Abstract: Methods and systems for predicting at least one temperature along a fluid flow path of a fluid flow system having a heater disposed in the fluid flow path are provided. In one example, a method includes: obtaining at least one input, wherein the at least one input includes a setpoint, a mass flow rate, an inlet temperature, or a combination thereof; calculating a temperature associated with the heater based on a predefined model and the at least one input; and setting a value of the at least one temperature along the fluid flow path to the temperature of the heater.

Abstract: Methods and systems for predicting at least one temperature along a fluid flow path of a fluid flow system having a heater disposed in the fluid flow path are provided. In one example, a method includes: obtaining at least one input, wherein the at least one input includes a setpoint, a mass flow rate, an inlet temperature, or a combination thereof; calculating a temperature associated with the heater based on a predefined model and the at least one input; and setting a value of the at least one temperature along the fluid flow path to the temperature of the heater.

Abstract: A method of predicting temperature of at least one location in a fluid flow system that has a heating system for heating fluid. The method includes obtaining a mass flow rate of fluid flow of the fluid flow system, obtaining at least one of a fluid outlet temperature and a fluid inlet temperature of a heater of the heating system, obtaining power provided to the heater, and calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate, fluid outlet temperature, and fluid inlet temperature.

Abstract: A heating system includes at least one electric heater disposed within a fluid flow system and a control device that is configured to determine a temperature of the at least one electric heater based on a model, at least one fluid flow system input, and at least one heater input. The at least one heater input includes at least one physical characteristic of the heating system, the at least one physical characteristic includes at least one of a resistance wire diameter, a heater insulation thickness, a heater sheath thickness, a conductivity, a specific heat and density of the material of the heater, an emissivity of the heater and the fluid flow pathway, and combinations thereof. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.

Abstract: A heating system includes a plurality of heater elements, a plurality of switches connected to the plurality of heater elements, a set of predetermined performance information including heater information specific for each heater element, at least one temperature sensor measuring temperature of at least one heater element from among the plurality of heater elements, and a heater control unit in communication with the temperature sensor(s). The heater control unit controls the heater elements differently, via the switches, based on the heater information and the measured temperature from the temperature sensor(s).

Abstract: A heating system includes at least one electric heater disposed within a fluid flow system and a control device that is configured to determine a temperature of the at least one electric heater based on a model, at least one fluid flow system input, and at least one heater input. The at least one heater input includes at least one physical characteristic of the heating system, the at least one physical characteristic includes at least one of a resistance wire diameter, a heater insulation thickness, a heater sheath thickness, a conductivity, a specific heat and density of the material of the heater, an emissivity of the heater and the fluid flow pathway, and combinations thereof. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.

Abstract: A heating system includes at least one electric heater disposed within the fluid flow system. A control device includes a microprocessor and is configured to determine a temperature of the at least one electric heater based on a model and at least one input from the fluid flow system. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.

Abstract: A control system includes an electric heater disposed within an exhaust fluid flow pathway, and a control device for receiving at least one input selected from the group consisting of temperature readings along the exhaust fluid flow pathway, alternator power/current/voltage, battery power/current/voltage/state of charge, IAT and EAT profiles, mass flow rate of an exhaust fluid flow, NH3 slip, TCR characteristics of the heater, alternator speed, engine speed, state of aging of an aftertreatment component, state of aging of engine, aging degradation characteristics, a dosing rate and a temperature of DEF, NH3 storage condition of aftertreatment system, an ambient temperature, and combinations thereof. The control device modulates power to the heater based on the at least one input such that the heater provides different power output as a function of the at least one input and a continuously variable power output during operation of the exhaust system.

Abstract: A heating system includes at least one electric heater disposed within the fluid flow system. A control device includes a microprocessor and is configured to determine a temperature of the at least one electric heater based on a model and at least one input from the fluid flow system. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.

Abstract: An exhaust system is provided that includes an exhaust aftertreatment unit, first and second exhaust pathway in communication with and upstream of the exhaust aftertreatment unit, a thermally activated flow control device operable in a first and second mode, and a thermal storage device. In the first mode, the flow control device permits exhaust to flow to the aftertreatment unit through the first pathway and inhibits flow through the second pathway. In the second mode, the flow control device permits exhaust flow to the aftertreatment unit through the second pathway and inhibits flow through the first pathway. The flow control device may switch between the first and second modes based on a change of temperature. The thermal storage device is within the second pathway, stores thermal mass, and provides thermal insulation to enable a catalyst of the aftertreatment unit to maintain a predetermined temperature for a predetermined time.

Abstract: A heating system includes a plurality of heater elements, a plurality of switches connected to the plurality of heater elements, a set of predetermined performance information including heater information specific for each heater element, at least one temperature sensor measuring temperature of at least one heater element from among the plurality of heater elements, and a heater control unit in communication with the temperature sensor(s). The heater control unit controls the heater elements differently, via the switches, based on the heater information and the measured temperature from the temperature sensor(s).

Abstract: A heater control module of the present disclosure controls exhaust temperature in an exhaust after treatment system. The heater control module includes a heating mode determination module and a heater operating module. The heating mode determination module is configured to select a desired heating mode from a plurality of heating modes based on an engine load and a status of a component of the exhaust aftertreatment system. The heater operating module is configured to operate an electric heater based on the desired heating mode. The plurality of modes includes at least a passive regeneration heating mode and an active regeneration heating mode. The electric heater is operated in the passive regeneration heating mode to heat an exhaust gas to a predetermined temperature to increase NO2 generation when an engine load is less than or equal to approximately 25%.

Abstract: A method of predicting temperature of at least one location in a fluid flow system that has a heating system for heating fluid. The method includes obtaining a mass flow rate of fluid flow of the fluid flow system, obtaining at least one of a fluid outlet temperature and a fluid inlet temperature of a heater of the heating system, obtaining power provided to the heater, and calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate, fluid outlet temperature, and fluid inlet temperature.

Abstract: A control system for a heating system of an exhaust system is provided. The control system includes at least one electric heater disposed within an exhaust fluid flow pathway, and a control device adapted to receive at least one input selected from the group consisting of mass flow rate of an exhaust fluid flow, mass velocity of an exhaust fluid flow, flow temperature upstream of the at least one electric heater, flow temperature downstream of the at least one electric heater, power input to the at least one electric heater, parameters derived from physical characteristics of the heating system, and combinations thereof. The control device is operable to modulate power to the at least one electric heater based on at least one input.

Abstract: A control system includes an electric heater disposed within an exhaust fluid flow pathway, and a control device for receiving at least one input selected from the group consisting of temperature readings along the exhaust fluid flow pathway, alternator power/current/voltage, battery power/current/voltage/state of charge, IAT and EAT profiles, mass flow rate of an exhaust fluid flow, NH3 slip, TCR characteristics of the heater, alternator speed, engine speed, state of aging of an aftertreatment component, state of aging of engine, aging degradation characteristics, a dosing rate and a temperature of DEF, NH3 storage condition of aftertreatment system, an ambient temperature, and combinations thereof. The control device modulates power to the heater based on the at least one input such that the heater provides different power output as a function of the at least one input and a continuously variable power output during operation of the exhaust system.

Abstract: An exhaust system is provided that includes an exhaust aftertreatment unit, first and second exhaust pathway in communication with and upstream of the exhaust aftertreatment unit, a thermally activated flow control device operable in a first and second mode, and a thermal storage device. In the first mode, the flow control device permits exhaust to flow to the aftertreatment unit through the first pathway and inhibits flow through the second pathway. In the second mode, the flow control device permits exhaust flow to the aftertreatment unit through the second pathway and inhibits flow through the first pathway. The flow control device may switch between the first and second modes based on a change of temperature. The thermal storage device is within the second pathway, stores thermal mass, and provides thermal insulation to enable a catalyst of the aftertreatment unit to maintain a predetermined temperature for a predetermined time.

Abstract: A heater control module of the present disclosure controls exhaust temperature in an exhaust after treatment system. The heater control module includes a heating mode determination module and a heater operating module. The heating mode determination module is configured to select a desired heating mode from a plurality of heating modes based on an engine load and a status of a component of the exhaust aftertreatment system. The heater operating module is configured to operate an electric heater based on the desired heating mode. The plurality of modes includes at least a passive regeneration heating mode and an active regeneration heating mode. The electric heater is operated in the passive regeneration heating mode to heat an exhaust gas to a predetermined temperature to increase NO2 generation when an engine load is less than or equal to approximately 25%.

Abstract: A method of heating an exhaust gas in an exhaust after treatment system includes selecting a heating mode between a plurality of heating modes based on an engine load and a status of a component of the exhaust aftertreatment system. The method further comprises heating the exhaust gas by operating the electric heater in the selected heating mode, and operating the electric heater in a passive regeneration heating mode to heat an exhaust gas to a predetermined temperature to increase NO2 generation when an engine load is less than or equal to approximately 25%.

Abstract: A method of heating an exhaust gas in an exhaust after treatment system includes selecting a heating mode between a plurality of heating modes based on an engine load and a status of a component of the exhaust aftertreatment system. The method further comprises heating the exhaust gas by operating the electric heater in the selected heating mode, and operating the electric heater in a passive regeneration heating mode to heat an exhaust gas to a predetermined temperature to increase NO2 generation when an engine load is less than or equal to approximately 25%.

Abstract: An exhaust system is provided that includes at least one exhaust aftertreatment unit provided in an exhaust fluid flow pathway and a thermal storage device disposed upstream from the exhaust aftertreatment unit. The thermal storage device is operable to store thermal mass and provide thermal insulation to enable a catalyst to maintain a minimum predetermined temperature for a minimum predetermined time. In one form, a heater is also provided proximate the thermal storage device, along with variations that include a secondary flow pathway for the thermal storage device.