Patents by Inventor Rafat F Hattar
Rafat F Hattar has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20250092814Abstract: An exhaust system comprises an engine, a three-way catalytic converter including a first catalyst and a second catalyst, a tailpipe adjacent to the three-way catalytic converter, a first oxygen sensor disposed between the engine and the catalytic converter, a nitrogen oxides (NOx) sensor disposed in the three-way catalytic converter, and an engine control module (ECM) configured to obtain first oxygen sensor data from the first oxygen sensor, second oxygen sensor data from the NOx sensor, and NOx sensor data from the NOx sensor, the ECM being configured to perform catalyst health diagnostic operations and adjust one or more characteristics of the exhaust system based on at least the first oxygen sensor data, the second oxygen sensor data, and the NOx sensor data.Type: ApplicationFiled: September 20, 2023Publication date: March 20, 2025Applicant: GM Global Technology Operations LLCInventors: Chengke Liu, Rafat F. Hattar, Janean Ellen Potter, Erika L. Pruski
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Patent number: 12247504Abstract: An exhaust system comprises an engine, a three-way catalytic converter including a first catalyst and a second catalyst, a tailpipe adjacent to the three-way catalytic converter, a first oxygen sensor disposed between the engine and the catalytic converter, a nitrogen oxides (NOx) sensor disposed in the three-way catalytic converter, and an engine control module (ECM) configured to obtain first oxygen sensor data from the first oxygen sensor, second oxygen sensor data from the NOx sensor, and NOx sensor data from the NOx sensor, the ECM being configured to perform catalyst health diagnostic operations and adjust one or more characteristics of the exhaust system based on at least the first oxygen sensor data, the second oxygen sensor data, and the NOx sensor data.Type: GrantFiled: September 20, 2023Date of Patent: March 11, 2025Assignee: GM Global Technology Operations LLCInventors: Chengke Liu, Rafat F. Hattar, Janean Ellen Potter, Erika L Pruski
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Patent number: 12085035Abstract: The concepts described herein relate to a system, method, and/or apparatus for monitoring a NOx sensor that is arranged in an exhaust gas feedstream of an internal combustion engine downstream of an exhaust aftertreatment system to detect a fault related to the NOx sensor. This includes utilizing a catalyst efficiency model to detect occurrence of a fault that may indicate an in-range biased or stuck NOx sensor.Type: GrantFiled: November 15, 2022Date of Patent: September 10, 2024Assignee: GM Global Technology Operations LLCInventors: Erika L. Pruski, Janean E. Potter, Rafat F. Hattar
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Publication number: 20240278793Abstract: Systems and methods are provided for vehicular data collection and analysis. The system may include a vehicle and a remote computing system. The vehicle may include a sensor system, a communication system, a controller configured to: receive vehicle data including sensor data that includes an observable condition of the vehicle as sensed with the sensor system, process the vehicle data to produce collected data, store the collected data as stored data in a data storage device of the vehicle, and upload the stored data through a communication network. The remote computing system may include a controller configured to, by a processor: receive the vehicle data, and perform statistical analysis thereof to quantify a change of the observable condition relative to historical data associated with the vehicle and relative to other vehicles within a fleet.Type: ApplicationFiled: February 22, 2023Publication date: August 22, 2024Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Janean Ellen Potter, Erika L Pruski, Rafat F Hattar
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Publication number: 20240159197Abstract: The concepts described herein relate to a system, method, and/or apparatus for monitoring a NOx sensor that is arranged in an exhaust gas feedstream of an internal combustion engine downstream of an exhaust aftertreatment system to detect a fault related to the NOx sensor. This includes utilizing a catalyst efficiency model to detect occurrence of a fault that may indicate an in-range biased or stuck NOx sensor.Type: ApplicationFiled: November 15, 2022Publication date: May 16, 2024Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Erika L. Pruski, Janean E. Potter, Rafat F. Hattar
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Patent number: 11913401Abstract: An engine consumes fuel and air to generate an exhaust gas stream. An exhaust system channels the exhaust gas stream from the engine to a tailpipe. An aftertreatment system is included in the exhaust system and includes a catalyst. An exhaust throttle valve is disposed in the exhaust system downstream from the aftertreatment system. An actuator controls an amount of air pumped through the engine. A controller operates the exhaust throttle valve and/or the actuator to control emissions from the exhaust system during a cold start and following a deceleration fuel cutoff event.Type: GrantFiled: May 1, 2023Date of Patent: February 27, 2024Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Chengke Liu, Vijay A Ramappan, Rafat F Hattar, Jeffrey M Kaiser, Joseph Shelton
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Patent number: 11885250Abstract: Vehicle systems and methods are provided for preheating an aftertreatment system prior to engine ignition. A method involves obtaining a first measurement indicative of a current temperature associated with the aftertreatment system, obtaining a second measurement indicative of a current state of an energy source coupled to a heating element integrated with the aftertreatment system, determining an amount of electrical energy to be applied to the heating element based at least in part on a difference between the current temperature associated with the aftertreatment system and a target temperature for the aftertreatment system, and automatically enabling current flow from the energy source to the heating element prior to ignition of the engine for a duration of time in a manner that is influenced by the amount of electrical energy to be applied to the heating element and the current state of the energy source.Type: GrantFiled: May 10, 2023Date of Patent: January 30, 2024Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Vijay A. Ramappan, Rafat F. Hattar
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Patent number: 11788455Abstract: Methods and systems are provided for recirculation of an engine exhaust gas. The system includes an engine, an exhaust system configured to channel exhaust gas from the engine to an outlet, an aftertreatment device, an exhaust recirculation system configured to divert at least some of the exhaust gas as recirculated exhaust gas from a first position in the exhaust system downstream of the aftertreatment device, through a buffer tank, and to a second position in the exhaust system upstream of the aftertreatment device, wherein the recirculated exhaust gas is combined with the exhaust gas at the second position, a controller configured to, by a processor, selectively operate the exhaust recirculation system to control the exhaust recirculation system to divert the exhaust gas and thereby cause the recirculated exhaust gas to be treated with the aftertreatment device more than once with sequentially increased catalyst temperatures.Type: GrantFiled: November 15, 2022Date of Patent: October 17, 2023Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Chengke Liu, Rafat F. Hattar
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Patent number: 11725601Abstract: Methods and systems are provided for recirculation of an engine exhaust gas. The system includes an engine, an exhaust system configured to channel exhaust gas from the engine to an outlet, an aftertreatment device, an exhaust recirculation system configured to divert at least some of the exhaust gas as recirculated exhaust gas from a first position in the exhaust system downstream of the aftertreatment device, through a housing enclosing the aftertreatment device, and to a second position in the exhaust system upstream of the aftertreatment device, wherein the recirculated exhaust gas is combined with the exhaust gas at the second position, a controller configured to, by a processor, selectively operate the exhaust recirculation system to control the exhaust recirculation system to divert the exhaust gas and thereby cause the recirculated exhaust gas to be treated with the aftertreatment device more than once.Type: GrantFiled: October 4, 2022Date of Patent: August 15, 2023Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Chengke Liu, Rafat F. Hattar
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Patent number: 11629625Abstract: Engine systems and methods use a dual air injection approach to control exhaust reactions and to maintain temperatures below a maximum limit of exhaust system components during engine enrichment operation conditions. Dual air injectors are disposed in the exhaust system with one upstream from, and another downstream from, the catalytic converter. Providing air injection before and/or after the converter helps convert all HC, CO, and PM emissions while keeping the catalyst temperature below the catalyst protection temperature limit. Air injection quantity may be controlled and diagnosed by monitoring the temperatures before and after the catalytic converter. The catalytic converter may be a three-way catalytic converter for lower cost or a downstream two-way catalytic converter may be added if further emission reduction is necessary.Type: GrantFiled: July 5, 2022Date of Patent: April 18, 2023Assignee: GM GLOBAL TECHNOLOGY OPERATONS LLCInventors: Chengke Liu, Rafat F Hattar, John Michael Ellenberger, Philipp A Seyfried
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Patent number: 11519317Abstract: Engine systems use a three-way catalyst followed by air injection and mixing to convert all hydrocarbons and carbon monoxide under various load conditions when exhaust gas temperature is above 500 degrees Celsius. A three-way catalytic converter is disposed in the exhaust system. A nozzle is configured to inject air into the exhaust system downstream from the three-way catalytic converter. A mixing plate with or without catalyst coatings is disposed in the exhaust system downstream from the nozzle. The mixing plate is bow shaped with a concave shaped side facing the nozzle to enhance carbon monoxide conversion. Optional two way catalytic converters are added downstream from the mixing plate to further reduce tailpipe hydrocarbon and carbon monoxide emissions.Type: GrantFiled: February 3, 2022Date of Patent: December 6, 2022Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Chengke Liu, Rafat F Hattar
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Patent number: 10683820Abstract: A vehicle propulsion system includes an internal combustion engine with a first combustion chamber and a second combustion chamber, a catalytic converter in an exhaust stream in communication with an exhaust of the internal combustion engine, a gasoline particulate filter in the exhaust stream downstream of the catalytic converter, and a controller in communication with the internal combustion engine. The controller is programmed to determine if a soot loading of the gasoline particulate filter exceeds a predetermined threshold, and adjust a set of engine operating parameters of the internal combustion engine to disable combustion in the first combustion chamber and enrich a fuel mixture in the second combustion chamber if the soot loading in the gasoline particulate filter exceeds the predetermined threshold.Type: GrantFiled: January 31, 2018Date of Patent: June 16, 2020Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventor: Rafat F. Hattar
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Patent number: 10655550Abstract: An engine control system includes a prediction module that, during an exhaust stroke of a first cylinder of an engine, determines a predicted intake manifold pressure at an end of a next intake stroke of a second cylinder following the first cylinder in a firing order of the cylinders. An air per cylinder (APC) module determines a predicted mass of air that will be trapped within the second cylinder at the end of the next intake stroke of the second cylinder based on the predicted intake manifold pressure. A fueling module controls fueling of the second cylinder during the next intake stroke based on the predicted mass of air.Type: GrantFiled: July 13, 2015Date of Patent: May 19, 2020Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Christopher E. Whitney, Layne K. Wiggins, Rafat F. Hattar, Gary Robert Cygan, Jr., Ning Jin, Gregory P. Matthews
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Publication number: 20200116093Abstract: Methods of treating exhaust in a vehicle, and exhaust systems for a vehicle, are disclosed. Example methods may include providing a catalytic converter in an exhaust tailpipe and an oxygen sensor downstream of the catalytic converter. The catalytic converter may be configured to reduce a concentration of a nitrogen oxide (NOx) present in an exhaust flow through the catalytic converter. The method further includes predicting an increase in an oxygen concentration within the catalytic converter based upon at least one or more real-time vehicle operating parameters, wherein the increase is predicted before a corresponding increase in oxygen concentration is measured by the downstream oxygen sensor. The method may also include adjusting an air-fuel ratio of an engine of the vehicle based upon the predicted increase in oxygen concentration, thereby at least partially preventing the corresponding increase in the oxygen concentration.Type: ApplicationFiled: October 10, 2018Publication date: April 16, 2020Inventors: Jianyang Geng, Jeffry A. Helmick, Rafat F. Hattar
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Patent number: 10577998Abstract: A method and system controls a regeneration of a particle filter of an internal combustion engine. A first value is measured for the oxygen content in exhaust gas upstream from the particle filter. A second value is measured for the oxygen content in exhaust gas downstream from the particle filter. The particle filter is determined to be free of soot when the second value for the oxygen content is equal to the first value for the oxygen content.Type: GrantFiled: June 1, 2018Date of Patent: March 3, 2020Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Alexander Michel, Rafat F. Hattar, Jochen Grieser, Daniel Siebert, Maximilian Melling, Simon Schiesser, Markus Kraft
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Publication number: 20190376460Abstract: Technical solutions described herein includes an exhaust system for treating exhaust gas from an internal combustion engine in a motor vehicle. The exhaust system includes a gas particulate filter, and a controller that controls soot loading estimation for the gas particulate filter. Controlling the soot loading estimation includes checking validity of soot loading estimation, and in response to the soot loading estimation being invalid, initiating a remedial action to limit soot deposition on the gas particulate filter. The remedial action includes determining a temperature at an inlet of the gas particulate filter, and if the temperature is within a predetermined range, inhibiting a deceleration fuel cut off of the internal combustion engine.Type: ApplicationFiled: June 8, 2018Publication date: December 12, 2019Inventors: Alexander Michel, Simon Schiesser, Daniel Siebert, Rafat F. Hattar, Jochen Grieser, Markus Kraft
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Patent number: 10415453Abstract: An active regeneration method for a gasoline particulate filter includes determining if a particulate filter soot load level is greater than a predetermined soot load level threshold and, if so, determining if the particulate filter's temperature is greater than a predetermined burn off temperature threshold. A particulate filter heating phase is initiated when the particulate filter's temperature is not greater than a predetermined burn off temperature threshold and a soot burning phase is started when the particulate filter's temperature is greater than a predetermined burn off temperature threshold.Type: GrantFiled: August 29, 2017Date of Patent: September 17, 2019Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Rafat F. Hattar, Alexander Michel, Simon Schiesser, Nils Oth, Markus Kraft
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Publication number: 20190234329Abstract: A vehicle propulsion system includes an internal combustion engine with a first combustion chamber and a second combustion chamber, a catalytic converter in an exhaust stream in communication with an exhaust of the internal combustion engine, a gasoline particulate filter in the exhaust stream downstream of the catalytic converter, and a controller in communication with the internal combustion engine. The controller is programmed to determine if a soot loading of the gasoline particulate filter exceeds a predetermined threshold, and adjust a set of engine operating parameters of the internal combustion engine to disable combustion in the first combustion chamber and enrich a fuel mixture in the second combustion chamber if the soot loading in the gasoline particulate filter exceeds the predetermined threshold.Type: ApplicationFiled: January 31, 2018Publication date: August 1, 2019Inventor: Rafat F. Hattar
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Publication number: 20190063295Abstract: An active regeneration method for a gasoline particulate filter includes determining if a particulate filter soot load level is greater than a predetermined soot load level threshold and, if so, determining if the particulate filter's temperature is greater than a predetermined burn off temperature threshold. A particulate filter heating phase is initiated when the particulate filter's temperature is not greater than a predetermined burn off temperature threshold and a soot burning phase is started when the particulate filter's temperature is greater than a predetermined burn off temperature threshold.Type: ApplicationFiled: August 29, 2017Publication date: February 28, 2019Inventors: Rafat F. Hattar, Alexander Michel, Simon Schiesser, Nils Oth, Markus Kraft
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Publication number: 20190040812Abstract: A method of diagnosing a high pressure fuel delivery system includes sensing an after shutdown fuel pressure in the fuel rail. An after shutdown leak rate is calculated from the after shutdown fuel pressure, and compared to a shutdown leak threshold. The high pressure fuel delivery system is analyzed to detect a leak in one of the fuel rail or the fuel injector when the after shutdown leak rate is greater than the shutdown leak threshold. A cranking fuel pressure in the fuel rail is also sensed. A cranking leak rate is calculated from the cranking fuel pressure, and compared to a cranking leak threshold. The high pressure fuel delivery system is analyzed to detect a leak in the high pressure fuel pump when the cranking leak rate is greater than the cranking leak threshold.Type: ApplicationFiled: August 4, 2017Publication date: February 7, 2019Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Azeem Sarwar, Xiangxing Lu, Rafat F. Hattar