Reductant Filling Assembly

- Caterpillar Inc.

A reductant filling assembly includes a first end and a second end, the first end adapted to connect from an interior side of a machine to a supply port attached to a receiver extending to an exterior side of the machine; a housing extending between the first end and the second end of the reductant filling assembly, the housing extending from a first housing end to a second housing end; a reductant supply conduit, a first circulating conduit, and a second circulating conduit extending through the housing from the first end to the second end. At least the first circulating conduit is in thermal communication with a wall of the reductant supply conduit, such that a heating fluid flowing through the first circulating conduit in a first direction transfers heat to a reductant fluid in the reductant supply conduit.

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Description
TECHNICAL FIELD

The present disclosure relates generally to engine exhaust systems, and more particularly, to exhaust aftertreatment systems including a ground level access point for introducing reductant to a machine for storage in, and delivery from, a tank positioned at a higher elevation than, or more generally, a substantial distance from, a supply port which is accessible from a ground level.

BACKGROUND

Various systems for removing or converting exhaust constituents, such as Selective Catalytic Reduction (SCR) systems, for example, have been incorporated into exhaust aftertreatment systems to control emissions of regulated exhaust constituents. These exhaust aftertreatment systems may use a pump electronics and tank unit (PETU), for example, to deliver a reductant to a flow of exhaust upstream of a catalyst. Some reductants may be susceptible to freezing due to their respective compositions, e.g., aqueous ammonia, an environment where a machine incorporating the exhaust aftertreatment system is operated, a frequency of operation of the machine wherein the reductant is stored, and/or a configuration for supplying the reductant. As a result, reductant being delivered to, stored in, and delivered from a tank of a PETU or other type of reductant delivery system, can be at risk of freezing.

U.S. Patent Application Publication No. 2013/0000729 (the 729 publication), entitled “DEF Pump and Tank Thawing System and Method,” relates to technology for an exhaust aftertreatment system that prevents freezing of reductant in a reductant storage tank and a reductant pump. The '729 publication describes a tank and a pump of the exhaust aftertreatment system being in thermal communication with a first coolant circuit and a second coolant circuit, respectively. Coolant from an engine is routed by the first coolant circuit and second coolant circuit to respective coolant loops inside the tank and the pump, to heat reductant in the tank and the pump.

While the '729 publication is focused on reductant that is stored in a tank or delivered from the tank to a flow of exhaust, reductant in other components of a reductant storage and delivery system may be susceptible to freezing. Therefore, there is a need for reductant storage and delivery systems and methods that address other freezing modes and/or other problems in the art.

SUMMARY

According to an aspect of the present disclosure, a reductant filling assembly comprises a first end and a second end, the first end adapted to connect from an interior side of a machine to a supply port attached to a receiver extending to an exterior side of the machine; a housing extending between the first end and the second end of the reductant filling assembly, the housing extending from a first housing end to a second housing end; a reductant supply conduit extending through the housing from the first end to the second end; a first circulating conduit extending through the housing from the first end to the second end; and a second circulating conduit extending through the housing from the first end to the second end. At least the first circulating conduit is in thermal communication with a wall of the reductant supply conduit, such that a heating fluid flowing through the first circulating conduit in a first direction transfers heat to a reductant fluid in the reductant supply conduit.

According to another aspect of the disclosure, a machine comprises an engine including an internal fluid circuit; an exhaust conduit connected to the engine that receives exhaust gas from the engine; a heating fluid circuit including a fluid supply conduit connected to an outlet of the internal fluid circuit and a fluid return conduit connected to an inlet of the internal fluid circuit; a receiver that extends to an exterior side of the machine; and a supply port on an interior side of the machine and fluidly connected to the receiver. The machine may further comprise an exhaust aftertreatment system including a tank that stores a reductant fluid to be delivered, a reductant output conduit in fluid communication with a portion of the exhaust conduit, and a pump in fluid communication with the reductant fluid to be delivered in the tank and the reductant output conduit. The machine may further comprise a reductant filling assembly including a first end and a second end, the first end adapted to connect from the interior side of the machine to the supply port, a housing extending between the first end and the second end of the reductant filling assembly, the housing extending from a first housing end to a second housing end, a reductant supply conduit extending through the housing from the first end to the second end, a first circulating conduit extending through the housing from the first end to the second end, and a second circulating conduit extending through the housing from the first end to the second end. The first circulating conduit and the second circulating conduit are fluidly connected to the heating fluid circuit downstream of the outlet of the internal fluid circuit and upstream of a section of the heating fluid circuit disposed in the tank. At least the first circulating conduit is positioned in thermal communication with a wall of the reductant supply conduit, such that a heating fluid flowing through the first circulating conduit in a first direction transfers heat to a reductant fluid in the reductant supply conduit.

Another aspect of the disclosure provides a method for heating a reductant fluid in a reductant filling assembly including a first end and a second end, the first end connected from an interior side of a machine to a supply port attached to a receiver extending to an exterior side of the machine, and the second end connected to a tank. The method for heating the reductant fluid may comprise supplying the reductant fluid from the exterior side through the supply port into a reductant supply conduit positioned within the reductant filling assembly and into the tank; supplying a flow of heating fluid to a heating fluid circuit fluidly coupled to the reductant filling assembly; supplying the flow of heating fluid from the heating fluid circuit to the second end of the reductant filling assembly and directing the flow of heating fluid in a first direction from the second end to the first end in a first circulating conduit positioned within the reductant filling assembly; transferring heat from a portion of the flow of heating fluid within the first circulating conduit to the reductant fluid in the reductant supply conduit; directing the flow of heating fluid from the first circulating conduit into a manifold at the first end and from the manifold into a second circulating conduit positioned within the reductant filling assembly; and directing the flow of heating fluid through the second circulating in a second direction from the first end to the second end and into the heating fluid circuit, the second direction being opposite to the first direction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a partial cutaway side view of a machine including an exhaust aftertreatment system, according an aspect of the present disclosure.

FIG. 2 illustrates a schematic front view of a filling system, according to an aspect of the present disclosure.

FIG. 3 illustrates a schematic top view of a filling system, according to an aspect of the present disclosure.

FIG. 4 illustrates a schematic side view of a filling system with a schematic cross sectional view of a filling assembly without reductant or heating fluid, according to an aspect of the present disclosure.

FIG. 5 illustrates a cross sectional view of the filling assembly of FIG. 4 with reductant and heating fluid added, taken along section line 5-5.

FIG. 6 illustrates a schematic side view of a filling system with a schematic cross sectional view of a filling assembly without reductant or heating fluid, according to an aspect of the present disclosure.

FIG. 7 illustrates a cross sectional view of the filling assembly of FIG. 6 with reductant and heating fluid added, taken along section line 7-7.

FIG. 8 illustrates a perspective view of a first manifold, according to an aspect of the present disclosure.

FIG. 9 illustrates a perspective view of a second manifold, according to an aspect of the present disclosure.

FIG. 10 illustrates a partial view of the second manifold of FIG. 9.

FIG. 11 illustrates a schematic side view of a filling system with a schematic cross sectional view of a filling assembly without reductant or heating fluid, according to an aspect of the present disclosure.

FIG. 12 illustrates a cross sectional view of the filling assembly of FIG. 11 with reductant and hearing fluid added, taken along section line 12-12.

FIG. 13 illustrates a schematic front view of a filling system, according to an aspect of the present disclosure.

FIG. 14 illustrates a schematic top view of a filling system, according to an aspect of the present disclosure.

FIG. 15 illustrates a schematic side view of a filling system including a filling assembly and a purge system, with a schematic cross sectional view of a filling assembly without reductant or heating fluid, according to an aspect of the present disclosure.

FIGS. 16A and 16B illustrate cross sectional views of the filling assembly of FIG. 15 with reductant and heating fluid added, taken along section line 16-16, according to aspects of the present disclosure.

FIG. 17 illustrates a flowchart of a method for filling a tank and purging a reductant supply conduit of a filling assembly, according to an aspect of the present disclosure.

FIG. 18 is a schematic top view of a filling system including a heating fluid bypass, according to an aspect of the present disclosure.

FIG. 19 illustrates a flowchart of a method for filling a tank and purging a reductant supply conduit of a filling assembly, according to an aspect of the present disclosure.

FIG. 20 illustrates a schematic side view of a filling system with a schematic cross sectional view of a filling assembly without reductant or heating fluid, according to an aspect of the present disclosure.

FIG. 21 illustrates a cross sectional view of the filling assembly of FIG. 20 with reductant and heating fluid added, taken along section line 21-21.

 DETAILED DESCRIPTION

Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, unless specified otherwise.

FIG. 1 illustrates a partial cutaway side view of a machine 1 including an exhaust aftertreatment system 30, according an aspect of the present disclosure. FIG. 1 illustrates the machine 1 including an engine 10 connected to an exhaust conduit 11. The machine 1 may be a hydraulic shovel (as illustrated), a tractor, an on-highway truck, an off-highway truck, a material handler, a logging machine, a compactor, construction equipment, a stationary power generator, a pump, an aerospace machine, a locomotive, a marine vehicle or machine, or any other device or application that produces combustion exhaust during operation. The engine 10 may include other features not shown, such as controllers, fuel systems, air systems, cooling systems, peripheries, drive-train components, turbochargers, exhaust gas recirculation systems, combinations thereof, or any other engine features or sub-systems known in the art. The engine 10 may be a reciprocating internal combustion engine, such as a spark ignition engine or a compression ignition engine; a turbomachine, such as a gas turbine; combinations thereof; or any other combustion engine known in the art. The engine 10 may be of any size, with any number of cylinders, in any configuration (“V,” in-conduit, radial, etc.), and operate on any cycle, such as a 4-stroke cycle, a 2-stroke cycle, a Diesel cycle, an Otto cycle, a Miller Cycle, a homogeneous charge compression ignition cycle, a reactivity controlled compression cycle ignition, combinations thereof, or any other internal combustion cycle known in the art.

Exhaust may flow in the exhaust conduit 11 to the aftertreatment system 30. Either the exhaust conduit 11 or the aftertreatment system 30 may include elements not shown, such as a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF), through which the exhaust may flow through prior to entering, for example, an SCR system provided in the aftertreatment system 30. A reductant delivery system 50 may supply reductant to the aftertreatment system 30 to promote conversion of exhaust constituents in the aftertreatment system 30. In a non-limiting aspect of the disclosure, the reductant may consist of or contain a diesel exhaust fluid (DEF) including urea, which may thermally decompose into ammonia (NH3) in admixture with the exhaust stream, and react with nitrogen oxides (collectively “NOx”) in the presence of a catalyst to produce nitrogen (N2) and water (H2O). However, the reductant may be any fluid known in the art that is capable of a reducing reaction with an exhaust constituent, whether or not in the presence of a catalyst.

The reductant may be supplied to the reductant delivery system 50 through a filling assembly 100 of a filling system from a source of reductant 3 located on a ground level G. The filling assembly 100 may be attached to a receiver 121, described in detail later, from an interior side 5 of the machine 1. The receiver 121 may be accessible from an exterior side 7 of the machine 1 by an operator on the ground level G (e.g., a ground level access point). For example, the receiver 121 may be attached to an arm 9, or other type of panel or access door, that the operator may lower to the ground level G to fluidly couple the filling assembly 100 with the source of reductant 3 through the receiver 121.

As illustrated in FIG. 1, a first end 100a of the filling assembly 100 is separated from the reductant delivery system 50 by a vertical distance Y, which may be in the range of 4-6 meters, depending upon the application. The vertical distance Y may represent a minimum length of a conduit used to supply reductant to the reductant delivery system 50. Accounting for other portions of a respective route profile, a total length between the first end 100a and the reductant delivery system 50 could be 8-10 meters long.

Combined with a location and frequency of use of the machine 1, after a filling operation, reductant remaining in a conduit that supplies the reductant may be at risk of freezing. As described in further detail below, aspects of the filling assembly 100 according to the present disclosure enable the filling assembly 100 to be integrated with a heating fluid circuit 200 to prevent freezing of reductant contained therein, or to thaw the filling assembly 100 should freezing occur.

FIG. 2 illustrates a schematic front view of a filling system (100, 111, 131), according to an aspect of the present disclosure. As illustrated in FIG. 2, the filling assembly 100 includes a housing 101, the first end 100a connected to a first manifold 111, and a second end 100b connected to a second manifold 131. The second manifold 131 is attached to a tank 51 of the reductant delivery system 50. The reductant delivery system 50 may include a Pump Electronics and Tank Unit (PETU) comprising the tank 51 and a pump 55. The pump 55 may obtain the reductant from the tank 51 through a pump reductant supply conduit 53, and pump the reductant through a pump reductant output conduit 57 to an injector 31 of the aftertreatment system 30. According to one aspect of the disclosure, the injector 31 may inject the reductant through an injector reductant output conduit 59, into a flow of the exhaust from the exhaust conduit 11 upstream of a Selective Catalytic Reduction (SCR) catalyst 33 of the aftertreatment system 30. The exhaust may then flow through the SCR catalyst 33 and out of the aftertreatment system 30 through an exhaust outlet 35 illustrated in FIG. 2.

Aspects of the heating fluid circuit 200 will now be described with reference to FIGS. 2 and 3, where FIG. 3 illustrates a schematic top view of a filling system (100, 111, 131), according to an aspect of the present disclosure.

FIG. 2 illustrates sections of the heating fluid circuit 200 connecting between the engine 10, the second manifold 131, the tank 51, the pump 55, and the injector 31. Beginning with a heating fluid supply conduit 201, which is in fluid communication with an outlet 13a of an internal fluid circuit 13 in the engine 10, a heating fluid, e.g. engine coolant which may be warmed to 212° F. or greater by heat rejection from the engine 10, flows within the heating fluid supply conduit 201 from the internal fluid circuit 13 to the second manifold 131. However, it will be appreciated the heating fluid supply conduit 201 may be connected to an additional or alternative source of heating fluid. A tank heating fluid supply conduit 205 fluidly connects the second manifold 131 with a section of the heating fluid circuit 200 disposed in the tank 51. The section of the heating fluid circuit 200 disposed in the tank 51 and a pump heating fluid supply conduit 207, fluidly connect the tank heating fluid supply conduit 205 and a housing of the pump 55. The housing of the pump 55 is fluidly connected to a housing of the injector 31 by an injector heating fluid supply conduit 209. As further illustrated in FIG. 2, the injector 31 may be fluidly connected to the engine 10 by a heating fluid return conduit 203, which is in fluid communication with an inlet 13b of the internal fluid circuit 13 in the engine 10. The heating fluid may flow within the heating fluid return conduit 203 from the injector 31 to the internal fluid circuit 13 in the engine 10.

As illustrated in FIG. 3, the tank heating fluid supply conduit 205 is connected to a tank circulating conduit 211, which provides at least a portion of the section of the heating fluid circuit 200 disposed in the tank 51. The tank circulating conduit 211 may be looped, or otherwise routed within the tank 51, to effect a desired heat transfer from the heating fluid flowing within the tank circulating conduit 211 to the reductant in the tank 51. Accordingly, the heating fluid flowing in the tank circulating conduit 211 may heat reductant stored in the tank 51 before flowing out of the tank 51 via the pump heating fluid supply conduit 207. According to an aspect of the disclosure, the heating fluid within the tank circulating conduit 211 is in thermal communication but not in fluid communication with reductant disposed within the tank 51.

A pump circulating conduit 213 positioned within the pump 55 is in fluid communication with the pump heating fluid supply conduit 207. The pump circulating conduit 213 may be looped, or otherwise routed within the pump 55, to effect a desired heat transfer from the heating fluid flowing within the pump circulating conduit 213 to the reductant in the pump 55. As illustrated in FIG. 3, the pump circulating conduit 213 may provide a fluid passage through the housing of the pump 55 to supply heat to an inside of the pump 55 and reductant pumped thereby. Alternatively, the pump circulating conduit 213 may be connected in line with a separate pumping mechanism (not shown), different from a pumping mechanism 55a used to pump reductant, which pumps the heating fluid to flow within the heating fluid circuit 200. The heating fluid may be pumped through the heating fluid circuit 200 exclusively by the separate pumping mechanism or in combination with other pumps connected to the heating fluid circuit 200, such as a water pump (not shown) associated with the engine.

The pump circulating conduit 213 is fluidly connected to an injector heating fluid supply conduit 209, which is fluidly connected to an injector circulating conduit 215 positioned within the injector 31. The injector circulating conduit 215 may be looped, or otherwise routed within the injector 31 and around the injector reductant output conduit 59, to effect a desired heat transfer from the heating fluid flowing within the injector circulating conduit 215 to the reductant flowing from the injector 31 through the injector reductant output conduit 59. Heating fluid flowing through the injector circulating conduit 215 heats the reductant supplied to and from the injector 31, and flows into to the heating fluid return conduit 203. It will be appreciated that other series or parallel arrangements of the first assembly circulating conduit 105, the second assembly circulating conduit 107, the tank circulating conduit 211, the pump circulating conduit 213, and the injector circulating conduit 215 are contemplated to be within the scope of the present disclosure.

FIG. 3 further illustrates the filling assembly 100 according to an aspect of the present disclosure. The filling assembly 100 includes a reductant supply conduit 103, a first assembly circulating conduit 105, and a second assembly circulating conduit 107 that may each extend through an intake end 101a and an outlet end 101b of the housing 101.

According to an aspect of the present disclosure, where the first end 100a of the filling assembly 100 is connected to the first manifold 111, the reductant supply conduit 103 may be connected to the first manifold 111 outside of the intake end 101a of the housing 101 by a reductant supply connection 113. The reductant supply connection 113 is in fluid communication with the receiver 121. According to an aspect of the present disclosure, the receiver 121 may be connected or mounted to the arm 9, or other type of panel or access door, of the machine 1 illustrated in FIG. 1. The arm 9 may be lowered for a filling operation so that from the ground level G, an operator may fluidly couple the source of reductant 3 to the filling assembly 100 through the receiver 121 and the reductant supply connection 113, and supply reductant to the reductant delivery system 50 through the filling assembly 100.

According to an aspect of the present disclosure, where the second end 100b is connected to the second manifold 131, the reductant supply conduit 103 may be connected to the second manifold 131 outside of the outlet end 101b of the housing 101 by a reductant outlet connection 133. The reductant outlet connection 133 is in fluid communication with a fill valve 141 that is positioned within the tank 51. The fill valve 141 controls a flow of reductant into the tank 51. According to one aspect of the present disclosure, the fill valve 141 may be mounted on an inner surface of a side wall of the tank 51. In another aspect of the present disclosure, the fill valve 141 may perform an automatic closing operation in response to a level of reductant in the tank 51 rising to a level such that a portion or all of the fill valve 141 is covered by the reductant.

Next, an integration of the heating fluid circuit 200 and the filling assembly 100 will be described. The heating fluid supply conduit 201 is in fluid communication with the first assembly circulating conduit 105 by a first inlet port 137a and a first outlet port 137b of the second manifold 131. As illustrated in FIG. 3, the first assembly circulating conduit 105 extends through the outlet end 101b, the housing 101, and the intake end 101a, and connects to an inlet port 117a of the first manifold 111. A manifold circulation channel 119 formed within the first manifold 111 connects the inlet port 117a to an outlet port 117b. The second assembly circulating conduit 107 is connected to the outlet port 117b of the first manifold 111. The second assembly circulating conduit 107 extends through the intake end 101a, the housing 101, and the outlet end 101b, and connects to a second inlet port 139a of the second manifold 131. The second assembly circulating conduit 107 is in fluid communication with the tank heating fluid supply conduit 205 through the second inlet port 139a and a second outlet port 139b of the second manifold 131.

According to the present disclosure, “thermal communication” refers to an orientation, position, or configuration of elements or materials that one of ordinary skill in the art would recognize as facilitating a degree of heat transfer from one element or material to another element or material that may not occur with a different orientation, position, or configuration of the elements or materials. For example, two elements or materials may be considered in thermal communication if heat is transferred more efficiently therebetween than if each element was thermally isolated or thermally insulated. An orientation, position, or configuration in which elements are in thermal communication may result in the elements approaching thermal equilibrium or thermal steady state. According to the present disclosure, elements in thermal communication may be separated by a space or gap, or a heat transfer material, or a component. Further, elements in thermal communication may also be provided in physical contact according to the present disclosure. Thermal communication may be limited according to the present disclosure to thermal communication via conduction and/or convection.

At the first end 100a, heating fluid may flow from the first assembly circulating conduit 105 to the second assembly circulating conduit 107 via the manifold circulation channel 119. Accordingly, heat from the heating fluid in the manifold circulation channel 119 is transferred to (1) the reductant supply connection 113, and (2) an end of the reductant supply conduit 103 that may be connected to the reductant supply connection 113 outside of the intake end 101a of the housing 101. At the second end 100b, the heating fluid flows through the second manifold 131 twice so that heat may be transferred to (1) an end of the reductant supply conduit 103 that may be connected to the reductant outlet connection 133 outside of the outlet end 101b of the housing 101, and (2) the reductant outlet connection 133. Thus, the first manifold 111 and the second manifold 131 are in thermal communication with, and function to heat portions of a combined reductant supply conduit (103, 113, 133) at connection points for the first end 100a and the second end 100b of the filling assembly 100 that may not be covered by the housing 101, and help prevent freezing of reductant being supplied to the reductant delivery system 50, or to thaw frozen reductant contained within the reductant delivery system 50.

FIG. 4 illustrates a schematic side view of a filling system (100, 111, 131) with a schematic cross sectional view of a filling assembly 100 without reductant or heating fluid, according to an aspect of the present disclosure. As illustrated in FIG. 4, the reductant supply conduit 103 of the filling assembly 100 extends through the intake end 101a and the outlet end 101b of the housing 101. Within the housing 101, the first assembly circulating conduit 105 and the second assembly circulating conduit 107 run parallel to the reductant supply conduit 103 and are in thermal communication with the reductant supply conduit 103 as will be described with reference to FIG. 5.

FIG. 5 illustrates a cross sectional view of the filling assembly 100 of FIG. 4 with reductant and heating fluid added, taken along section line 5-5. As illustrated in FIG. 5, the first assembly circulating conduit 105 and the second assembly circulating conduit 107 are positioned adjacent to opposite sides of the reductant supply conduit 103. A gap may be maintained, or heat transfer material (not shown), having a relatively high thermal conductivity, may be provided between the reductant supply conduit 103 and each of the first assembly circulating conduit 105 and the second assembly circulating conduit 107. The heat transfer material may be adhered to outer walls of the reductant supply conduit 103, the first assembly circulating conduit 105, and the second assembly circulating conduit 107, to form a body (e.g., a bridge) of material across which heat may be transferred. In an alternative embodiment not illustrated, portions of the outer walls of the first assembly circulating conduit 105 and the second assembly circulating conduit 107 may be in direct contact with the outer wall of the reductant supply conduit 103.

According to one aspect of the disclosure, heat is transferred from both the first and second assembly circulating conduits (105, 107) along the length of the reductant supply conduit 103 in the filling assembly 100. The housing 101 is formed with a layer of insulation 101c that insulates the filling assembly 100, and helps facilitate heat transfer from both the first and second assembly circulating conduits (105, 107) to the reductant flowing in the reductant supply conduit 103. According to another aspect of the present disclosure, a thermal conductivity of the heat transfer material is greater than a thermal conductivity of the layer of insulation 101c. For example, the layer of insulation 101c could be formed of rubber, fiberglass, or other insulating materials known in the art, and the heat transfer material may be formed of a material having a relatively high thermal conductivity, such as a metal, including aluminum, steel, and copper alloys that may be adhered (e.g. via welding or other type of adhesion) to the outer surfaces of the reductant supply conduit 103 and the circulating conduits (105, 107).

The layer of insulation 101c may be wrapped around a combination of the reductant supply conduit 103, first assembly circulating conduit 105, and the second assembly circulating conduit 107. Alternatively, the housing 101 may be formed as a sleeve including a slit along a longitudinal axis that may be opened to place the combination of the reductant supply conduit 103, first assembly circulating conduit 105, and the second assembly circulating conduit 107 within the sleeve.

FIG. 6 illustrates a schematic side view of a filling system (111, 131, 1100) with a schematic cross sectional view of a filling assembly 1100 without reductant or heating fluid, according to an aspect of the present disclosure. The filling assembly 1100 includes a reductant supply conduit 1103, a first assembly circulating conduit 1105, and a second assembly circulating conduit 1107 positioned inside of a housing 1101. Similar to the filling assembly 100, the reductant supply conduit 1103, the first assembly circulating conduit 1105, and the second assembly circulating conduit 1107 of the filling assembly 1100 connect to the first manifold 111 and the second manifold 131.

The first assembly circulating conduit 1105 and the second assembly circulating conduit 1107 are wrapped around the reductant supply conduit 1103, and along with the reductant supply conduit 1103, extend through an intake end 1101a and an outlet end 1101b of the housing 1101. As illustrated in FIG. 6, the first assembly circulating conduit 1105 and the second assembly circulating conduit 1107 are wrapped around the reductant supply conduit 1103 in an alternating configuration. An advantage of such a configuration is that substantially all of a surface area of an outer wall of the reductant supply conduit 1103 within the housing 1101 is in contact with a portion of an assembly circulating conduit. Accordingly, an amount of heat transferred to reductant flowing in the reductant supply conduit 1103 may be increased relative to other configurations.

FIG. 7 illustrates a cross sectional view of the filling assembly 1100 of FIG. 6 with reductant and heating fluid added, taken along section line 7-7. Similar to the housing 101 of the filling assembly 100, the housing 1101 of the filling assembly 1100 includes a layer of insulation 1100c that surrounds the reductant supply conduit 1103, the first assembly circulating conduit 1105, and the second assembly circulating conduit 1107. The housing 1101 may have a structure similar to the housing 101 of the filling assembly 100 illustrated in FIGS. 4 and 5.

FIG. 8 illustrates a perspective view of a first manifold 111, according to an aspect of the present disclosure. A first coupling 123 attached to the reductant supply conduit (103, 1103) may be connected to the reductant supply connection 113 of the first manifold 111. The reductant supply connection 113 includes a reductant supply connector 113a, through which the reductant supply conduit 103 is in fluid communication with a reductant supply channel 113b of the reductant supply connection 113. The reductant supply connector 113a may be fixed on the reductant supply channel 113b or a component of the first coupling 123 that connects the reductant supply conduit (103, 1103) to the reductant supply connection 113. The reductant supply channel 113b extends through the first manifold 111 to a reductant supply port 113c. The reductant supply port 113c is fluidly connected to the receiver 121. The reductant supply connection 113 may be located on the interior side 5 of the machine 1 and surrounded by the manifold circulation channel 119 to facilitate heat transfer to the reductant flowing to the reductant supply conduit (103, 1103). In addition, at least a portion of the first manifold 111 between the circulation channel 119 and a surface of the first manifold 111 that surrounds the reductant supply port 113c and reductant supply channel 113b may be formed of a material having a relatively high thermal conductivity, such as a metal, including aluminum, steel, and copper alloys, for example.

Vertical sections (119a, 119c) of the manifold circulation channel 119 may be connected to the inlet port 117a and the outlet port 117b of the first manifold 111. In addition, a connecting section 119b of the manifold circulation channel 119 that fluidly couples the vertical sections (119a, 119c), may extend to an additional port 119d formed in the first manifold 111. The additional port 119d may receive a plug 119e or be connected to a conduit, such as the assembly circulating conduits (105, 107, 1105,1107). According to one aspect of the disclosure, the plug 119e is placed in the additional port 119d, and can be removed to drain the manifold circulation channel 119, as well as the first and second assembly circulating conduits (105, 107, 1105, 1107).

A second coupling 125 is provided at an end of the first assembly circulating conduit (105, 1105) and the second assembly circulating conduit (107, 1107). A reducer 125a of the second coupling 125 is connected to a respective heating assembly conduit, and a fitting 125b is attached the inlet port 117a and the outlet port 117b of the first manifold 111. To avoid heating fluid leaking from the heating fluid circuit 200, the inlet port 117a, outlet port 117b, and fitting 125b may include corresponding threaded sections to provide threaded connections between the first and second assembly circulating conduits (105, 107, 1105, 1107) and the first manifold 111.

FIGS. 9 and 10 respectively illustrate a perspective view and a partial view of a second manifold 131, according to an aspect of the present disclosure. As illustrated in FIG. 9, the second manifold 131 includes a second manifold mounting plate 135, as well as a first sub-manifold 137 and a second sub-manifold 139 removably attached to the second manifold mounting plate 135. The reductant supply conduit (103, 1103) is connected by a first coupling 123 attached to a reductant outlet connector 133a of the reductant outlet connection 133. The reductant outlet connector 133a may be fixed on the reductant outlet channel 133b or a component of the first coupling 123 that connects the reductant supply conduit (103, 1103) to the reductant outlet connection 133. A reductant outlet channel 133b extends from the reductant outlet connector 133a to a reductant outlet port 133c provided in the second manifold mounting plate 135. The reductant outlet channel 133b is in fluid communication with the fill valve 141 that is positioned within the tank 51.

The first outlet port 137b and the second inlet port 139a of the second manifold 131 are respectively attached by second couplings 125 to ends of the first assembly circulating conduit (105, 1105) and the second assembly circulating conduit (107, 1107) that extend through the outlet end (101b, 1101b) of the housing (101, 1101). The first outlet port 137b is provided at an end of a first sub-manifold channel 137c. The first sub-manifold channel 137c is in fluid communication with the heating fluid supply conduit 201 through the first inlet port 137a. The second inlet port 139a is provided at an end of a second sub-manifold channel 139c. The second sub-manifold channel 139c is in fluid communication with the tank heating fluid supply conduit 205 through the second outlet port 139b.

Each of the sub-manifolds (137, 139) may be formed of material having a relatively high thermal conductivity, such as metals, including aluminum, steel, and copper alloys, for example. Thus, heat may be absorbed by portions of a sub-manifold surrounding a respective channel, and transferred via convection, conduction, or both, from a respective external wall to an area around the end of the reductant supply conduit (103, 1103) connected to the reductant outlet connection 133. In the non-limiting embodiment illustrated in FIGS. 9 and 10, each sub-manifold channel (137c, 139c) is formed within a respective sub-manifold (137, 139) with a 90° turn. It will be understood that different configurations for a path of a sub-manifold channel may be provided to promote an amount of heat absorbed and transferred to an area where portions of the reductant supply conduit (103, 1103) and reductant outlet connection 133 are located. Additionally, the second manifold mounting plate 135 may provide a heat sink that absorbs heat from the sub-manifolds (137, 139) and directs the heat to an area surrounding the reductant outlet port 133c. The sub-manifolds (137, 139) may be attached to the second manifold mounting plate 135 by bolts or any other fastening mechanism or structure known in the art.

FIG. 11 illustrates a schematic side view of a filling system (2100, 2111, 2131) with a schematic cross sectional view of a filling assembly 2100 without reductant or heating fluid, according to an aspect of the present disclosure. FIG. 11 illustrates a first manifold 2111 connected to the filling assembly 2100 that is connected to a second manifold 2131, which is in fluid communication with the fill valve 141 in the tank 51. A reductant supply conduit 2103 of the filling assembly 2100 is positioned within a first assembly circulating conduit 2105. The first assembly circulating conduit 2105 is formed as a hollow tube in which the reductant supply conduit 2103 is positioned. The housing 2101 may be provided with a layer 2101c of insulation placed around the reductant supply conduit 2103, first assembly circulating conduit 2105, and the second assembly circulating conduit 2107.

Heating fluid flows within the first assembly heating conduit 2105 from the second manifold 2131 to a first manifold 2111 in direct contact with an outer wall of the reductant supply conduit 2103. Alternatively, the first assembly circulating conduit 2105 may include two concentric tubes, a smaller concentric tube engaging the outer wall of the reductant supply conduit 2103 by an interference fit, a sliding fit, or a slip fit, for example. In these configurations, an outer surface of the reductant supply conduit 2103 is in contact with heating fluid, or a wall in contact with heating fluid, flowing in the first assembly circulating conduit 2105 for a substantially entire length of the reductant supply conduit 2103.

Heating fluid in the first assembly circulating conduit 2105 flows through a manifold circulation channel 2119 of the second manifold 2131, and into a second assembly circulating conduit 2107. As illustrated in FIGS. 11 and 12, where FIG. 12 illustrates a cross sectional view of the filling assembly 2100 of FIG. 11 with reductant and heating fluid added, taken along section line 12-12, the second assembly circulating conduit 2107 runs parallel with, and is adjacent to the first assembly circulating conduit 2105 within the housing 2101.

FIGS. 13-15 respectively illustrate schematic front, top, and side views of a filling system (300, 2100, 2111, 2131), according to various aspects of the present disclosure. As illustrated in FIGS. 13-15, a purge system 300 includes a controller 301 that communicates with a purge control valve 303, a tank reductant sensor 305, and the receiver 121. The purge control valve 303 is incorporated in the tank heating fluid supply conduit 205 between the second manifold 2131 and the tank 51. The tank reductant sensor 305 is positioned within the tank 51 and may detect a parameter related to an amount of reductant or a level of reductant in the tank 51.

The controller 301 operates the purge control valve 303 to be normally open, i.e., the purge control valve 303 is open in a default state. During a filling operation in which reductant is supplied to the reductant delivery system 50 through the receiver 121 and the filling assembly 2100, the controller 301 monitors the parameter associated with the amount or level of reductant entering the tank 51 with the tank reductant sensor 305. In response to the reductant reaching a certain amount or level within the tank 51 (e.g., when the tank 51 is substantially full), the controller 301 may receive a signal from the tank reductant sensor 305, close the receiver 121, and close the purge control valve 303.

The reductant supply conduit 2103 of the filling assembly 2100, or any other filling assembly described herein, may be formed of a flexible material such as rubber, a rubber/nylon composite, or any other flexible material that is resistant to corrosion. According to an aspect of the present disclosure, the reductant supply conduit 2103 is sufficiently flexible to be compressed and become substantially flat under pressure applied by the heating fluid according to an operation of the purge control valve 303.

In an operational mode in which the purge control valve 303 is closed, the heating fluid will not flow within the heating fluid circuit 200 past the purge control valve 303. Pressure applied to the outer wall of the reductant supply conduit 2103 will increase as the heating fluid continues to flow into the filling assembly 2100 without subsequently passing through the purge control valve 303. Due to the flexibility of the reductant supply conduit 2103, an outer wall thereof will begin compressing under the increase in pressure applied by an increasing volume of heating fluid flowing into the first assembly circulating conduit 2105. During this mode, it may be preferable that reductant is not supplied to the filling assembly 2100 through the receiver 121 from an external source.

FIGS. 16A and 16B illustrate cross sectional views of the filling assembly 2100 of FIG. 15 with reductant and heating fluid added, taken along section line 16-16, according to aspects of the present disclosure. As illustrated in FIG. 16A, when the purge control valve 303 is open, the reductant supply conduit 2103 is substantially circular in cross-section and not compressed. As illustrated in FIG. 16B, when the purge control valve 303 is closed, the reductant supply conduit 2103 can become substantially flat under the pressure applied by the heating fluid continuing to flow in the first assembly circulating conduit 2105. As the reductant supply conduit 2103 becomes increasingly flat, reductant therein will be forced out of the reductant supply conduit 2103 and into the tank 51.

FIG. 17 illustrates a flowchart of a method 1700 for filling a tank 51 and purging a reductant supply conduit 2103 of a filling assembly 2100, according to an aspect of the present disclosure. At step 1701 the method 1700 begins, at which time the source of reductant 3 located on the ground level G, or another source of reductant, may be connected to the receiver 121. During step 1703, reductant from the source of reductant 3 may be supplied through the receiver 121 and the filling assembly 2100 into the tank 51. Next, at step 1705, the controller 301 communicates with the tank reductant sensor 305 to check a level of reductant in the tank 51. As the level of reductant in the tank 51 rises, a level sensor 305b illustrated in FIG. 15, may float on a surface of the reductant and move along a sensor guide rod 305a until reaching a level sensor detector 305c of the tank reductant sensor 305 located at a threshold level. The controller 301 continuously monitors the tank reductant sensor 305 and repeats step 1705 until a communication with the level sensor detector 305c indicates a detection of the level sensor 305b has occurred. The method 1700 moves to step 1707 once the controller 301 determines the level sensor 305b has been detected.

As illustrated in FIG. 15, the tank reductant sensor 305 includes a float sensor (305a, 305b, 305c). However, the tank reductant sensor 305 may be any other type of fluid level sensor known in the art, such as an optical liquid level sensor, for example. Alternatively, as noted above, the tank reductant sensor 305 may include any type of sensor that detects a parameter associated with an amount of reductant in the tank 51. For example, a sensor that measures a volume of reductant may be connected to the controller 301 and installed in the tank 51 to communicate a detected volume of reductant in the tank 51 to the controller 301. The controller 301 could therefore perform step 1703 and maintain the purge control valve 303 in an open position until the sensor communicates to the controller 301 that the volume of the reductant in tank 51 is equal to a predetermined threshold volume referenced by the controller 301.

At step 1707, the controller 301 closes the receiver 121, and a supply of reductant to reductant supply conduit 2103 is stopped. Next, at step 1709, the controller 301 closes the purge control valve 303. At this point in the method 1700, the controller 301 may start to track a time that the purge control valve 303 is closed or initiate a counter. With respect to step 1711, a monitored variable t may represent an elapsed time or a current value of the counter. At step 1711, the controller 301 may check the time or increment a value of the counter until the monitored variable t is equal to a reference value s representing a predetermined threshold for an elapsed time or count value.

When the monitored variable t is greater than or equal to the reference value s the method 1700 moves on to step 1713 and the controller 301 opens the purge control valve 303. Thus, the reductant supply conduit 2103 will expand and the heating fluid will again flow through the filling assembly 2100, past the purge control valve 303, and in to the tank 51 and heat the reductant fluid stored in the tank 51. If the machine 1 continues to operate, reductant remaining in the reductant supply conduit 2103 may receive heat transferred from the heating fluid flowing though the filling assembly 2100 and past the purge control valve 303.

At step 1715 the method 1700 ends with the purge control valve 303 in an open state and the heating fluid flowing in series from the engine 10, through the filling assembly 2100, past the purge control valve 303 into the tank heating fluid supply conduit 205, and into the tank circulating conduit 211.

In addition to the method 1700 of FIG. 17, an operation of the purge control valve 303 may be responsive to an operation of the engine 10.

For example, the purge control valve 303 may be closed according to a shutdown operation, or other type of operation, of the engine 10 being requested or initiated. Thus, in response to the request or the initiation of a particular operation of the engine, the controller 301 may estimate a first time to complete the operation, or a portion of a shutdown operation, of the engine 10, and monitor an elapsed time after the first time is estimated. When the first time is estimated, the controller 301 may also estimate a second time to complete a purging operation, or a combination of operations including the purging operation.

In response to the elapsed time being equal to the first time, either the controller 301, or a central controller (not shown) for the machine 1 receiving a signal from the controller 301, may operate the engine 10 in an idle state or a predetermined operating condition for the second time following a point when the elapsed time is equal to the first time. In response to a start, or an elapsing of a predetermined period of time after the start of the engine 10 operating in the idle state or the predetermined operating condition, the controller 301 may close the purge control valve 303. The controller 301 may continue to monitor the elapsed time. In response to the elapsed time being equal to the first time plus the second time, the controller 301 can open the purge control valve 303 and either stop, or send a signal to the central controller to stop the engine 10 operating in the idle state or the predetermined operating condition.

Accordingly, the engine 10 may be operated in the idle state or the predetermined operating condition so that heating fluid is circulated in the heating fluid circuit 200 for a period of time sufficient to close the purge control valve 303 and substantially compress the reductant supply conduit 2103 and purge reductant in the reductant supply conduit 2103 into the tank 51. As such, the reductant supply conduit 2103 may be purged at a time corresponding to immediately before an end of an operating session of the machine 1, reducing the amount of reductant in the reductant supply conduit 2103 that may be at risk of freezing when the machine 1 is not in use.

In another operation responsive to a state of the engine 10, a filling operation may be delayed based on a temperature of the engine. According to an aspect of the present disclosure, when the engine 10 operates during a filling operation, reductant in the reductant supply conduit 2103 is heated by the heating fluid in the fluid heating circuit 200 which may be heated by the engine 10 (e.g., when the heating fluid is engine coolant). In a situation where the engine 10 has just been started or is otherwise in a cold state, and a filling operation is attempted, signals indicating (1) a temperature of the engine and/or of the heating fluid in the heating fluid circuit 200, and (2) an attempt to perform the filling operation, may be sent to the controller 301. As a result, the controller 301 may close the shut-off mechanism in the receiver 121 and operate the engine 10 at a higher than normal idle so the temperature of the heating fluid reaches a predetermined temperature in a shorter period of time. Subsequently, the controller 301 may open the receiver 121 and a filling operation may be performed.

FIG. 18 illustrates a filling system (300, 2100, 2111, 2131) including a heating fluid bypass (307, 309), according to an aspect of the disclosure. As illustrated in FIG. 18, the purge system 300 includes a bypass conduit 307 and a bypass control valve 309. The bypass conduit 307 branches off of the heating fluid supply conduit 201 and reconnects with the heating fluid circuit 200 downstream of the purge control valve 303. A portion of the bypass conduit 307 that is downstream of the bypass control valve 309 connects with a portion of the tank heating fluid supply conduit 205 that is downstream of the purge control valve 303. As a result, the bypass conduit 307 can permit heating fluid to flow through the tank 51 even when the reductant supply conduit 2103 is purged by a closing operation of the purge control valve 303.

FIG. 19 illustrates a flowchart of a method 1900 for filling a tank 51 and purging a reductant supply conduit 2103 of a filling assembly 2100, according to an aspect of the present disclosure. At step 1901 the method 1900 begins, at which time the source of reductant 3 located on the ground level G, or another source of reductant, may be connected to the receiver 121. During step 1903, reductant from the source of reductant 3 may be supplied through the receiver 121 and the filling assembly 2100 into the tank 51. Next, at step 1905, the controller 301 communicates with the tank reductant sensor 305 to check a level of reductant in the tank 51. The controller 301 continuously monitors the tank reductant sensor 305 and repeats step 1905 until a communication with the level sensor detector 305c indicates a detection of the level sensor 305b has occurred, and thus an amount of reductant in the tank 51 is equal or greater than a predetermined threshold. The method 1900 moves to step 1907 once the controller 301 determines the level sensor 305b has been detected.

At step 1907, the controller 301 closes the receiver 121, and a supply of reductant to reductant supply conduit 2103 is stopped. Next, at step 1909, the controller 301 opens the bypass control valve 309 and closes the purge control valve 303. As a result, heating fluid flows through the bypass conduit 307 to the tank circulating conduit 211 so reductant in the tank 51 continues to be heated while the reductant supply conduit 2103 is purged. The controller 301 may start to track a time that the purge control valve 303 is closed, or initiate a counter. Similar to method 1700, at step 1911 of the method 1900, the controller 301 may check the time or increment a value of a counter until a monitored variable t is equal to a reference value s. When the monitored variable t is greater than or equal to the reference value s, the method 1900 moves to step 1913.

At step 1913, the controller 301 opens the purge control valve 303 and closes the bypass control valve 309. According to another aspect of the present disclosure, additional sensors that detect a presence of reductant in the reductant supply conduit 2103 may communicate with controller 301. In response, the controller 301 may close the purge control valve 303 at other times which do not correspond to a filling operation. Thus, the controller 301 may perform a purge operation during different times of operation of the machine 1 in which the heating fluid flows through the filling assembly 2100, based on different monitored parameters of operation and reductant delivery. Alternatively, the purge control valve 303 could remain closed and the bypass control valve 309 could remain open while the machine 1 is operating. This may avoid reductant flowing back into the reductant supply conduit 2103 from the tank 51, while continuing to heat the reductant in the tank 51, the pump 55, and the injector 31.

At step 1915 the method 1900 ends with the purge control valve 303 in an open state and the heating fluid flowing in series from the engine 10, through the filling assembly 2100, past the purge control valve 303 in to the tank heating fluid supply conduit 205, and into the tank circulating conduit 211.

Any of the methods or functions described herein may be performed by or controlled by the controller 301. Further, any of the methods or functions described herein may be embodied in a computer-readable non-transitory medium for causing the controller 301 to perform the methods or functions described herein. Such computer-readable non-transitory media may include magnetic disks, optical discs, solid state disk drives, combinations thereof, or any other computer-readable non-transitory medium known in the art. Moreover, it will be appreciated that the methods and functions described herein may be incorporated into larger control schemes for an engine, a machine, or combinations thereof, including other methods and functions not described herein.

FIG. 20 illustrates a schematic side view of a filling system (3100, 3111, 3131) with a schematic cross sectional view of a filling assembly 3100 without reductant or heating fluid, according to an aspect of the present disclosure. FIG. 21 illustrates a cross sectional view of the filling assembly 3100 of FIG. 20 with reductant and heating fluid added, taken along section line 21-21 in FIG. 20, according to an aspect of the disclosure. The filling assembly 3100 includes a reductant supply conduit 3103, a first assembly circulating conduit 3105, and a second assembly circulating conduit 3107 in a housing 3101. The filling assembly 3100 is connected to a first manifold 3111 and a second manifold 3131. The first assembly circulating conduit 3105 and the second assembly circulating conduit 3107 are semi-annular in cross-section as illustrated in FIG. 21. A partition 3109 extends in a radial direction from an outer surface of the reductant supply conduit 3103 to an inner surface of the housing 3101. The partition 3109 extends on opposite sides of a circumference of the reductant supply conduit 3103 between the first assembly circulating conduit 3105 and the second assembly circulating conduit 3107 at least from an intake end 3101a to an outlet end 3101b of the housing 3101. According to an aspect of the present disclosure, heat is transferred from heating fluid in the first and second assembly circulating conduits (3105, 3107) to reductant in the reductant supply conduit 3103 across substantially an entire surface area of the reductant supply conduit 3103.

Heat provided by assembly circulating conduits and first and second manifolds described herein may be supplemented by heat generated by other heating devices. According to an aspect of the present disclosure, an electrically powered heating device may be incorporated with any filling assembly described herein. For example, an electrical heating wire or wrap (e.g., heat tape) may be wrapped around a portion, or substantially all, of a reductant supply conduit prior to being assembled in a filling assembly. Ends of the electrical heating wire or wrap (e.g., leads) may extend through an intake end or an outlet end of a housing so as to be able to connect, disconnect, or reconnect to a power source that supplies a current passing through the electrical heating wire or wrap.

An amount of current required for the electrical heating wire or wrap to generate a desired heat output is proportional to a length of the electrical heating wire or wrap. A current required for a length for an electrical heating wire or wrap provided along an entire length of a reductant supply conduit may be large and could require an additional alternator as a power source. Accordingly, a system that relies solely on an electrical heating wire or wrap (i.e., a system without assembly circulating conduits as described herein) to heat a conduit carrying reductant to a PETU, for example, may require an alternator not provided for in an original design of a machine. According to one aspect of the present disclosure, only a portion of a reductant supply conduit may be provided with the electrical heating wire or wrap, such that a length of the portion corresponds to a length of an electrical heating wire or wrap that requires an amount of current which can be supplied by an existing power source of a machine. The existing power source preferably not being generally dedicated to supplying power to electrical heating wires or wraps in the machine.

An electrical heating wire or wrap that is incorporated, preferably without an additional alternator, in a filling assembly according the present disclosure may be utilized at different times to heat a reductant supply conduit to a desired extent in combination with operations utilizing heating fluid flowing in a filling assembly. For example, the electrical heating wire or wrap may be used to preheat, but not necessarily completely thaw, a reductant supply conduit during a cold start of an engine or just before a filling operation begins. Any method or function employing an electrical heating device described herein may be performed by or controlled by the controller 301, and/or incorporated into larger control schemes for an engine, a machine, or combinations thereof, including other methods and functions not described herein.

INDUSTRIAL APPLICABILITY

The present disclosure is applicable to diesel emission treatment systems that enable engine exhaust systems to meet international emission standards (e.g., Tier 4 Final/EU Stage IV emission standards). In particular, the present disclosure is applicable to diesel emission treatment systems that incorporate Selective Catalytic Reduction (SCR), which targets nitrogen oxides (NOx) in diesel exhaust for reduction to nitrogen (N2) and water vapor (H2O).

The present disclosure is particularly applicable to situations where a reductant delivery system is supplied with reductant conveyed through a fluid carrying conduit attached to a receiver positioned on a machine at a significantly lower elevation than the reductant delivery system. Issues of the reductant freezing in the conduit may arise for several reasons. First, since the conduit is long, a surface area exposed to a temperature of an environment surrounding the conduit is large. Thus, if a path of the conduit in a particular application exposes the conduit to low ambient temperatures or other components that may absorb heat, the reductant in the conduit may also be exposed to these temperature lowering factors across a large surface area due to a length of the conduit. Second, when reductant is not being supplied, since an elevation of the reductant delivery system is higher than a receiver through which reductant is initially supplied, reductant in the conduit remains in the conduit; it does not flow to the reductant delivery system and is not drained to another location. Thus, reductant in the conduit during these periods remains stagnate and exposed to the temperature of the environment and heat absorbing characteristics of the components surrounding the conduit.

According to one aspect of the present disclosure, an existing heat source (e.g., engine 10) in the machine 1 may be used to heat a reductant supply conduit (103, 1103, 2103, 3103). This provides certain benefits over adding an additional heat source, such as electrically heating the supply conduit (103, 1103, 2103, 3102); for instance there is no requirement for additional electrical power generation.

Referring to FIGS. 2, 3, 13, 14, 18, reductant is supplied to the reductant delivery system 50 (i.e., an initial supply of reductant to the machine 1, in general) through the reductant supply conduit (103, 1103, 2103, 3103). The heating fluid supply conduit 201 is in fluid communication with the first assembly circulating conduit (105, 1105, 2105, 3105) through the second manifold (131, 2131, 3131). The heating fluid is returned through the heating fluid return conduit 203 after flowing through the first manifold (111, 2111, 3111) and the second assembly circulating conduit (107, 1107, 2107, 3107). The heating fluid may be coolant circulated through the engine 10 that is at a very high temperature at the outlet 13a of the internal fluid circuit 13 within the engine 10, or some other heating fluid. By flowing through the assembly circulating conduits (105, 107, 1105, 1107, 2105, 2107, 3105, 3107), which are positioned adjacently or coaxially relative to the reductant supply conduit (103, 1103, 2103, 3103) to be in thermal communication with the reductant supply conduit (103, 1103, 2103, 3103), heat is transferred from the heating fluid to the walls and reductant within the reductant supply conduit (103, 1103, 2103, 3103). Thus, according to one aspect of the disclosure, what may be considered waste heat from a component required by the machine 1 (e.g., the engine 10), is utilized to efficiently heat reductant before the reductant is supplied to the reductant delivery system 50.

According to one aspect of the present disclosure, heat is transferred to reductant prior to being received by the tank 51 of the reductant delivery system 50, over substantially an entire respective path between the tank 51 and the receiver 121.

Referring to FIGS. 4, 6, 11, 15, and 20, the reductant supply conduit (103, 1103, 2103, 3103) extends from the first manifold (111, 2111, 3111), having a substantial length thereof inside the housing (101, 1101, 2101, 3101). Within the housing (101, 1101, 2101, 3101), the reductant supply conduit (103, 1103, 2103, 3103) is positioned to be in thermal communication, either by contact or through a heat transfer material, with an assembly circulating conduit (105, 107, 1105, 1107, 2105, 2107, 3105, 3107) within a space that is insulated by the layer of insulation (101c, 1101c, 2101c, 3101c) of the housing (101, 1101, 2101, 3101). The assembly circulating conduits (105, 107, 1105, 1107, 2105, 2107, 3105, 3107) are positioned to be in close proximity to the reductant supply conduit (103, 1103, 2103, 3103) from the intake end (101a, 1101a, 2101a, 3101a) to the first manifold (111, 2111, 3111), and from the outlet end (101b, 1101b, 2101b, 3101b) to the second manifold (131, 2131, 3131). As a result, heat may be transferred from heating fluid flowing in the assembly circulating conduits (105, 107, 1105, 1107, 2105, 2107, 3105, 3107), to reductant in the reductant supply conduit (103, 1103, 2103, 3103), over a substantial length of the reductant supply conduit (103, 1103, 2103, 3103) between the first manifold (111, 2111, 3111) and the second manifold (131, 2131, 3131).

Referring to FIG. 8, the heating fluid flows in the first manifold 111 in the manifold circulation channel 119 which surrounds the reductant supply connection 113. Referring to FIGS. 9 and 10, the heating fluid flows through the sub-manifolds (137, 139) closely positioned to the reductant outlet connection 133 on the second manifold mounting plate 135. Accordingly, even at connection points between the reductant supply conduit 103 and the first and second manifolds (111, 131), heat from the heating fluid may be transferred to the reductant being supplied to the tank 51.

According to an aspect of the present disclosure, the method (1700, 1900) may be performed to reduce a risk of reductant freezing during periods when reductant is not supplied through a filling assembly, when a machine is operating, and when a machine is about to stop operating.

In the method (1700, 1900), reductant in the reductant supply conduit 2103 being supplied to the reductant delivery system 50 may be discharged from the reductant supply conduit 2103 at the end of a filling operation. The controller 301 may monitor the tank reductant sensor 305 and close the purge control valve 303 at the end of the filling operation when a monitored parameter related to an amount of reductant in the tank 51 is equal to or greater than a predetermined threshold. Heating fluid continues to be supplied to the first assembly circulating conduit 2105, but does not flow beyond the purge control valve 303. The flexible material of the reductant supply conduit 2103 enables the reductant supply conduit 2103 to elastically compress under the increased pressure applied by the heating fluid still flowing into the first assembly circulating conduit 2105.

As portions of a wall of the reductant supply conduit 2103 move together under increasing pressure, the reductant is forced out of the reductant supply conduit 2103 and into the tank 51. This may continue for a period of time controlled by the controller 301, until only a very small amount of reductant remains between small spaces between the flattened portions of the wall of the reductant supply conduit 2103, as illustrated in FIG. 16B. Essentially, reductant in the reductant supply conduit 2103 may be squeezed similar to a tube of toothpaste by pressure exerted by the first assembly circulating conduit 2105. Thus, after the purging operation, a very small amount of reductant that could freeze may remain in the reductant supply conduit 2103, particularly when the machine 1 is running after the filling operation. The purging operation may be performed at the end of a run of the machine 1, just before an operation of the machine 1 is stopped. Accordingly, only a small amount of reductant capable of freezing in the reductant supply conduit 2103 will remain during a period when the machine 1 is idle or not in use.

The controller 301 may open the purge control valve 303 after the purge operation, and heating fluid may flow past the purge control valve 303 into the tank 51 and heat the reductant stored in the tank 51. Alternatively, reductant in the tank 51 may be heated while the reductant supply conduit 2103 is purged. The bypass control valve 309 may be provided in the bypass conduit 307, and operated by the controller 301 to open when the purge control valve 303 is closed. The heating fluid may then flow through the bypass conduit 307 into the tank 51 to heat the reductant therein while the reductant supply conduit 2103 is purged.

According to an aspect of the present disclosure, the filling assembly (100, 1100, 2100, 3100) can be easily installed or removed as a single assembly.

Referring to FIGS. 8-10, each of the reductant supply conduit (103, 1103), first assembly circulating conduit (105, 1105), and second assembly circulating conduit (107, 1107), are detachably coupled to the first and second manifolds (111, 131), by respective first and second couplings (123, 125). The filling assembly (100, 1100) can be disconnected and repaired or replaced as a unit. In addition, existing machines may be modified to include the first and second manifolds (111, 131), or fittings corresponding to fittings on existing manifolds may be attached to reductant and circulating conduits of a filling assembly described herein, and a conduit that supplies reductant to a reductant delivery system can be replaced with a filling assembly described herein.

It will be appreciated that the foregoing description provides examples of the disclosed systems and techniques. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated.

It is noted that as used in the specification and the appending claims the singular forms “a,” “an,” and “the” can include plural references unless the context clearly dictates otherwise.

Unless specified otherwise, the terms “substantial” or “substantially” as used herein mean “considerable in extent,” or “largely but not necessarily wholly that which is specified.”

Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

1. A reductant filling assembly comprising:

a first end and a second end, the first end adapted to connect from an interior side of a machine to a supply port attached to a receiver extending to an exterior side of the machine;
a housing extending between the first end and the second end of the reductant filling assembly, the housing extending from a first housing end to a second housing end;
a reductant supply conduit extending through the housing from the first end to the second end;
a first circulating conduit extending through the housing from the first end to the second end; and
a second circulating conduit extending through the housing from the first end to the second end,
wherein at least the first circulating conduit is in thermal communication with a wall of the reductant supply conduit, such that a heating fluid flowing through the first circulating conduit in a first direction transfers heat to a reductant fluid in the reductant supply conduit.

2. The reductant filling assembly of claim 1, wherein the heating fluid flows within the second circulating conduit in a second direction that is opposite to the first direction.

3. The reductant filling assembly of claim 2, wherein the first circulating conduit is coaxial with the reductant supply conduit, and

wherein a wall of the first circulating conduit surrounds at least a portion of a circumference of the reductant supply conduit.

4. The reductant filling assembly of claim 3, wherein the portion of the circumference is an entire circumference of the reductant supply conduit, and

wherein the second circulating conduit is positioned outside of the first circulating conduit and extends from the first end to the second end parallel to the first circulating conduit.

5. The reductant filling assembly of claim 4, further comprising a control valve fluidly coupled to the second circulating conduit downstream of a portion of the second circulating conduit disposed within the housing,

wherein the reductant supply conduit includes a flexible conduit,
wherein the first circulating conduit is in fluid communication with the second circulating conduit, and
wherein the heating fluid is supplied to the first circulating conduit, the control valve is closed and the heating fluid remains upstream of the control valve in the first circulating conduit and the second circulating conduit, and the reductant supply conduit is compressed according to an increased pressure applied by the heating fluid in the first circulating conduit.

6. The reductant filling assembly of claim 3, further comprising a partition extending from the first housing end to the second housing end and positioned adjacently between the first circulating conduit and the second circulating conduit,

wherein the second circulating conduit is coaxial with the reductant supply conduit and surrounds a remaining portion of the circumference of the reductant supply conduit that is not surrounded by the first circulating conduit, and
wherein the second circulating conduit is in thermal communication with the reductant supply conduit.

7. The reductant filling assembly of claim 2, wherein a wall of the first circulating conduit is positioned adjacent to the wall of the reductant supply conduit from the first housing end to the second housing end,

wherein a wall of the second circulating conduit is positioned adjacent to the wall of the reductant supply conduit from the first housing end to the second housing end, and
wherein the second circulating conduit is positioned within the housing in thermal communication with the wall of the reductant supply conduit, such that the heating fluid flowing through the second circulating conduit in the second direction transfers heat to the reductant fluid in the reductant supply conduit.

8. The reductant filling assembly of claim 7, wherein the first circulating conduit and the second circulating conduit extend parallel to the reductant supply conduit from the first housing end to the second housing end.

9. The reductant filling assembly of claim 7, wherein the first circulating conduit and the second circulating conduit are wrapped around the reductant supply conduit from the first housing end to the second housing end.

10. The reductant filling assembly of claim 2, wherein the first end of the reductant filling assembly is attached to a first manifold,

wherein the first manifold includes: the supply port, a reductant supply connection connecting the supply port and the reductant supply conduit, a first channel formed within the first manifold and extending from a first port that is formed in a surface of the first manifold and fluidly connected to the first circulating conduit, a second channel formed within the first manifold and extending from a second port that is formed in the surface of the first manifold and fluidly connected to the second circulating conduit, and a connection channel in fluid communication with the first channel and the second channel, and
wherein at least one of the first channel, the second channel, and the connection channel is in thermal communication with the reductant supply conduit.

11. The reductant filling assembly of claim 10, wherein the second end of the reductant filling assembly is attached to a second manifold,

wherein the second manifold includes: a reductant outlet connection connecting a reductant outlet port and the reductant supply conduit, a first sub-manifold channel formed within a first sub-manifold of the second manifold and connected to the first circulating conduit, and a second sub-manifold channel formed within a second sub-manifold of the second manifold and connected to the second circulating conduit, and
wherein the first sub-manifold channel and the second sub-manifold channel are in thermal communication with at least one of the reductant supply conduit and the reductant outlet connection.

12. The reductant filling assembly of claim 2, wherein the second end of the reductant filling assembly is attached to a manifold,

wherein the manifold includes: a reductant connection connecting a reductant outlet port and the reductant supply conduit, a first sub-manifold channel formed within a first sub-manifold of the manifold and connected to the first circulating conduit, and a second sub-manifold channel formed within a second sub-manifold of the manifold and connected to the second circulating conduit, and
wherein the first sub-manifold channel and the second sub-manifold channel are in thermal communication with at least one of the reductant supply conduit and the reductant connection.

13. A machine comprising:

an engine including an internal fluid circuit;
an exhaust conduit connected to the engine that receives exhaust gas from the engine;
a heating fluid circuit including a fluid supply conduit connected to an outlet of the internal fluid circuit and a fluid return conduit connected to an inlet of the internal fluid circuit;
a receiver that extends to an exterior side of the machine;
a supply port on an interior side of the machine and fluidly connected to the receiver;
an exhaust aftertreatment system including: a tank that stores a reductant fluid to be delivered to the exhaust conduit, a reductant output conduit in fluid communication with a portion of the exhaust conduit, and a pump in fluid communication with the reductant fluid to be delivered in the tank and the reductant output conduit; and
a reductant filling assembly including: a first end and a second end, the first end adapted to connect from the interior side of the machine to the supply port, a housing extending between the first end and the second end of the reductant filling assembly, the housing extending from a first housing end to a second housing end, a reductant supply conduit extending through the housing from the first end to the second end, a first circulating conduit extending through the housing from the first end to the second end, and a second circulating conduit extending through the housing from the first end to the second end,
wherein the first circulating conduit and the second circulating conduit are fluidly connected to the heating fluid circuit downstream of the outlet of the internal fluid circuit and upstream of a section of the heating fluid circuit disposed in the tank,
wherein at least the first circulating conduit is positioned within the housing in thermal communication with a wall of the reductant supply conduit, such that a heating fluid flowing through the first circulating conduit in a first direction transfers heat to a reductant fluid in the reductant supply conduit.

14. The machine of claim 13, wherein the heating fluid flows within the second circulating conduit in a second direction that is opposite to the first direction.

15. The machine of claim 14, further comprising a first manifold attached to the first end of the reductant filling assembly,

wherein the first manifold includes: the supply port, a reductant supply connection connecting the supply port and the reductant supply conduit, a first channel formed within the first manifold and extending from a first port that is formed in a surface of the first manifold and connected to the first circulating conduit, a second channel formed within the first manifold and extending from a second port that is formed in the surface of the first manifold and connected to the second circulating conduit, and a connection channel in fluid communication with the first channel and the second channel, and
wherein at least one of the first channel, the second channel, and the connection channel is in thermal communication with the reductant supply conduit.

16. The machine of claim 15, further comprising a second manifold attached to the second end of the reductant filling assembly,

wherein the second manifold includes: a reductant outlet connection connecting a reductant outlet port and the reductant supply conduit, a first sub-manifold channel formed within a first sub-manifold of the second manifold and connected to the first circulating conduit, and a second sub-manifold channel formed within a second sub-manifold of the second manifold and connected to the second circulating conduit, and
wherein the first sub-manifold channel and the second sub-manifold channel are in thermal communication with at least one of the reductant supply conduit and the reductant outlet connection.

17. The machine of claim 14, further comprising:

a tank fluid supply conduit fluidly coupled to the second circulating conduit at the second end of the reductant filling assembly;
a control valve fluidly coupled to the tank fluid supply conduit downstream of the second circulating conduit;
a sensor that detects a parameter associated with an amount of reductant fluid in the tank; and
a controller that operates the control valve in response to the sensor detecting the parameter is equal to or greater than a threshold,
wherein the reductant supply conduit includes a flexible conduit positioned within the first circulating conduit between the first end and the second end,
wherein the first circulating conduit is in fluid communication with the second circulating conduit,
wherein the controller determines the parameter is equal to or greater than the threshold and closes the control valve, the reductant supply conduit is compressed according to an increased pressure applied by the heating fluid in the first circulating conduit, and a remaining amount of reductant fluid in the reductant supply conduit is forced into the tank.

18. The machine of claim 13, further comprising:

a reductant supply connection connecting the supply port and the reductant supply conduit at the first end of the reductant filling assembly; and
a reductant outlet connection connecting a reductant outlet port and the reductant supply conduit at the second end of the reductant filling assembly, the reductant outlet connection being mounted on the tank,
wherein the reductant supply connection is positioned at a first elevation relative to a portion of the machine configured to contact a ground level below the machine,
wherein the reductant outlet connection is positioned at a second elevation relative to the portion of the machine configured to contact the ground level below the machine, and
wherein the second elevation is greater than the first elevation.

19. The machine of claim 18, wherein a vertical distance separating the first elevation and the second elevation is in the range of 4 to 6 meters.

20. A method for heating a reductant fluid in a reductant filling assembly including a first end and a second end, the first end connected from an interior side of a machine to a supply port attached to a receiver extending to an exterior side of the machine, the second end connected to a tank, the method for heating the reductant fluid comprising:

supplying the reductant fluid from the exterior side through the supply port into a reductant supply conduit positioned within the reductant filling assembly and into the tank;
supplying a flow of heating fluid to a heating fluid circuit fluidly coupled to the reductant filling assembly;
supplying the flow of heating fluid from the heating fluid circuit to the second end of the reductant filling assembly and directing the flow of heating fluid in a first direction from the second end to the first end in a first circulating conduit positioned within the reductant filling assembly;
transferring heat from a portion of the flow of heating fluid within the first circulating conduit to the reductant fluid in the reductant supply conduit;
directing the flow of heating fluid from the first circulating conduit into a manifold at the first end and from the manifold into a second circulating conduit positioned within the reductant filling assembly; and
directing the flow of heating fluid through the second circulating in a second direction from the first end to the second end and into the heating fluid circuit, the second direction being opposite to the first direction.

21. The method of claim 20, further comprising:

detecting a value of a parameter associated with an amount of reductant fluid in the tank and comparing the value to a threshold;
determining the value is equal to or greater than the threshold; and
purging reductant fluid in the reductant supply conduit from the reductant supply conduit into the tank,
wherein the reductant supply conduit is a flexible conduit positioned within the first circulating conduit between the first end and the second end, such that the heating fluid contacts a wall of the reductant supply conduit, and
wherein the purging includes: closing a control valve connected to the second circulating conduit at the second end in response to the determining the value is equal to or greater than the threshold, stopping the supplying of the reductant fluid, increasing a pressure applied to the wall of the reductant supply conduit to compress the reductant supply conduit and force a remaining amount of reductant in the reductant supply conduit into the tank by continuing to supply the heating fluid to the first circulating conduit, and releasing a fluid pressure in the second circulating conduit by opening the control valve, and expanding the reductant supply conduit in response to the releasing the fluid pressure.

22. The method of claim 20, further comprising:

estimating a first time to complete an engine operation of an engine of the machine;
monitoring an elapsed time;
comparing the elapsed time to the first time;
determining the elapsed time is equal to the first time and operating the engine in an idle state or a predetermined operating condition for a second time following a time when the elapsed time is equal to the first time;
purging reductant fluid in the reductant supply conduit from the reductant supply conduit into the tank during the second time; and
determining the elapsed time is equal to the first time plus the second time and stopping the operating the engine in the idle state or the predetermined operating condition.

23. The method of claim 22, wherein the reductant supply conduit is a flexible conduit positioned within the first circulating conduit between the first end and the second end, such that the heating fluid contacts a wall of the reductant supply conduit, and

wherein the purging includes: closing a control valve connected to the second circulating conduit at the second end in response to the determining the elapsed time is equal to the first time plus a predetermined amount of time less than the second time, increasing a pressure applied to the wall of the reductant supply conduit to compress the reductant supply conduit and force a remaining amount of reductant in the reductant supply conduit into the tank by continuing to supply the heating fluid to the first circulating conduit, and releasing a fluid pressure in the second circulating conduit by opening the control valve, and expanding the reductant supply conduit in response to the releasing the fluid pressure.
Patent History
Publication number: 20160273430
Type: Application
Filed: Mar 16, 2015
Publication Date: Sep 22, 2016
Applicant: Caterpillar Inc. (Peoria, IL)
Inventors: Brian Cole (Peoria, IL), Xiaohui Gong (Dunlap, IL), Dustin Landwehr (Kewanee, IL)
Application Number: 14/658,580
Classifications
International Classification: F01N 3/20 (20060101); F01N 5/02 (20060101); F01N 3/28 (20060101);