determine whether a flame is present in a combustion chamber based on feedback from the flame sensor assembly. The control module may detect contamination on the insulator based on feedback from the flame sensor assembly. The control module may operate the heating element in a first mode in response to detection of a contamination in which the control module causes electrical power to be applied to the heating element to raise a temperature of the heating element to burn contamination off of the insulator.

Abstract: A burner for an exhaust aftertreatment system is provided that includes a nozzle assembly having a body and a heating element. The body may include first and second cavities, a fuel inlet passage and an air inlet passage. The first cavity may receive portion of the heating element and may be in fluid communication with the fuel inlet passage and a fuel discharge passage such that fuel from the fuel inlet passage is heated in the first cavity by the heating element and discharged from the first cavity through the fuel discharge passage. The second cavity may be in fluid communication with the air inlet passage and an air discharge passage. The first and second cavities may be fluidly isolated from each other and may supply fuel and air, respectively, to an exit aperture disposed downstream of the fuel discharge aperture and the air discharge aperture.

Abstract: An exhaust aftertreatment system may include a first housing and a burner. The first housing may include first and second chambers. The first chamber may include an exhaust gas inlet receiving exhaust gas from an engine. The second chamber may receive exhaust gas from the first chamber and may include an exhaust gas outlet. The burner may include a second housing and a combustion chamber disposed within the second housing. The second housing may be at least partially disposed within the first chamber. The burner may supply heated gas to the second chamber. The heated gas within the burner may be fluidly isolated from exhaust gas in the first chamber. The second housing may be in a heat transfer relationship with exhaust gas in the first chamber.

Abstract: An exhaust aftertreatment system for an engine is provided that includes a burner, an air supply system and a control module. The air supply system may be in fluid communication with the burner and may include an air compressor disposed upstream from the burner. The air compressor may include a pump mechanism, a clutch assembly selectively transferring torque from the engine to the pump mechanism, and a motor selectively driving the pump mechanism. The control module may be in communication with the clutch assembly and the motor. The control module may selectively switch the air compressor between a first operating mode in which the clutch assembly transfers torque from the engine to the pump mechanism and a second operating mode in which the motor drives the pump mechanism.

Abstract: An exhaust aftertreatment system for an engine is provided that includes a burner, an air supply system and a control module. The air supply system may be in fluid communication with the burner and may include an air compressor disposed upstream from the burner. The air compressor may include a pump mechanism, a clutch assembly selectively transferring torque from the engine to the pump mechanism, and a motor selectively driving the pump mechanism. The control module may be in communication with the clutch assembly and the motor. The control module may selectively switch the air compressor between a first operating mode in which the clutch assembly transfers torque from the engine to the pump mechanism and a second operating mode in which the motor drives the pump mechanism.

Abstract: An exhaust treatment system may include a burner, a flame sensor assembly and a control module. The flame sensor assembly may be at least partially disposed within the burner and may include an insulator and an electric heating element in heat transfer relation with the insulator. The control module may be in communication with the flame sensor assembly. The control module may determine whether a flame is present in a combustion chamber based on feedback from the flame sensor assembly. The control module may detect contamination on the insulator based on feedback from the flame sensor assembly. The control module may operate the heating element in a first mode in response to detection of a contamination in which the control module causes electrical power to be applied to the heating element to raise a temperature of the heating element to burn contamination off of the insulator.

Abstract: A burner for an exhaust aftertreatment system may include a housing assembly and an ignition device. The housing assembly may include an inner shell surrounded by intermediate and outer shells. The inner shell may at least partially define a combustion chamber. The housing assembly may include an airflow passage having an opening extending through the outer shell. The airflow passage may extend between the outer shell and the intermediate shell as well as between the intermediate shell and the inner shell. The airflow passage may provide fluid communication between the opening and the combustion chamber. The ignition device may be at least partially disposed within the housing assembly and may ignite fuel received from a fuel source and air received from the airflow passage to produce a flame in the combustion chamber. The airflow passage may be in a heat transfer relationship with the flame in the combustion chamber.

Abstract: A method of detecting a fracture as it occurs in a component during a manufacturing process includes positioning an acoustic sensor in acoustic communication with the component. A manufacturing process is performed while the acoustic sensor remains in acoustic communication with the component. A signal indicative of acoustic emissions from the component during the manufacturing process is provided to a controller where it is determined whether the component has fractured based on the signal.

Abstract: A method of detecting a fracture as it occurs in a component during a manufacturing process includes positioning an acoustic sensor in acoustic communication with the component. A manufacturing process is performed while the acoustic sensor remains in acoustic communication with the component. A signal indicative of acoustic emissions from the component during the manufacturing process is provided to a controller where it is determined whether the component has fractured based on the signal.

Abstract: A particulate filter cartridge has a woven metal fiber filter medium surrounding a perforated support tube. The filter medium is crimped down to the support tube at opposite ends thereof and then welded to the support tube at the crimped regions. A plurality of such cartridges can then be nested within each other and separated by appropriate exhaust gas flow directing baffles to form a particulate filter assembly.

Abstract: Apparatus for inserting a substrate surrounded by a compressible mat into a compartment of a housing of an exhaust treatment device includes an insertion member having a bore shaped substantially identically to a shape of an opening to the housing compartment and a fluid bearing generator establishing a compressed fluid bearing at a surface of the bore. The fluid bearing is operative to reduce a coefficient of friction between the compressible mat and a surface of the bore when the substrate/mat combination is moved axially in the bore into the compartment opening.

Abstract: A particulate filter cartridge has a woven metal fiber filter medium surrounding a perforated support tube. The filter medium is crimped down to the support tube at opposite ends thereof and then welded to the support tube at the crimped regions. A plurality of such cartridges can then be nested within each other and separated by appropriate exhaust gas flow directing baffles to form a particulate filter assembly.