Patent Application
20160239954
This application relates in general to spray injection and, in particular, to a system and method for spray visualization and measurement.
Spray injectors comprise hardware, including pump, nozzle, control electronics, detectors and so forth, and software that provide calibration, operational control, and other functions. Currently, spray visualization techniques use various techniques, such as laser diffraction, optical imaging and phase Doppler technologies, to detect spray droplet size, speed and/or distribution patterns. These techniques are used in observing and evaluating the performance of the hardware and software utilizing sprays. In the popular laser diffraction technique, for instance, an image of an injected spray pattern through a laser sheet is captured using a high-resolution camera and software is then used to visualize and characterize the injected spray using a pre-determined, mathematical algorithm.
There are limitations to these technologies. Most are expensive, complex; require highly-trained users or special measurement set-ups. For instance, in the laser diffraction technique, due to the sensitivity of the laser instruments employed, accurate measurements of spray pattern information requires the set-up of the measurement system to be in a vibration-free environment. In addition, the instruments used are typically expensive and can cost tens of thousands of dollars per set-up. Likewise, operating these devices requires experienced, advanced skills.
Therefore, a need remains for a low cost and relatively simple, versatile approach to visualizing and measuring patterns of injected liquid spray droplets, including for use in closed environments.
Embodiments of a device and method for spray pattern visualization and characterization are disclosed. This disclosure provides a flexible alternative technique at low cost. The techniques disclosed herein could be used for visualization of gaseous phases, fumes, fluids, vapor, fuel or other liquids such urea-water mixtures, gas-liquid combinations or multi-phases injected in an engine, enclosure or pipe, or any combustion environment.
In one aspect of the disclosure, a method of visualizing a spray of a fluid, comprising steps of injecting a mixture of a hydrocarbon fuel and a fluorescent compound (a fluorophore) into a hollow flow tube having a cross-flow positioned surface material capable of absorbing the fuel and fluorescent compound is disclosed. The injection may be pulsed for a desired duration, or may be continuous. In a further embodiment the method includes collecting flowing droplets on the surface material that is configured to non-attenuate and absorb a flow system comprising the fluorescent compound mixed with the hydrocarbon fuel and an exhaust in the hollow flow tube. The method further comprises removing the surface material following the collecting step and drying the surface material, next observing the droplet markers on surface material using UV light. In still another embodiment, the method includes scanning the surface material for an image of at least one droplet pattern residing on the surface material using an ultraviolet light scanning device, converting the image of at least one droplet pattern into a digitized image of the at least one droplet pattern; and analyzing the digitized image of at least one droplet pattern for droplet size, distribution, uniformity index and/or amount. In a further embodiment, the method includes a hydrocarbon fuel or a synthetic fuel or a bio fuel that includes, but is not limited to, diesel oil, a biodiesel, a petroleum product, petrol, a gasoline and kerosene. In yet another embodiment, the method includes injecting such that injections of the mixture of the hydrocarbon fuel and the fluorescent compound are made in a pulsed mode. In still another embodiment, the method includes injecting such that injections of the mixture of the hydrocarbon fuel and the fluorescent compound are made in a continuous mode.
In a different embodiment, a system for visualizing a spray of fluid comprises a means for injecting a mixture of a hydrocarbon fuel and a compatible fluorescent additive into a hollow flow tube having at least one substantially cross-flow positioned surface material capable of absorbing the fuel and fluorescent additive compound; a means for collecting flowing droplets on the surface material that is configured to non-attenuate a flow and absorb a flow system comprising the fluorescent compound mixed with the hydrocarbon fuel and an exhaust in the hollow flow tube. The system further includes a means for removing the surface material following the collecting step; a means for drying the surface material; a means for observing by naked eye using UV light the surface material for an image of at least one droplet pattern residing on the surface material using an ultraviolet light scanning device; a means for capturing a photographic image for an image of at least one droplet pattern residing on the surface material using an ultraviolet light scanning device; a means for scanning the surface material for an image of at least one droplet pattern residing on the surface material using a scanning device, a means for converting the image of at least one droplet pattern into a digitized image of at least one droplet pattern; and a means for analyzing the digitized image of the at least one droplet pattern for droplet size, uniformity index and amount. Yet another embodiment of the system includes, a camera or a device capable of capturing one or more images of the surface material using ultraviolet or infrared or white light or other spectra thereof.
In embodiment, an apparatus for visualizing a spray of fluid comprises a hollow tube having a first end and a second end, the first end being configured to attach in-line to an automobile exhaust system outlet while the second end includes an opening. An embodiment further includes at least one membrane surface material substantially cross-flow positioned in the hollow tube between the first end and the second end, the membrane surface material further comprises material capable of absorbing and retaining material from the exhaust and a fluorescent compound that has been added to the exhaust. The embodiment includes an injector device functionally coupled to the hollow tube and positioned in between the first end and the second end, the injector device being capable of injecting a mixture of fuel spray and a compatible fluorescent additive compound into the hollow tube. In a further embodiment, the hollow tube is linear and/or curvilinear. The apparatus further comprises a hollow tube that is made from a group of metals including iron, steel, aluminum, copper, zinc, titanium and nickel. The apparatus includes a hollow tube that is made from a group of substances including plastic, polyvinyl, carbon, rubber and glass. Another embodiment includes an apparatus with the membrane surface material made from a group of substances including paper, film, cellulose, nylon, polymer vinyl, and nitrocellulose. The membrane surface material is porous to the flow of gases, exhaust fumes, vapor and the like, yet capable of absorbing or capturing particulates or droplets. There is included in the apparatus at least one membrane surface material, which is positioned using a rigidly placed holder that holds the membrane. Embodiments include at least one membrane that is porous to flow of gas, vapor, fumes and fluids while retaining a particulate material including droplets containing at least one fluorophore or a quencher or a luminescent substance or a colored substance. Additional embodiments include an apparatus having at least one membrane that retains micron scale-size droplets containing at least one fluorophore. Further embodiments include an apparatus having at least one membrane that retains droplets containing at least one fluorophore quencher. In still another embodiment, an apparatus includes an injector device that is configured such that injections can be made in a pulsed mode or a continuous mode. The apparatus is further configured to make injections using urea-water mixtures or paint or AdBlue or diesel exhaust fluid (DEF).
The foregoing summary is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, further improved aspects, embodiments, and devices and methods will become apparent by reference to the drawings and the detailed description.
A person skilled in the art will recognize that the drawings and accompanying brief descriptions are illustrative without limitations and are not drawn to scale.
The following disclosure is drawn to a spray visualization methodology. In the following detailed description, reference is made to the accompanying drawings, which form a part and parcel thereof. The illustrative embodiments described in the detailed description, drawings and claims are not meant to be limiting in any way. Other embodiments may be utilized, and other changes may be made, without departing from the spirit, letter or scope of the subject matter presented here.
Turning now to
Downstream of the injector nozzle is present at least one membrane surface material 39 that is capable of capturing any incoming flow substance droplet 40 and/or is capable of selectively capturing the marker/fluorescent dye-containing droplet 41. The membrane may be positioned cross-sectionally at right angle to the longitudinal axis of the tube 31. Alternatively, the membrane 39 may be positioned anywhere inside the tube 31 in such manner as to not interrupt or attenuate the incoming base flow 42 within the tube. To add rigidity to the membrane, it may be framed in a metal holder. In the alternative, there is present other means for rigidly holding the membrane in a substantially cross-flow position inside the tube. In certain embodiments, the membrane may comprise of, but is not limited to, absorbent or filtration material such as 3M Filtrete™ brand used in household air conditioning and heating units or heat pump furnace filters or other equivalent household or industrial dust filters. Alternatively, the membrane may be made from cellulose, nitrocellulose, nylon, plastic, carbon-based materials, paper, cloth, cotton, polyvinyl, a thin film, film-type, fiber or fibrous material.
In a further embodiment, a study/test of a sample of a diesel fuel or a mixture of urea and water is used. A minute amount of a UV-fluorescent dye compound in the form of a solution is added to the study fuel, which includes, but is not limited to, for example, diesel oil, diesel fuel, biodiesel or a petroleum product or a hydrocarbon fuel. In an exemplary test run the dye solution includes an additive fluorescent dye 41. One skilled in the art will recognize that selection of a dye/indicator should be governed by due diligence knowledge that the fluorescent dye should be compatible with test liquid or gas or particle or particulate system. Care should be taken that addition of a selected dye will not alter the chemical or physical properties of the test fuel, fluid or liquid. A skilled artisan will also recognize that marker dye may include, but is not limited to, fluorophores, non-fluorophores, luminescent analogues and suitable quenchers, colored substances visible to the naked eye, textured substances, or luminescent compounds, or any substance that may have a physico-chemical characteristic. The signal detection method include using ultraviolet light, visible light, infrared, ultrasonic, radiative or nonradiative methods, or other electro-magnetic methods, sonic or physico-chemical detection methods. Those skilled in the art will further recognize that fluorescent dyes include, but are not limited to, commonly known compounds such as naphthalene-based or phenanthrene-based compounds have been disclosed previously (E.g., U.S. Pat. No. 4,515,8960 and U.S. Pat. No. 3,027,754). When chosen and used properly, the additive should not change the test's fuel's properties such as density, viscosity, surface tension, heat capacity or the like. Some physical properties such as density, viscosity and surface tension affect the atomization of the fuel. A mixture of fuel plus a fluorescent additive is injected into the tube 31 or an engine or combustion chamber or any suitable device, which forms spray droplets, such as upon exiting the injector 35. Flowing spray droplets 41 in the tube 31 are captured or absorbed or adhered by the absorbent membrane 39 or film or other suitable absorbent material positioned downstream of the injection point in the flow path of the spray droplets. A distribution pattern of droplets is formed by the impinging of spray droplets onto the absorbent surface of the membrane. The factors that influence or change the pattern of flow and droplets within will alter the amount and distribution of droplet material deposited on the membrane. These factors include, but are not limited to, flow speed, flow patterns, flow turbulence (if any), flow temperature, distance from injector 36 to membrane 39, droplet size, uniformity index, incoming droplet distribution, rate of flow, injection pressure, injection amount, and the like. In an embodiment, the mean diameter of droplet is about 100 microns and the flow rate is about 451 kg/h and the temperature is 25° C. After the test run is complete, the absorbent membrane is removed and dried and processed as described below.
In an embodiment a method of spray visualization is depicted in
The terms surface material, membrane, surface membrane material or surface material membrane or the like are used interchangeably to refer to or connote any porous material comprising a paper, a film, a parchment, a filter, a skin, a mesh, a screen, a netting, interwoven fibers or strands or the like. The term cross-flow is used to mean normal to the direction of base flow carrying the spray. The term uniformity index defines the degree of homogeneity in the droplet distribution on the membrane cross section or at any desired location. The terms urea-water mixture include, but is not limited to, urea and water solutions of any concentration of urea mixed with water and/or any compatible solvent, or solid ammonia, or gaseous ammonia or anahydrous ammonia compounds, ammonia derivatives, ammonium compounds and the like.
Most vehicles equipped with diesel engines must employ a diesel particulate filter (DPF) and selective catalytic reduction (SCR) system to comply with exhaust emission standards for diesel soot and nitrogen oxides (NOx), respectively. DPFs significantly reduce diesel exhaust particulate (soot) resulting from diesel fuel combustion. In many diesel vehicles, DPF performance requires in situ injection of fuel spray inside the exhaust stream, which causes the temperature inside the DPF to become sufficiently high to oxidize (i.e., clean) the soot inside the filter; this process is known as DPF regeneration. Likewise, SCR performance requires the injection of urea-water solution (uws) in the form of a spray introduced into the exhaust stream upstream of the SCR. In some SCR systems, gaseous ammonia is injected, instead of uws spray.
Exhaust system design engineers must ensure that appropriate amounts of diesel fuel or uws in the correct spray pattern and distribution are respectively injected inside the exhaust pipe upstream of DPF or SCR. Correct spray injection, dispersion, mixing, evaporation and uniformity index parameters, for instance, are crucial to ensuring successful performance of DPF and SCR, as injecting diesel fuel and uws of a proper amount and in a correct spray pattern will result in an optimal diesel fuel and uws spray distribution upstream of the DPF or SCR, as applicable, respectively for successful DPF regeneration or SCR NOx reduction. Indeed, poor spray distribution of diesel fuel or uws upstream of a DPF or SCR would not only create undesirable performance, but may possibly result in DPF or SCR failure, including DPF melting or underperformance during regeneration due to non-uniform distribution of fuel spray injected upstream, or SCR underperformance or failure due to non-uniform uws spray distribution or urea deposit formation upstream of the SCR. Hence, proper engineering and integration of a fuel spray injector (for DPF regeneration) and of an uws spray injector (for NOx reduction in SCR) is imperative to assure successful and optimal performance of the DPF and the SCR system in diesel exhaust systems.
Design engineers must analyze and assure proper, uniform spray distribution of diesel fuel or uws respectively upstream of the DPF or the SCR via in situ measurements. Prior art light-based techniques, such as laser light, spectroscopy or phase Doppler techniques, cannot penetrate steel exhaust pipes, nor can they be used near vibration-prone combustion engine systems; hence, laser sheet-based techniques are impracticable for investigating spray injection and distribution inside exhaust assembles. By contrast, the herein disclosed technique can be employed to evaluate whether in-exhaust diesel fuel or uws spray injection parameters, such as spray droplet size and distribution, fit optimized performance requirements of DPF or SCR. In this example, a dye solution is added to the diesel fuel or uws prior to its injection. Preferably, a fluorescent dye visible under a black light or ultraviolet light is used, although other dyes visible under white light, room light or other lights could also be employed. A short injection pulse of the mixed liquid is injected into the engine exhaust upstream of the DPF or SCR. An absorbent, yet non-restrictive membrane surface material, such as the material in filters used in air conditioning system, suitable to capture micron scale-size particulates. Such filters allow the diesel exhaust to flow through unimpeded, yet they enable deposition of droplets of the fluorescent dye. The membrane is removed following testing and an image is observed and photographed by a camera, or is scanned in a UV scanner imaging system or a compatible imaging spectrometer, or in a digitizing system or in a compatible imaging spectrometer. Black, ultraviolet, or visible or other types of light, as appropriate, is used in the process. The digital image is then uploaded to a computer where image processing software can evaluate the size and dispersion pattern of the injected liquid spray.
The foregoing technique does not require expensive optical tables, laser instruments, producing laser beams or sheets, or involve the complexities in using such instruments and materials. The instrumentation set-up is relatively simple and, unlike laser set-ups, is resilient to vibrations in the testing environment. The set-up is ideal for taking measurements where a quiescent environment may not be possible, such as fuel injection in or near a combustion engine, turbine, or exhaust emission systems, for instance in situ in a diesel exhaust system, where fuel or urea sprays are often injected for emission reduction purposes. The instant disclosure may be adapted to other systems, for instance, inside opaque pipes or other enclosures, typically inaccessible by laser sheet techniques. The full set-up is low cost and can be operated by a layman or unskilled personnel with modest training.
The foregoing spray visualization technique offers several key advantages over prior art:
1. Laser sheet forming instruments are not required. A substantial simplification of the overall droplet measurement cost.
2. High speed cameras are not required in the current method. This leads to further cost reduction.
3. Using laser techniques requires advanced skills. The foregoing technique is simpler and the droplet spray measurements could be performed with low or modest training.
4. The disclosed methodology is versatile and can be applied to other systems and assembly. Vibration and similar disturbances render the laser-based technology very expensive to maintain since optical tables are required for mounting the equipment. The technique disclosed herein however could be used in any conventional room, with or without background vibration. Hence, the instant technique is ideal for in-situ characterization of exhaust fumes from commonly used automobiles, trucks, marine platforms or the like. Other applications of the current methodology includes, but is not limited to, spray injection investigations near engines, exhaust pipes and assemblies, or other tightly enclosed environments. The disclosed methodology and technique may be adopted with minimal redesign and modifications for testing any new exhaust assembly because the absorbent surface material could be positioned at any desired location in an extended or contracted spray path, in opaque or transparent pipes or other enclosures, as any situation may require.
5. Laser sheet/beam techniques require advanced data processing hardware and software because the data are acquired through real-time measurements using high speed video recording devices. That is not the case with the current disclosure technique because the data are acquired on a static membrane surface material throughout the brief injection cycle. Static images of the membrane are less prone to the variables inherent in dynamic sensitivity of real-time technology. Static data can be repeatedly processed without re-running the entire methodology. Here, the membrane surface material is a permanent record of a given sample test run and the images thereof can be scanned and re-scanned for further processing as required.
Some of the advantages of the present technique are summarized in the following table.
The foregoing detailed description has set forth various embodiments of devices or methods via the use of examples and drawings. In so far as such drawings and examples comprise one or more devices, steps or methods, it will be understood by those skilled in the art that each component or device or method or step within such drawing and example can be implemented, individually and/or collectively, by a wide range of any combination thereof. One skilled in the art will recognize that the herein described methods, protocols or devices or steps and objects and the discussion accompanying them are used as examples for the sake of conceptual clarity and that various methods, modifications are within the skill of those in the art. Consequently, as used herein, the specific examples or embodiments set forth and the accompanying comments and observations are intended to be representative of their more general classes. In general, use of any specific exemplar or embodiment herein is also intended to be representative of its class, and the non-inclusion of such specific steps, examples, embodiments or drawings and examples or the like herein shall not be taken as indicating that limitation is desired. The herein described subject matter sometimes illustrates different devices or methods comprised within, or associated with, different or other device(s) or methods. It is to be understood that such described device or methods, drawings and examples are merely exemplary, and that in fact many other drawings, and examples can be implemented, which achieve the same or similar results. In a conceptual sense, any device or method or protocol to achieve the same result is effectively “equivalent” to this disclosure such that the desired result is achieved. Hence, any two or more devices or methods or steps herein combined to achieve a particular result can be seen as “equivalent” to each other such that the desired result is achieved, irrespective of differences in method(s) or steps. Likewise, any two device(s) so equivalent can also be viewed as being “functionally “equivalent”, to each other to achieve a desired result, and any two methods or devices capable of being so associated can also be viewed as being capable of acting together, with each other to achieve a desired result.
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can transmute from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations are not expressly set forth herein for sake of clarity.
While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the embodiments herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. Furthermore, it is to be understood that the invention is defined by the appended claims. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” or “has” should be interpreted as “having or has at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions comprising only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.
This application claims benefit of Provisional U.S. Application No. 62/155,292 filed Apr. 30, 2015, which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62155292 | Apr 2015 | US |
