This invention relates to an exhaust system for a motor vehicle with a particulate filter. Furthermore, this invention relates to a process for regenerating a particulate filter in an automotive exhaust system.
To comply with environmental regulations, the exhaust gases of motor vehicles driven by internal combustion engines must be subjected to cleaning. For reducing the particulate emissions of the exhaust gases of motor vehicles, which are driven by a Diesel engine or a lean-burning gasoline engine, suitable particulate filters are used. Such particulate filters must be regenerated from time to time by burning off the particulates accumulated on the filter surface. For this purpose, a burner is arranged upstream of the particulate filter for example, to generate the heat required for burning off by combustion of an air-fuel mixture. For igniting the air-fuel mixture, a glow plug can be used such as that known from DE 298 02 226 U1. In connection with a burner, it is also known from DE 42 42 991 A1 to use a glow plug for introducing energy into the liquid fuel.
Another known arrangement for regenerating a particulate filter disposes an oxidation catalyst upstream of the particulate filter, which generates the heat required for burning off the soot particulates by oxidizing an oxidizable substance present in the exhaust-gas stream. From DE 102 56 769 B4, for instance, a system is known, in which upstream of the oxidation catalyst an evaporation unit is disposed, in which the fuel is evaporated and introduced into the exhaust-gas stream.
In practice, however, the systems known from the prior art involve numerous difficulties, which are due to a multitude of partly contradictory system requirements.
For instance, the time of regeneration depends on the loading condition, i.e. the “degree of filling” of the particulate filter. If this time is chosen too early, not enough soot is present to perform a stable regeneration. If it is chosen too late, however, the particulate filter is clogged, or the combustion of soot produces very high temperatures in the particulate filter, which can lead to its destruction.
If the exhaust gas temperature before the oxidation catalyst is too low, the oxidizable vapour supplied cannot be converted thermally. It is condensed in the oxidation catalyst and leads to its destruction.
If too much fluid is introduced into the evaporation unit, and if the fluid cannot evaporate sufficiently, it enters the exhaust system in the liquid condition. If the fluid entering the exhaust system cannot sufficiently be reevaporated by the hot exhaust gases and the hot tube walls, the downstream oxidation catalyst is damaged.
If too much fluid is evaporated, too much energy is generated by the catalyst and the particulate filter is damaged by excessive regeneration temperatures. At the same time, fluid consumption is rising unnecessarily.
If too little fluid is introduced into the evaporator, the catalyst cannot produce the temperature increase of the exhaust gas necessary for the regeneration of the particulate filter. There is no regeneration of the particulate filter, but an unnecessary fluid consumption.
If a heating element provided in the evaporation unit is switched on too soon, power consumption rises unnecessarily. On the other hand, if the heating element is put into operation too late, the oxidizable fluid is not sufficiently evaporated, partly reaches the exhaust system in the liquid condition, and damages the oxidation catalyst. The postheating time of the heating element also determines the proper conversion of the fluid into vapour.
In addition, there are further influential factors which depend on the operating point of the engine, a possibly present exhaust gas turbocharger, components for exhaust gas recirculation, and many more. These factors also influence the regeneration of the particulate filter and must be considered by the regeneration system.
It is the object underlying the invention to solve the described technical contradictions and make the regeneration of a particulate filter safe and suitable for series production.
In accordance with the invention, there is provided an exhaust system for a motor vehicle, comprising a particulate filter upstream of which an oxidation catalyst is provided, and a regeneration device for the particulate filter. The regeneration device includes an evaporation unit for introducing a vapour generated from an oxidizable fluid into the exhaust gas stream before the oxidation catalyst. The evaporation unit includes a heating element arranged in a housing and a fluid supply with a controllable fluid pump. A control device is provided for controlling the fluid pump. By suitable control of the fluid pump, in particular in dependence on the temperatures existing at various points of the exhaust system, the difficulties known from the prior art can be solved satisfactorily.
In particular, the oxidizable fluid can be the same fuel which is also supplied to the internal combustion engine, whereby an additional fluid supply can be omitted. The fuel simply is withdrawn from the fuel tank of the vehicle or from the fuel return conduit.
The heating element advantageously is a glow plug, i.e. a mass-produced article available at low cost.
In accordance with a preferred embodiment, the control device is connected with the engine control or integrated in the same. In particular, the control device utilizes data present in the engine control in order to consider the same in the control of the fluid pump.
The object of the invention is also solved by a process for regenerating a particulate filter with upstream oxidation catalyst in an automotive exhaust system with a regeneration device, which comprises an evaporation unit for introducing a vapour generated from an oxidizable fluid into the exhaust gas stream before the oxidation catalyst. The evaporation unit includes a heating element arranged in a housing and a fluid supply with a controllable fluid pump. The process includes the following steps, which are performed periodically: The regeneration process first is started in dependence on the back pressure of the particulate filter or on the time elapsed since the last regeneration process (step a). Subsequently, the heating element is switched on, as soon as the temperature upstream of the oxidation catalyst exceeds a specified minimum value (step b). After waiting a specified preheating time for the heating element (step c), the fluid pump is switched on with a specified delivery rate (step d), and a specified pumping period is allowed to pass (step e). Subsequently, the fluid pump is operated according to specified parameters, if downstream of the oxidation catalyst a higher temperature exists than upstream of the oxidation catalyst (step f). Thereupon, a likewise specified regeneration period is allowed to pass, which starts as soon as the temperature downstream of the oxidation catalyst has exceeded a specified minimum value, wherein during the regeneration period the temperature downstream of the particulate filter is checked periodically and possibly controlled at least by influencing the introduced fuel quantity (step g). After the regeneration period has passed, the fluid pump is switched off (step h), a specified postheating time of the heating element is allowed to pass (step i), and finally the heating element is switched off (step j). Subsequently, the process starts again. Thus, the process of the invention not only makes sure that the regeneration is started at the proper time (step a) and the exhaust gas temperature before the oxidation catalyst is high enough (step b), but due to the pre-heating and postheating times, also ensures a safe evaporation of the oxidizable fluid. A precisely adapted metering of fluid, which prevents the particulate filter from being damaged or even destroyed, is achieved by the temperature-dependent control (step g). Thus, the process of the invention meets all requirements mentioned above.
To prevent the system from being damaged, an error can be registered, if after waiting for the specified pumping period, the temperature downstream of the oxidation catalyst is not higher than the temperature upstream of the oxidation catalyst.
Preferably, the process proceeds to step d) after registering the error, as long as the number of registered errors does not exceed a specified maximum value.
Upon exceeding the specified maximum value for registered errors, the regeneration process should be stopped and an error signal should be issued. This can include, for instance, switching on an error signal lamp, which informs the driver of the motor vehicle that repair is necessary.
To prevent the particulate filter from being damaged by excessive regeneration temperatures, the fluid pump is switched off in connection with the temperature control during the regeneration period, as soon as the temperature downstream of the particulate filter exceeds a specified first value during the regeneration period (step g).
In accordance with a first embodiment of the invention, operation of the fluid pump according to specified parameters is resumed after switching off the fluid pump during the regeneration period, as long as the specified regeneration period is not terminated and as soon as one of the following conditions occurs, which are checked periodically in the indicated order:
the temperature downstream of the particulate filter lies below a specified second value,
the temperature downstream of the oxidation catalyst falls below a specified minimum value,
the temperature downstream of the particulate filter no longer lies above the specified first value.
In this way, it is prevented that an insufficient fluid quantity is supplied to the exhaust gas stream during the regeneration period, which would impair the regeneration.
In accordance with a second embodiment of the invention, a proportional-integral-derivative (PID) controller is used for controlling the temperature during the regeneration period (step g), if the temperature downstream of the oxidation catalyst lies within a specified control interval. Such PID controller offers the advantage of a faster temperature control than a control by merely varying the introduced fuel quantity. As a control parameter, the temperature downstream of the oxidation catalyst, i.e directly upstream of the particulate filter, is used.
To prevent an “overshooting” of the PID controller caused by system-related oscillation processes, it should be checked after each control operation of the PID controller whether the temperature downstream of the oxidation catalyst still lies within the specified control interval.
In the variant with the PID control, after switching off the fluid pump during the regeneration period, the operation of the fluid pump according to specified parameters is resumed, if the temperature downstream of the particulate filter lies below a specified second value and the temperature downstream of the oxidation catalyst lies outside the specified control interval for the PID controller. This is of course only applicable for the time period of regeneration.
In addition, the current flowing through the heating element can be monitored during operation of the heating element.
It should be appreciated that the regeneration process only is started with running engine.
Further features and advantages of the invention can be taken from the following description of several preferred embodiments with reference to the attached drawing, in which:
a shows a flow diagram of a first part of the process of the invention;
b shows a flow diagram of a second part of the process of the invention directly adjoining the first part in accordance with a first variant;
c shows a flow diagram of a third part of the process of the invention, which directly adjoins the second part; and
The evaporation unit 20 forms part of a regeneration device for the particulate filter 16, which furthermore comprises a control device 30 for controlling the fluid pump 28. The heating element 24 is connected with the control device 30 and can be driven by the same. The control device 30 in turn is connected with the engine control 32 or, alternatively, directly integrated in the same.
The exhaust system 12 furthermore includes a plurality of temperature sensors 34, which likewise are connected with the control device 30 and determine the temperature before and after the oxidation catalyst 18 and the temperature after the particulate filter 16. Furthermore, pressure sensors (not shown) can be provided to determine the back pressure of the particulate filter 16.
For regenerating the particulate filter 16, a process is employed, which will be described below with reference to
After the start of the process (step 100), it is first checked in step 101 whether the internal combustion engine 10 is running. If this is not the case, there is no further activity; the process starts again. If the engine is running, the current back pressure value pDPF of the particulate filter 16 is determined in the next step 102 by using the pressure sensors, and it is checked whether this current back pressure value exceeds a specified limit value preg for the regeneration. If this is the case, a regeneration requirement is detected (step 104). However, if the current back pressure value pDPF lies below the specified limit value preg, it is checked in step 103 whether the time elapsed since the last regeneration process (also referred to as “loading time” of the particulate filter) exceeds a specified limit value. If this is the case, the process likewise continues with step 104, otherwise the process goes back to step 102.
After the regeneration requirement has been detected, it is checked whether the temperature upstream of the oxidation catalyst 18, Tbefore
After switching on the heating element 24, a specified preheating time is allowed to pass, in that in step 107 a count value for the preheating time first is incremented, and in step 108 it is checked whether the value of the counter for the preheating time exceeds a specified value. If this is not the case, steps 107 and 108 are repeated, until the value for the preheating time finally exceeds the specified value. Subsequently, the counter for the preheating time is reset (step 109), and the fluid pump 28 is switched on with a specified delivery rate (step 110). The delivery rate can for instance be adjusted via a pumping frequency.
After switching on the fluid pump (see
Subsequently, the count value for the time to the temperature measurement is set to zero (step 113), and it is checked whether the temperature after the oxidation catalyst 18, Tafter
Otherwise, an error is registered, in that the value of an error counter is incremented by 1 (step 115), whereupon it is checked whether the error count value already is greater than a specified maximum value for registered errors (step 116). If this is not the case, the process is resumed with step 110, namely switching on the pump with a specified delivery rate. However, if the error count value already exceeds the specified maximum value, the regeneration process is stopped, in that first the fluid pump (step 117) and then the heating element 24 is switched off (step 118). To inform the owner of the vehicle that repair or a system check is necessary, an error signal lamp finally is switched on (step 119), and the regeneration process ends with step 120, so as not to be resumed again until after a possible repair.
If, as expected, a higher temperature exists downstream of the oxidation catalyst 18 than upstream of the oxidation catalyst, the fluid pump 28 is operated according to specified parameters (step 121), as already mentioned. Subsequently, it is checked whether the temperature after the oxidation catalyst 18, Tafter
As long as the end of the regeneration period has not yet been reached, it is checked subsequent to step 124 whether the temperature downstream of the particulate filter, Tafter
On the other hand, if the temperature after the particulate filter 16 exceeds the specified temperature Tmax, the fluid pump 28 is switched off (step 126), in order to thus decrease the temperature existing after the particulate filter 16 (and also in the same). Subsequently, it is checked in step 127 whether the temperature after the particulate filter, Tafter
If the temperature after the particulate filter does not lie below the specified second value Tcontinue, the process proceeds from step 127 to step 122, in which the temperature after the oxidation catalyst 18 is compared with the minimum value Treg
As soon it is detected in step 124 that the specified regeneration period is terminated, the count value for the regeneration period is set to a specified value, which is stored in the control device 30 (step 128), and the fluid pump 28 is switched off (step 129, see
Subsequently, the counter for the time elapsed since the last regeneration process (also referred to as “loading time” of the particulate filter 16) is set back to zero (step 134), and the process goes back to the start (step 100). In this way, a discontinuous, periodic regeneration of the particulate filter 16 is achieved.
The process in accordance with the second variant including step 121 proceeds analogous to the process described above. In the succeeding step 222, it is likewise checked whether the temperature after the oxidation catalyst 18 exceeds the specified minimum value for regeneration, Treg
In contrast to the process in accordance with the first embodiment, step 224 of the process is performed, if the temperature after the oxidation catalyst does not reach the minimum temperature Treg
If the temperature after the oxidation catalyst lies within the specified control interval, a PID controller, which can be integrated in the control device 30, is used for controlling the temperature (step 229), so as to bring the same to an optimum temperature value for regeneration. The PID controller offers the advantage that the desired temperature can be adjusted much faster than would be possible by merely switching on and off the fluid pump 28. After the control operation 229, it is checked in step 230 whether the temperature downstream of the oxidation catalyst 18 now possibly lies outside the specified control interval, i.e. whether the PID controller has controlled too much in the one or other direction. If this is the case, the process goes back to step 121; however, if the temperature after the oxidation catalyst still lies within the control interval, the process continues with step 231, which corresponds to step 222, and checks whether the temperature after the oxidation catalyst 18 lies above the specified minimum temperature for regeneration Treg
As long as the regeneration period is not terminated, the temperature after the particulate filter 16 subsequently is checked, as to whether it exceeds the specified first temperature value Tmax (step 234). If this is not the case, the process continues with step 229, namely the control operation by the PID controller; otherwise, the fluid pump 28 is switched off (step 235), and it is checked whether the temperature after the particulate filter 16 lies below the second specified value Tcontinue (step 236). If the temperature after the particulate filter 16 is smaller than Tcontinue, there is likewise effected a control operation by the PID controller (step 229); however, if the temperature after the particulate filter 16 exceeds the temperature Tcontinue, the process continues with step 231, i.e. checks whether the temperature after the oxidation catalyst exceeds the specified minimum value Treg
Thus, in the process in accordance with the second embodiment, the fluid pump 28 likewise is always switched off, as soon as the temperature downstream of the particulate filter 16 exceeds a specified first value Tmax during the regeneration period. In contrast to the process in accordance with the first embodiment, the operation of the fluid pump 28 subsequently is resumed according to specified parameters, if the temperature downstream of the particulate filter 16 lies below the specified second value Tcontinue and the temperature downstream of the oxidation catalyst 18 lies outside the specified control interval for the PID controller.
Upon termination of the regeneration period, which is detected in step 233 or 224, the counter for the regeneration period is set equal to a value specified in the control device (step 128), and the process for regeneration is terminated, as described already with reference to
Finally, it should be noted that none of the specified values stored in the control device 30 must be universally applicable individual values, but for each specified value a list of values can exist, from which depending on the current operating condition (current data from the engine control, currently existing temperatures at different points of the exhaust system 12, and further parameters such as exhaust gas mass flow, etc.) the specified value corresponding to this operating condition or most suitable for this operating condition is selected.
10 internal combustion engine
12 exhaust system
14 exhaust gas conduit
16 particulate filter
18 oxidation catalyst
20 evaporation unit
22 housing
24 heating element
26 fluid supply
28 fluid pump
30 control device
32 engine control
34 temperature sensors
100-134 process steps
222-236 process steps
Number | Date | Country | Kind |
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10 2005 062 924.5 | Dec 2005 | DE | national |
This application is a U.S. National Phase application of PCT Application No. PCT/EP2006/011503 filed Nov. 30, 2006 which claims priority to German Application No. 10 2005 062 924.5 filed Dec. 29, 2005.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2006/011503 | 11/30/2006 | WO | 00 | 9/9/2008 |