METHOD OF CONTROLLING EXHAUST EMISSION OF MACHINE

Abstract

A method of controlling exhaust emission of a machine is provided. The method includes coupling a control unit with an engine of the machine. The method also includes connecting at least one aftertreatment device to the engine of the machine. The at least one aftertreatment device is adapted to control the exhaust emission of the machine. The method further includes receiving, by the control unit, an input signal from the at least one aftertreatment device The method includes identifying the at least one aftertreatment device based on the input signal. The method also includes correlating the input signal with the data stored in the data storage module. The method further includes selecting a mode of operation associated with the at least one aftertreatment device. The method includes controlling the exhaust emission of the machine based on the mode of operation.

Description

TECHNICAL FIELD

The present disclosure relates to a method of controlling exhaust emission of a machine.

BACKGROUND

Machines, such as locomotives, earthmoving vehicles, and automobiles require compliance with a variety of emission standards. The emission standards vary with regions throughout the world. In order to meet the emission standards, an engine of the machine is tuned or adjusted by a control unit. This affects the engine performance and/or fuel economy. Further, the emission standards are met by an aftertreatment device of the machine. In order to meet the emission standards of the machine at a location, the aftertreatment device of the machine is changed accordingly. The aftertreatment device is controlled by the control unit, based on the location of the machine. The control unit also needs to be changed with a change in the aftertreatment device.

US Patent Publication 2005/0149248, hereinafter referred to as ‘the '248 Publication’, discloses a location-sensitive engine control system. The location-sensitive engine control system includes position locating system (PLS). Further, the PLS interfaces with a control logic which in turn interfaces with an engine control. The PLS relays location coordinates to the control logic. The control logic compares the location coordinates to an emissions map to determine the emission requirements and corresponding engine control settings. The engine control receives the engine control settings from the control logic and adjusts engine parameters to allow the engine to comply with the emission requirements. An antenna or other suitable device for receiving and transmitting information may interface with the control logic to provide emissions map updates and to allow transmission of the emissions information. However, the '248 publication does not disclose a method to control the aftertreatment device associated with the engine to meet the emission standards at a particular area.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a method of controlling exhaust emission of a machine is provided. The method includes coupling a control unit with an engine of the machine. The control unit includes a data storage module for storing data associated with operation of one or more aftertreatment devices. The method also includes connecting at least one aftertreatment device to the engine of the machine. The at least one aftertreatment device is adapted to control the exhaust emission of the machine. The method further includes receiving, by the control unit, an input signal from the at least one aftertreatment device. The method includes identifying the at least one aftertreatment device based on the input signal. The method also includes correlating the input signal with the data stored in the data storage module. The method further includes selecting a mode of operation associated with the at least one aftertreatment device. The method includes controlling the exhaust emission of the machine based on the mode of operation.

Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an exemplary machine, according to the concepts of the present disclosure;

FIG. 2 is a block diagram of a power supply system for controlling exhaust emissions from the machine of FIG. 1; and

FIG. 3 is a flow chart of a method for controlling the exhaust emissions from the machine of FIG. 1.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. Moreover, references to various elements described herein, are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also he construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims.

FIG. 1 illustrates an exemplary machine 10. As illustrated, the machine 10 is embodied as a locomotive. The machine 10 may pull cargo containers or passenger cars on a pair of rails 12. Alternatively, the machine 10 may include, but not limited to, a marine vessel, an off-highway vehicle, an on-road vehicle, or any other machine powered by a prime mover, such as an internal combustion engine. It should be understood that the machine 10 may embody any wheeled or tracked machine associated with mining, agriculture, forestry, construction, and any other known industrial applications.

Referring to FIG. 1, the machine 10 includes a chassis 14 and an operator cabin 16 mounted on the chassis 14. The operator cabin 16 includes a number of input devices (not shown) for controlling and monitoring operations of the machine 10. The input devices may include, but not limited to, a push-button and a control lever to control the movement of the machine 10. The machine 10 includes a number of axles 18. In the illustrated example, the machine 10 includes six axles. Each of the axles 18 is associated with a pair of wheels 20. The pair of wheels 20 may be disposed to support and move the machine 10 on the pair of rails 12.

The machine 10 includes a power supply system 22. The power supply system 22 includes an engine 24 and an aftertreatment device 26 coupled to an exhaust conduit (not shown) of the engine 24. The engine 24 is mounted on the chassis 14 of the machine 10. The engine 24 provides driving power to propel the machine 10. In an example, the engine 24 may include a diesel engine, a gasoline engine, and a gaseous fuel powered engine such as, a natural gas engine.

The aftertreatment device 26 is connected to the engine 24 for receiving the exhaust gases flowing out of the engine 24. The aftertreatment device 26 controls exhaust emissions from the machine 10. More particularly, the aftertreatment device 26 removes constituents present in the exhaust gases, including, but not limited to, NOx, CO, Unburnt Hydro Carbons emissions, particulates, and/or any other constituents known in the art. As shown in FIG. 1, the aftertreatment device 26 is supported on a frame 21 of the machine 10, via an aftertreatment mounting system 30. The aftertreatment mounting system 30 may include a number of mounts 32 provided on the frame 21 of the machine 10.

The machine 10 further includes a control unit 28 in electric communication with the engine 24 and the aftertreatment device 26. The control unit 28 determines various operating parameters of the engine 24 and the aftertreatment device 26 and, accordingly, controls operations of the engine 24 and the aftertreatment device 26. Specifically, the control unit 28 is communicably coupled with multiple operating systems, such as a fuel supply system, an air intake system, and an exhaust gas outlet system of the engine 24.

A sensing unit 29 (shown in FIG. 2) may be disposed in each of the operating systems of the engine 24 and the aftertreatment device 26. The control unit 28 may communicate with the sensing unit 29 of each of the operating systems and the aftertreatment device 26 to receive a signal indicative of the various operating parameters of the engine 24 and the aftertreatment device 26. Upon receiving the signal, the control unit 28 determines the various operating parameters associated with the engine 24.

Further, it may he contemplated that the control unit 28 may be implemented as one or more microprocessors, microcomputers, digital signal processor, central processing units, state machine, logic circuitries, and/or any device that is capable of manipulating signals based on operational instructions. Among the capabilities mentioned herein, the control unit 28 may receive, transmit, and execute computer-readable instructions.

Alternatively, the machine 10 may include multiple control units, each dedicated to communicate with one of the operating systems of the engine 24 and the aftertreatment device 26. For example, the engine 24 may include one control unit to control various operations pertaining to the engine 24 and the aftertreatment device 26 may include another control unit that may be used to control various operations of the aftertreatment device 26. In such a case, the control units of the engine 24 and the aftertreatment device 26 may communicate with each other.

It may be contemplated that the machine IC) may include a reductant system (not shown). The reductant system may include a tank for storing a reductant, such as urea, and a pump (not shown) for supplying the reductant to the aftertreatment device 26 from the tank.

FIG. 2 illustrates a block diagram of the power supply system 22 having the engine 24, the aftertreatment device 26, and the control unit 28 of the machine 10. The aftertreatment device 26 may include one or more aftertreatment modules 34. The aftertreatment modules 34 may include, but not limited to, a silencer, a spark arrester, a diesel particulate filter (DPF), a diesel oxidation catalyst (DOC), a selective catalytic reduction (SCR), a hydro-carbon (HC) dosing system, a catalytic converter, a fuel burner, or any other aftertreatment modules known in the art. In one example, the aftertreatment device 26 (see FIG. 1) may include a housing (not shown) coupled to the exhaust conduit of the engine 24. The housing may receive one or more of the aftertreatment modules 34 to control the emissions from the engine 24. In such a case, the control unit 28 may communicate with the one or more of the aftertreatment modules 34 to control one or more operations of the aftertreatment device 26.

A cable member 44 connects the sensing unit 29 of the aftertreatment device 26 with the control unit 28. In an example, the cable member 44 may be a pigtail. The cable member 44 has a first end 46 connected to the sensing unit 29 and a second end 48 that is connected to the control unit 28. The second end 48 is provided with jumper pins (not shown). A number of the jumper pins and a configuration of the jumper pins are defined based on a specification of the aftertreatment device 26. In one example, the aftertreatment mounting system 30 may include receptacles for connection of the cable member 44 with the sensing unit 29. The cable member 44 communicates the signal indicative of the operating parameters of the aftertreatment device 26 with the control unit 28.

For illustration purpose of the present disclosure, additional aftertreatment devices 26A and 26B are shown in communication with the engine 24. The additional aftertreatment devices 26A and 26B are hereinafter interchangeably referred to as ‘the first additional aftertreatment device 26A’ and ‘the second additional aftertreatment device 26B’. In one example, the exhaust conduit of the engine 24 may be designed to couple with at least one of the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 26B. Each of the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 26B control the emissions of the engine 24, based on a statutory requirement. The statutory requirements in one region may he vary from the statutory requirements in another region. Accordingly, each of the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 26B are defined to meet the statutory requirement of a particular region, where the machine 10 is operating. As such, at least one of the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 26B is coupled to the exhaust conduit of the engine 24 to control the emission based on the statutory requirements of the region.

In an example, for illustration purpose of the present disclosure, the aftertreatment device 26 may include a silencer (not shown). Also, the first additional aftertreatment device 26A may include a DOC (not shown). Further, the second additional aftertreatment device 26B may include a DPF (not shown) and an SCR (not shown). Based on the statutory requirements, each of the aftertreatment devices 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 26B may include aftertreatment modules that are different from those listed above, without limiting the scope of the present disclosure.

Each of the first additional aftertreatment device 26A and the second additional aftertreatment device 26B includes a first additional sensing unit 29A and a second additional sensing unit 29B, respectively. Further, each of the first and second additional sensing units 29A, 29B are coupled with a first additional cable member 44A and a second additional cable member 44B, respectively, for connecting with the control unit 28. Although, the present disclosure depicts the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 26B, it may be understood that the exhaust conduit of the engine 24 may be coupled to any other aftertreatment device having one or more aftertreatment modules.

As shown in FIG. 2, the control unit 28 includes a sensor module 36. The sensor module 36 communicably couples with the sensing unit 29 of the aftertreatment device 26. Specifically, the second end 48 of the cable member 44 is coupled with the control unit 28 such that the signal indicative of the operating parameters of the aftertreatment device 26 is communicated with the control unit 28. The configuration of the jumper pins provided in the cable member 44 generates an input signal indicative of various characteristic parameters of the aftertreatment device 26. In an example, the various characteristic parameters may include, but not limited to, a type of the aftertreatment module 34 contained in the aftertreatment device 26 and/or dimensional specifications of the aftertreatment device 26.

The control unit 28 further includes a processing module 38. The processing module 38 is in communication with the sensor module 36. The processing module 38 receives the input signal from the sensor module 36 and determines whether the aftertreatment device 26 is currently coupled to the engine 24. The processing module 38 receives the signal indicative of the various operating parameters of the aftertreatment device 26.

The control unit 28 further includes a data storage module 40. The data storage module 40 is in communication with the processing module 38. The data storage module 40 stores data associated with the operation of the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 269. The data associated with the operation of the aftertreatment device 26, the first additional aftertreatment device 26A and the second additional aftertreatment device 26B may be a predefined data. The predefined data may be collected based on lab tests and/or real time simulation of the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 26B. The predefined data may be stored in the data storage module 40 by an operator through an operator interface of the control unit 28.

The data storage module 40 is also used for storing data associated with the various operating parameters of the engine 24 and the aftertreatment device 26 that are determined in real time. The data may be stored in the form of records, look-up tables, and algorithms. The data storage module 40 also includes a number of modes of operation associated with the aftertreatment device 26, the first additional aftertreatment device 26A, and the second additional aftertreatment device 269.

Modes of operation may be defined as a set of instructions that allow desired control of the operating parameters of the aftertreatment device 26, based on the statutory requirements. In an example, the mode of operation for the aftertreatment device 26 may be defined based on one or more mathematical relationships between the input signal received by the processing module 38 and the predefined data associated with the operation of the aftertreatment device 26. Each mode of operation is associated with the operation of the engine 24 and the operation of the aftertreatment device 26.

In one implementation, the first additional aftertreatment device 26A may be coupled to the engine 24 in place of the aftertreatment device 26, in order to control the emissions based on the statutory requirements. In such a case, the first additional sensing unit 29A of the first additional aftertreatment device 26A may be coupled to the first additional cable member 44A. Further, a first additional first end 464 is connected to the first additional sensing unit 294 and a first additional second end 48A of the first additional cable member 44A is coupled to the control unit 28 such that the signal indicative of the operating parameters of the first additional aftertreatment device 26A is communicated with the control unit 28. A configuration of the jumper pins is provided in the first additional cable member 44A to generate an input signal indicative of various characteristic parameters of the first additional aftertreatment device 26A. The processing module 38 in communication with the sensor module 36 receives the input signal and determines whether the first additional aftertreatment device 26A is currently coupled to the engine 24.

In another implementation, the second additional aftertreatment device 26B may be coupled to the engine 24 in place of the aftertreatment device 26, in order to control the emissions based on the statutory requirements. In such a case, the second additional sensing unit 29B of the second additional aftertreatment device 26B may be coupled to the second additional cable member 44B. Further, a second additional first end 46B is connected to the second additional sensing unit 29B and a second additional second end 48B of the second additional cable member 44B is coupled to the control unit 28 such that the signal indicative of the operating parameters of the second additional aftertreatment device 26B is communicated with the control unit 28. A configuration of the jumper pins is provided in the second additional cable member 44B to generate an input signal indicative of various characteristic parameters of the second additional aftertreatment device 26B. The processing module 38 in communication with the sensor module 36 receives the input signal and determines whether the second additional aftertreatment device 26B is currently coupled to the engine 24.

The control unit 28 further includes a control module 42. The control module 42 is in communication with the processing module 38. The control module 42 receives the input signal indicative of the aftertreatment device 26, and correlates the input signal with the data stored in the data storage module 40. Upon correlating the input signal with the data stored in the data storage module 40, the control module 42 selects the mode of operation associated with the aftertreatment device 26. Further, the control module 42 generates an output signal indicative of the mode of operation. The control module 42 further communicates this output signal with the engine 24 and the aftertreatment device 26 to control the exhaust emissions of the machine 10, based on the selected mode of operation. Thus, the exhaust emissions of the machine 10 may be controlled as per the statutory requirements of the region where the machine 10 is operating with the aftertreatment device 26.

Similarly, for the first additional aftertreatment device 26A the control module 42 receives the input signal indicative of the first additional aftertreatment device 26A, and correlates the input signal with the data stored in the data storage module 40. Upon correlating the input signal with the data stored in the data storage module 40, the control module 42 selects the mode of operation associated with the first additional aftertreatment device 26A. Further, the control module 42 generates an output signal indicative of the mode of operation. The control module 42 further communicates this output signal with the engine 24 and the first additional aftertreatment device 26A to control the exhaust emissions of the machine 10, based on the selected mode of operation. Thus, the exhaust emissions of the machine 10 may be controlled as per the statutory requirements of the region where the machine 10 is operating with the first additional aftertreatment device 26A.

Further, for the second additional aftertreatment device 26B, the control module 42 receives the input signal indicative of the second additional aftertreatment device 26B, and correlates the input signal with the data stored in the data storage module 40. Upon correlating the input signal with the data stored in the data storage module 40, the control module 42 selects the mode of operation associated with the second additional aftertreatment device 26B. Further, the control module 42 generates an output signal indicative of the mode of operation. The control module 42 further communicates this output signal with the engine 24 and the second additional aftertreatment device 26B to control the exhaust emission of the machine 10, based on the selected mode of operation. Thus, the exhaust emission of the machine 10 may be controlled as per the statutory requirements of the region where the machine 10 is operating with the second additional aftertreatment device 26B.

FIG. 3 illustrates a flowchart of a method 50 for controlling the exhaust emissions of the machine 10. The method 50 will now be explained in reference to the machine 10 having the aftertreatment device 26. However, it should be noted that the description provided below is equally applicable to the first and second additional aftertreatment devices 26A, 26B, without limiting the scope of the present disclosure.

At step 52, the control unit 28 is coupled with the engine 24 of the machine 10. The control unit 28 includes the data storage module 40. The data storage module 40 stores data associated with operation of the aftertreatment device 26. At step 54, the aftertreatment device 26 is connected to the engine 24 of the machine 10. At step 56, the input signal from the aftertreatment device 26 is received by the control unit 28. The input signal generated by the sensing unit 29 is then conveyed to the control unit 28, via the cable member 44 mounted on the aftertreatment mounting system 30.

At step 58, the control unit 28 identifies the aftertreatment device 26 based on the input signal. More particularly, the control unit 28 that is in communication with the sensing unit 29 receives the input signal and determines the type of the aftertreatment device 26 present based on the juniper pin configuration on the second end 48 of the cable member 44,

At step 60, the input signal is correlated with the data stored in the data storage module 40. More particularly, the input signal detected by the control unit 28 is processed by the processing module 38 that is in communication with the data storage module 40. The input signal indicating the aftertreatment device 26 is then correlated to the predefined data in the data storage module 40 corresponding to that particular aftertreatment device 26.

At step 62, the mode of operation associated with the aftertreatment device 26 is selected. Based on the input signal, the data storage module 40 associates the aftertreatment device 26 with the predefined mode of operation and conveys the mode of operation to the control module 42. At step 64, the exhaust emissions from the machine 10 are controlled based on the mode of operation. The control module 42 operates the engine 24 based on the mode of operation selected for the aftertreatment device 26, thereby controlling exhaust emissions from the machine 10.

INDUSTRIAL APPLICABILITY

Machines operating in a particularly area are required to meet emission limits as per the statutory requirements that are laid down by governments of the area. Accordingly, the machine 10 needs to be compliant with the emission limits of the area in which it is operated. Based on the emission limits, different aftertreatment devices are interchangeably installed on the machine. Different aftertreatment devices require different control units for controlling the exhaust emissions.

The present disclosure may find applicability in eliminating the utilization of different control units and to better facilitate in the sensing, fault monitoring, and active aftertreatment controlling. More particularly, the present disclosure relates to the control unit 28 that is associated with the power supply system 22 of the machine 10. The control unit 28 ensures that the machine 10 is compliant with increasingly stringent emissions regulations. Specifically, the control unit 28 determines a type of the aftertreatment devices 26, 26A, 26B that is coupled to the engine 24, and selects the mode of operation based on the aftertreatment devices 26, 26A, 263, such that the control unit 28 controls the emissions of the machine 10. By using a single control unit 28 for the power supply system 22 with different modes of operation, an overall complexity associated with interchanging the aftertreatment devices 26, 26A, 26B, may be reduced. Thus, the operator of the machine 10 doesn't need to change the control unit 28 every time the aftertreatment device 26 is changed, thereby reducing the machine 10 downtime. The control unit 28 described in the present disclosure is compatible with a number of aftertreatment devices and can be easily adapted as per the requirement.

While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.

Claims

1. A method of controlling exhaust emission of a machine, the method comprising:

coupling a control unit with an engine of the machine, wherein the control unit comprises a data storage module for storing data associated with operation of one or more aftertreatment devices;

connecting at least one aftertreatment device to the engine of the machine, wherein the at least one aftertreatment device is adapted to control the exhaust emission of the machine:

receiving, by the control unit, an input signal from the at least one aftertreatment device;

identifying the at least one aftertreatment device based on the input signal;

correlating the input signal with the data stored in the data storage module;

selecting a mode of operation associated with the at least one aftertreatment device; and

controlling the exhaust emission of the machine based on the mode of operation.