Patent Application
20060191412
The present disclosure relates generally to a filter service system and, more particularly, to a system for removing matter from a filter.
Engines, including diesel engines, gasoline engines, natural gas engines, and other engines known in the art, may exhaust a complex mixture of pollutants. The pollutants may be composed of gaseous and solid material, including particulate matter, nitrogen oxides (“NOx”), and sulfur compounds.
Due to heightened environmental concerns, engine exhaust emission standards have become increasingly stringent over the years. The amount of pollutants emitted from an engine may be regulated depending on the type, size, and/or class of engine. One method that has been implemented by engine manufacturers to comply with the regulation of particulate matter, NOx, and sulfur compounds exhausted to the environment has been to remove these pollutants from the exhaust flow of an engine with filters. However, extended use and repeated regeneration of such filters may cause the pollutants to build up in the components of the filters, thereby causing filter functionality and engine performance to decrease.
One method of removing built-up pollutants from a filter may be to remove the clogged filter from the work machine to which it is connected and direct a flow of gas through the filter in a direction that is opposite the direction of normal flow. The filter may be large, heavy, and difficult to disconnect, however, making it cumbersome, time consuming, and potentially dangerous to remove the filter from the engine of the work machine for such servicing.
Another method of removing matter from a filter may be to divert an exhaust flow from a clogged filter to a separate filter, without disconnecting either filter from the engine. While the exhaust flow is diverted, air may be directed through the clogged filter in a direction opposite the normal flow. Since such matter removal systems include a second filter, however, they may be larger and more costly than single filter systems. Furthermore, such systems may not be capable of applying a negative pressure to the clogged filter to assist in removing the matter.
U.S. Pat. No. 5,566,545 (“the '545 patent”) teaches a system for removing particulate matter from an engine filter. In particular, the '545 patent discloses a first filter and a second filter connected to an engine exhaust line, a valve structure within the exhaust line, and an air feeder for supplying air to the filter in need of service in a reverse direction. When air is supplied to the filter in a reverse flow direction, the air may remove captured particulates from the filter.
Although the '545 patent may teach the removal of matter from a filter using a reversed flow, the system described therein requires the use of a second filter during the reverse flow condition, thereby increasing the overall cost and size of the system. In addition, the system is not capable of supplying a negative pressure to the filter to assist in the filter cleaning process.
The present disclosure is directed to overcoming one or more of the problems set forth above.
In one embodiment of the present disclosure, an on-vehicle service system for removing matter from a filtering device of a single filtering device exhaust system includes a controllable filter bypass line fluidly connecting a first orifice of the filtering device of the single filtering device exhaust system to a second orifice of the filtering device. The service system also includes a receptacle fluidly connected to the filtering device and configured to collect at least a portion of the matter removed by the on-vehicle service system when a fluid is provided through a portion of the filter bypass line into the filtering device.
In another embodiment of the present disclosure, an on-vehicle service system for removing matter from a filtering device of a single filtering device exhaust system includes a filter bypass line configured to assist in selectively delivering a flow through the filtering device of the single filtering device exhaust system in a reverse flow direction. The service system also includes a receptacle fluidly connected to the filtering device and configured to collect at least a portion of the matter removed by the on-vehicle service system when the filter bypass line is delivering a flow through the filtering device in the revere flow direction.
In yet another embodiment of the present disclosure, a method of removing matter from a filtering device of a single filtering device exhaust system with an on-vehicle service system includes supplying a flow of fluid to the filtering device of the single filtering device exhaust system in a reverse flow direction, a portion of the flow passing through a filter bypass line. The method also includes capturing at least a portion of the matter removed from the filtering device within a receptacle of the on-vehicle service system when the portion of the flow passes through the filter bypass line.
In still another embodiment of the present disclosure, an engine system of a work machine includes an engine having an exhaust outlet and a single filtering device for receiving an exhaust flow from the exhaust outlet of the engine. The filtering system further includes an on-vehicle service system for removing matter from the single filtering device. The on-vehicle service system includes a controllable filter bypass line fluidly connecting a first orifice of the single filtering device to a second orifice of the filtering device. The on-vehicle service system also includes a receptacle fluidly connected to the single filtering device and configured to collect at least a portion of the matter removed from the single filtering device.
Exemplary embodiments of the present disclosure are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
In an embodiment of the present disclosure, the filter 30 may be connected to an internal combustion engine 46, such as, for example, a diesel engine. The engine 46 may include an exhaust line 44 connecting an exhaust flow of the engine 46 with an inlet 34 of the filter 30. The engine 46 may also include a turbo (not shown) connected to the exhaust line 44. In such an embodiment, the inlet 34 of the filter 30 may be connected to an outlet of the turbo.
An inlet valve 140 may be disposed at a first orifice 54 of the filter 30. In an exemplary embodiment of the present disclosure, the first orifice 54 may be an inlet 34 of the filter 30. In such an embodiment, the inlet valve 140 may be disposed between the exhaust line 44 of the engine 46 and the inlet 34 of the filter 30. The inlet valve 140 may be configured to allow an exhaust flow of the engine 46 to pass into the filter 30 while blocking the exhaust flow from passing to, for example, the bypass line 146 and/or other components of the service system 10. The inlet valve 140 may also be configured to block communication between the engine 46 and the filter 30 at the first orifice 54. Such a configuration may be advantageous during, for example, servicing of the filter 30. For example, while the filter 30 is being serviced, the inlet valve 140 may prohibit captured material from flowing back to the engine 46 through the inlet 34. As will be described in greater detail below, in such an embodiment, the inlet valve 140 may also assist in directing the flow and/or the captured material to, for example, the receptacle 16. It is understood that the engine 46 may remain running during servicing and may produce the exhaust flow used to remove matter from the filter 30. The inlet valve 140 may be controlled and/or actuated by any means known in the art, such as, for example, a solenoid or pneumatics. Alternatively, the inlet valve 140 may be manually controlled.
The filter 30 may further include an outlet valve 142 disposed proximate a second orifice 56 of the filter 30. In an exemplary embodiment of the present disclosure, the second orifice 56 may be an outlet 36 of the filter 30. In such an embodiment, the outlet valve 142 may be disposed at the outlet 36. Outlet valve 142 and inlet valve 140 may be the same type of valve or may be different types of valves, depending on the requirements of the application. The valves 140, 142 may be, for example, one-way valves, two-way valves, three-way valves, or any other type of controllable flow valves known in the art. For example, the valves 140, 142 may be controlled to allow any range of exhaust flow to pass from the engine 46 to the filter 30 and out of the filter 30. The valves 140, 142 may also be configured to allow any range of exhaust flow to pass from the engine 46 to the bypass line 146 and into the filter 30 in a reverse flow direction. It is understood that the service systems described herein may include any combination of valves and/or bypass lines useful in supplying a flow to the filter 30 in a desired manner. For example, a plurality of one-way valves may be used in place of the two-way and/or three-way valves described above to achieve a desired flow path. As mentioned above, it is also understood that the valves 140, 142 may be configured to assist in-directing the flow and/or matter removed from the filter 30 to, for example, the receptacle 16.
In some embodiments, one or more work machine diagnostic devices 88 may be disposed proximate the second orifice 56 of the filter 30. The work machine diagnostic devices 88 may be, for example, part of the work machine or other device to which the filter 30 is connected and may be external to the filter 30. Alternatively, the work machine diagnostic devices 88 may be internal to the filter 30. Work machine diagnostic devices 88 may be any sensing devices known in the art, such as, for example, flow meters, emission meters, pressure transducers, radio devices, or other sensors. Such work machine diagnostic devices 88 may sense, for example, an increase in the levels of soot, NOx, or other pollutants leaving the filter 30. The work machine diagnostic devices 88 may send pollutant level information to a controller or other device (not shown) and may assist in, for example, triggering filter regeneration and/or filter servicing.
As shown in
The filter 30 may be any type of filter known in the art, such as, for example, a foam cordierite, sintered metal, or silicon carbide type filter. As illustrated in
The filter 30 includes a filter housing 31 and may be secured by any means known in the art. The filter 30 may include, for example, filter brackets 32 connected to the filter housing 31. Filter brackets 32 may be made of metal, plastic, rubber, or any other material known in the art to facilitate connecting a filter to a structure associated with the engine 46. For example, filter brackets 32 may secure the filter 30 to a work machine and may dampen the filter 30 from vibration, jarring, or sudden movements of the work machine to which the filter 30 is attached.
As shown in
The receptacle 16 of the service system 10 may be configured to collect matter removed from the filter 30. The receptacle 16 may be any size useful in collecting the matter removed from the filter 30 and may have any useful capacity and shape. For example, the receptacle 16 may be cylindrical or box shaped, and may be a rigid container or a flexible bag. The receptacle 16 may be designed to collect and store matter of any type or composition. In one embodiment of the present disclosure, the receptacle 16 may be designed to store harmful pollutants, such as, for example, ash, and may be made of, for example, steel, tin, reinforced cloth, aluminum, composites, ceramics, or any other material known in the art. The receptacle 16 may be rapidly disconnected and reconnected to the matter removal line 26 and/or the vacuum source 14 to facilitate disposal of the matter collected therein.
As shown in
As shown in
It is understood that the gas source 12 may be fluidly connected to the filter 30 in any way, and at any location, so as to be capable of providing a flow to the filter 30 in a reverse flow direction. The gas source 12 may include, for example, an air compressor or any other device capable of compressing a gas and delivering the compressed gas to the filter 30. For example, in one embodiment of the present disclosure, the gas source 12 may be a shop air compressor of a type known in the art and may supply compressed air at approximately 70 to 110 psi. This range may be increased or decreased depending on the size of the gas source 12 used. The gas source 12 may deliver a gas in either a pulsed flow, a uniform flow, or some combination thereof. The gas may be any gas known in the art useful in removing ash or other matter from a filter, such as, for example, air, oxygen, hydrogen, nitrogen, or helium. It is understood that the gas may be capable of being compressed by the gas source 12 and delivered through the bypass line 146 to the outlet 36 of the filter 30.
As shown in
The gas storage device 100 mats have any capacity useful in supplying a controlled volume of high pressure gas to a device, such as, for example, a filter. The gas storage device 100 may be capable of storing gas at any desirable pressure relative to atmosphere. For example, in one embodiment of the present disclosure, the gas storage device 100 may be capable of storing pressurized gas in a range that may be safe for servicing filters containing, for example, cordierite plugs. As previously discussed, such plugs, and other like filter media 42, may not be capable of withstanding a pressure of greater than approximately 150 psi without sustaining damage.
The gas storage device 100 may include at least one gas storage device sensor 109 capable of sensing, for example, flow, pressure, temperature, or other flow metrics known in the art. The couplings or other means used to fluidly connect the gas storage device 100 to, for example, the gas source 12 may be sized and otherwise designed to form a sealed connection, regardless of the gas pressure within the gas storage device 100. The wall thickness of the gas storage device 100 may also be appropriate for such pressures. In addition, the gas storage device 100 may be advantageously shaped to store and controllably release a desired volume of pressurized gas. For example, the gas storage device 100 may be cylindrical or spherical to maximize structural integrity.
A gas storage device valve 106 may be disposed proximate an outlet of the gas storage device 100. The gas storage device valve 106 may be, for example, a poppet valve, butterfly valve, controllable membrane, or any other type of controllable flow regulation device known in the art. For example, the gas storage device valve 106 may be controlled to allow any range of gas to pass from the gas source 12 to the filter 30. The gas storage device valve 106 may be positioned to completely restrict a flow of gas from the gas source 12 or may allow the flow to pass unrestricted. The gas storage device valve 106 may be connected to the gas storage device 100 by any conventional means known in the art. In some embodiments, the gas storage device valve 106 may be controlled to fully open and/or fully close at-relatively high speeds. This high speed movement may be facilitated by a high speed control mechanism 120. The high speed control mechanism 120 may include, for example, an electric, piezoelectric, pneumatic, hydraulic, or other controller. In some embodiments, the high speed control mechanism 120 may be a solenoid, servo motor, or other conventional means.
The gas storage device 100 may also include a check valve 124. The check valve 124 may be disposed, for example, proximate an inlet of the gas storage device 100 or within the bypass line 146 between the gas source 12 and the gas storage device 100. The check valve 124 may be configured to permit compressed gas to flow into the gas storage device 100 from the gas source 12 and to prohibit gas from exiting through the gas storage device inlet. The check valve 124 may, thus, assist in the storage of pressurized gas within the gas storage device 100.
It is understood that in further exemplary embodiments of the present disclosure, various other flow paths, bypass lines, valve configurations, and/or other service system components may be used to direct a flow through the filtering device 30. The operation of the exemplary embodiments of the service systems 10, 200, 300 described above will now be discussed in greater detail.
The service system components, configurations, and flow paths described herein may enable a user to bypass components of an exhaust system of a work machine and direct a flow through a filter in a reverse flow direction. The service systems 10, 200, 300 of the present disclosure may assist in removing matter from single filtering device exhaust systems. Such exhaust systems may only have one filter or other filtering device dedicated to removing, for example, soot and other harmful particulates and/or pollutants from an engine exhaust flow. In addition, each of the service systems 10, 200, 300 disclosed herein may be on-vehicle systems. As used herein, the term “on-vehicle” means a system in which each component of the system remains connected to a work machine during operation of the work machine. For example, an on-vehicle service system may be operatively connected to a filter, and the components of the system may be mounted and/or otherwise connected to the work machine, vehicle, or other device to which the filter is attached, during operation of the work machine as well as during filter servicing. Such on-vehicle service systems may be fixedly secured within a compartment of the work machine, such as the engine compartment. In addition, as discussed above the filter 30 may include additional upstream devices, such as, for example, catalysts and/or work machine diagnostic devices 88, within the filter housing 31. These additional upstream devices may be moved and/or removed to allow access to the filter media 42 for servicing in an on-vehicle system 10, 200, 300. As used herein, the term “work machine” may include on-road vehicles, off-road vehicles, and stationary machines, such as, for example, generators and/or other exhaust producing devices.
The disclosed service systems 10, 200, 300 may be used with any filter 30, filtering device, or other matter collection device known in the art. Such devices may be used in any application where the removal of matter is desired. For example, such devices may be used on diesel, gasoline, natural gas, or other combustion engines or furnaces known in the art.
A variety of different methods and systems may be used to remove matter from the filtering-devices of work machines. For example, some filters used in such machines may be cleaned through regeneration. During regeneration, a heater or some other heat source may be used to increase the temperature of the filter components. The heater may also increase the temperature of trapped particulate matter above its combustion temperature, thereby burning away the collected particulate matter and regenerating the filter while leaving behind a small amount of ash. Although regeneration may reduce the buildup of particulate matter in the filter, repeated regeneration of the filter may result in a buildup of ash in the components of the filter over time and a corresponding deterioration in filter performance. Unlike particulate matter, ash cannot be burned away through regeneration. Thus, in some situations, it may be necessary to remove built-up ash from an engine filter using other techniques and systems.
As illustrated by exhaust flow arrow 72 in
Over time, the work machine diagnostic devices 88 may sense an increase in the amount of pollutants being released to the atmosphere. Based on these readings, the filter 30 may undergo regeneration either automatically or as a result of some operator input. As described above, after a number of regeneration cycles, ash may begin to build up in the filter media 42. The service system 10 of the present disclosure may then be activated to assist in removing the ash collected therein. It is understood that the system 10 may also be used to assist in the removal of soot and/or other matter collected within the filter 30.
To begin the removal of ash from the filter 30, the inlet valve 140 may be manipulated and/or otherwise controlled to direct the exhaust flow from the engine 46 to the bypass line 146. It is understood that in the embodiment illustrated in
The exhaust flow may pass through the filter 30 in the direction of reverse flow arrows 80. While in this reverse flow condition, ash and other matter trapped within the filter media 42 may be broken free and carried with the reverse flow toward the inlet 34. Once ash is broken free, it may be carried out of the filter 30, through the receptacle line 26, and into the receptacle 16 and/or the vacuum source 14, as shown by receptacle flow arrow 82. The ash may be safely stored in the receptacle 16 throughout the ash removal process and may reside in the receptacle 16 until disposed of.
In an embodiment where the service system 10 includes a vacuum source 14, the vacuum source 14 may supply a vacuum or negative pressure to the filter 30 while the exhaust flow passes through the filter 30 in the direction of reverse flow arrows 80. The vacuum source 14 may, thus, assist in pulling a flow through the filter 30 in a direction opposite the direction of exhaust flow during normal filter operating conditions. The vacuum supplied by the vacuum source 14 may improve the ash removal capabilities of the service system 10 and may be useful in removing ash lodged deep within the filter media 42 of the filter 30.
The user may determine whether the filter 30 is substantially free of ash by using existing work machine diagnostic devices 88, or other means known in the art. For example, after directing a reversed flow through the filter 30, the user may control the inlet and outlet valves 140, 142 to allow an exhaust flow to pass from the inlet 34 of the filter 30 to the outlet 36 in the direction of process flow arrow 74. Work machine diagnostic devices 88 downstream of the filter 30 may determine whether the filter 30 is operating under substantially ash-free conditions or whether the filter 30 requires further service.
In an exemplary embodiment of the present disclosure in which the service system 200 further includes a gas source 12 fluidly connected to the bypass line 146 by a gas source valve 143, the user may begin to service the filter. 30 by controlling the inlet valve 140 to divert the exhaust flow from the engine 46 to the bypass line 146. In this configuration, the inlet valve 140 may substantially prohibit any flow from passing into the filter 30 through the inlet 34. The user may also activate the gas source 12. The gas source valve 143 may be controlled to permit the exhaust flow of the engine and a compressed gas flow from the gas source 12 to pass through the bypass line 146 to the outlet valve 142. Such a flow is illustrated by compressed flow arrow 78. The outlet valve 142 may be controlled to direct the flow from the bypass line 146 into the filter 30 in the direction of reverse flow arrow 80.
Alternatively, the engine 46 may be turned off during servicing such that combustion ceases and no exhaust flow is produced. In this embodiment, the gas source valve 143 may be controlled to permit a flow of compressed gas to pass through the bypass line 146 from the gas source 12 to the outlet valve 142. In such an embodiment, the gas source valve 143 may also be controlled to prohibit a flow from passing through the bypass line 146 in the direction of the inlet valve 140.
In embodiments where the service system 200 includes a vacuum source 14, the volume of compressed gas supplied by the gas source 12 may substantially coincide with the volume of gas removed by the vacuum source 14. In other embodiments, however, the output of the gas source 12 may not be related to the input of the vacuum source 14. It is understood that in embodiments where the input of the vacuum source 14 and the output of the gas source 12 are not calibrated to be substantially equivalent, the overall efficiency of the service system 200 may not be maximized.
As shown in
As described above with respect to
The gas storage device valve 106 may be opened rapidly to maximize the force with which the stored gas is released from the gas storage device 100. The released gas may create a shockwave of compressed gas across the filter media 42 and may improve the matter removal capabilities of the system 300. For instance, a shockwave of gas may be capable of removing matter deep within the filter media 42 in less time and with less effort than a system where a shockwave is not utilized. As described above, the stored flow of gas may be supplied in a direction opposite from the direction of normal flow through the filter 30. It is understood that in embodiments in which the service system 300 includes a vacuum source 14, the vacuum source 14 may be activated before, or at substantially the same time, the gas storage device valve 106 is opened.
Alternatively, as described above the engine 46 may be turned off during servicing such that combustion ceases and no exhaust flow is produced. In this embodiment, the gas source valve 143 may be controlled to permit a flow of compressed gas to pass through the bypass line 146 from the gas storage device 100 to the outlet valve 142. In such an embodiment, the gas source valve 143 may also be controlled to prohibit a flow from passing through the bypass line 146 in the direction of the inlet valve 140.
Other embodiments of the disclosed service system 10 will be apparent to those skilled in the art from consideration of the specification. For example, the filter 30 may be fitted with at least one boss to facilitate insertion of a flow distribution device and/or a flow receiving device into the filter 30. The flow distribution device may be, for example, a nozzle and the flow receiving device may be, for example, a pipe or vacuum tube. Furthermore, the gas source 12 and the vacuum source 14 may be the same device.
Moreover, the service systems 10, 200, 300 may include at least one sensor for sensing a characteristic of a flow through the filter 30. The sensor may be connected to a service system controller. The controller may control aspects of the ash removal process in response to signals received from the at least one sensor. To facilitate this control, the inlet and outlet valves 140, 142, the gas source 12, and/or the vacuum source 14 may be controllably connected to the controller. It is intended that the specification and examples be considered as exemplary only, with the true scope of the invention being indicated by the following claims.
