Title of Invention

OXYGEN BASED PARTICULATE FILTER REGENENERATION STRATEGY

Abstract A particulate filter regeneration method for an internal combustion engine system is provided. The method includes: receiving an outlet temperature signal corresponding to a temperature at an outlet of a particulate filter; receiving an oxygen signal corresponding to an oxygen level in exhaust flowing from said particulate filter; and controlling at least one of airflow and fuel based on said oxygen level such that said outlet temperature is within a desired range.
Full Text 1
GP-307045
OXYGEN BASED PARTICULATE FILTER REGENERATION STRATEGY
FIELD OF THE INVENTION
[0001] The present invention relates to participate filters and more
particularly to methods and systems for controlling the temperature of a
particulate filter during regeneration.
BACKGROUND OF THE INVENTION
[0002] Diesel Particulate Filters (DPF) are used on diesel engines to
reduce emissions of particulate matter (soot) generated during a
heterogeneous combustion process. These filters must be cleaned or
"regenerated" when the filter is determined full of soot. An engine control
system can estimate the DPF accumulation, and determine when the filter
needs regeneration. Once the filter is determined to be full, the control system
will enable regeneration by modifying the combustion process and/or injecting
fuel into the exhaust system to increase the temperature of exhaust flowing
into the DPF. The elevated exhaust temperatures will initiate oxidation of the
stored soot within the DPF.
[0003] Normally, this process is well controlled, and results in
acceptable filter temperatures and durability. However, under some
conditions, the filter can be overloaded with particulates or regenerated during
conditions that result in run-away temperatures. These excessively high
temperatures can result in filter failure due to cracking from thermal stress, or
even melting of the filter substrate.
[0004] In order to improve DPF durability, peak temperatures within
the DPF should be controlled. One method of controlling peak temperatures
includes limiting particulate loading. This cannot always be guaranteed due to
customer driving cycles, ambient conditions, and/or variations in engine
operating modes. Another method includes limiting the heat input into the
DPF by the fuel injection process. This too is not always effective, since the

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stored particulate mass is often sufficient to lead to highly exothermic
reactions that can damage the DPF material.
SUMMARY OF THE INVENTION
[0005] Accordingly, a particulate filter regeneration method for an
internal combustion engine system is provided. The method includes:
receiving an outlet temperature signal corresponding to a temperature at an
outlet of a particulate filter; receiving an oxygen signal corresponding to an
oxygen level in exhaust flowing from said particulate filter; and controlling at
least one of airflow and fuel based on said oxygen level such that said outlet
temperature is within a desired range.
[0006] In other features, a system for controlling regeneration of a
particulate filter is provided. The system includes: an outlet temperature
sensor that senses a temperature at an outlet of the particulate filter and that
generates a temperature signal based on said outlet temperature; an air fuel
sensor that senses an oxygen level in exhaust flowing from the particulate
filter and generates an oxygen signal based on said oxygen level; and a
control module that receives said outlet temperature signal and said oxygen
signal and controls regeneration of said particulate filter based on said outlet
temperature signal and said oxygen signal.
[0007] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter. It should
be understood that the detailed description and specific examples, while
indicating the preferred embodiment of the invention, are intended for
purposes of illustration only and are not intended to limit the scope of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will become more fully understood
from the detailed description and the accompanying drawings, wherein:
[0009] Figure 1 is a schematic view of an exemplary diesel engine
system that includes a particular filte regeneration system according to the
present invention;

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[0010] Figure 2 is flow chart illustrating the oxygen based particulate
filter regeneration method according to the present invention; and
[0011] Figure 3 is a graph illustrating a control band of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The following description of the preferred embodiment(s) is
merely exemplary in nature and is in no way intended to limit the invention, its
application, or uses. For purposes of clarity, the same reference numbers will
be used in the drawings to identify similar elements. As used herein, the term
module refers to an application specific integrated circuit (ASIC), an electronic
circuit, a processor (shared, dedicated, or group) and memory that executes
one or more software or firmware programs, a combinational logic circuit,
and/or other suitable components that provide the described functionality.
[0013] Referring now to Figure 1 an exemplary diesel engine
system 10 is schematically illustrated in accordance with the present
invention. It is appreciated that the diesel engine system 10 is merely
exemplary in nature and that the particulate filter regeneration system
described herein can be implemented in various engine systems
implementing a particulate filter. Such engine systems may include, but are
not limited to, gasoline direct injection engine systems and homogeneous
charge compression ignition engine systems. For ease of the discussion, the
disclosure will be discussed in the context of a diesel engine system.
[0014] The diesel engine system 10 includes a diesel engine 12, an
intake manifold 14, a common rail fuel injection system 16 and an exhaust
system 18. The exemplary engine 12 includes eight cylinders 20 configured
in adjacent cylinder banks 22,24 in V-type layout. Although Figure 1 depicts
eight cylinders (N = 8), it can be appreciated that the engine 12 may include
additional or fewer cylinders 20. For example, engines having 2, 4, 5, 6, 8,
10, 12 and 16 cylinders are contemplated. It is also anticipated that the
particulate filter regeneration control of the present invention can be
implemented in an inline-type cylinder configuration.

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[0015] Air is drawn into the intake manifold 14 through a throttle (not
shown). Air is drawn into the cylinders 20 from the intake manifold 14 and is
compressed therein. Fuel is injected into cylinder 20 by the common rail
injection system 16 and the heat of the compressed air ignites the air/fuel
mixture. The exhaust gases are exhausted from the cylinders 20 into the
exhaust system 18. In some instances, the diesel engine system 10 can
include a turbocharger that uses an exhaust driven turbine 26 to drive a
compressor 27 that compresses the air entering the intake manifold 14. The
compressed air typically passes through an air cooler (not shown) before
entering into the intake manifold 14.
[0016] The exhaust system 18 includes exhaust manifolds 28,30,
exhaust conduits 29,31, and 36, a diesel oxidizing catalyst (DOC) 38, and a
diesel particulate filter (DPF) 40. The exhaust manifolds 28,30 direct the
exhaust exiting corresponding cylinder banks 22,24 into the exhaust conduits
29,31. The exhaust is directed into the turbocharger to drive the turbine 26.
A combined exhaust stream flows from the turbocharger through the exhaust
conduit 36, the DOC 38, and the DPF 40. The DPF 40 filters particulates from
the combined exhaust stream as it flows to the atmosphere.
[0017] A control module 42 regulates operation of the diesel engine
system 10 according to the oxygen based particulate filter regeneration
method of the present invention. More particularly, the control module 42
communicates with a DPF outlet temperature sensor, a wide-range air fuel
sensor 46, and a DPF inlet temperature sensor 48. The DPF outlet
temperature sensor generates a signal indicating a temperature at the outlet
of the DPF 40. In various embodiments, the DPF outlet temperature sensor
senses a temperature of the DPF substrate as shown by temperature sensor
44 and generates a substrate temperature signal. In various embodiments,
the DPF outlet temperature sensor senses a temperature of gases exiting the
DPF as shown by temperature sensor 45 and generates a gas temperature
signal. The wide-range air fuel sensor 46 generates a signal indicating the
amount of oxygen (O2) in the exhaust. The DPF inlet temperature sensor 48
generates a signal indicating the temperature of exhaust flowing into the DPF
40.

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[0018] The control module 42 determines when regeneration is
needed and controls engine operation to allow regeneration to occur. Based
on the outlet temperature signal and the oxygen signal, control continues to
control engine operation at regeneration levels until regeneration is complete.
[0019] Referring now to Figure 2, a flowchart illustrates steps
performed by the oxygen based particulate filter regeneration method. In step
100, control estimates soot accumulation in the DPF and determines whether
regeneration is needed based on an accumulation threshold. If the DPF is
full, control determines whether engine operating conditions are sufficient to
permit regeneration in step 110. If the DPF is not full, control proceeds to the
end. If regeneration is permitted, control enables regeneration by modifying
the combustion process and/or injecting fuel into the exhaust stream to raise
the DPF inlet temperature above a soot light-off threshold in step 120. The
elevated exhaust temperature initiates oxidation of the stored soot within the
DPF. If regeneration is not permitted, control proceeds to the end.
[0020] If regeneration has begun and the temperature signal
indicates a substrate temperature of greater than a selectable threshold in
step 130, the proper temperature for regeneration is maintained by
commanding air and/or fuel such that the oxygen level indicated by the air fuel
sensor is within a pre-defined control band. In an exemplary embodiment, the
selectable threshold can be five hundred degrees Celsius. Figure 3 illustrates
an exemplary control band. The oxygen level is indicated along the y-axis at
200 and ranges from zero percent to ten percent. The DPF outlet
temperature is indicated along the x-axis at 210 and ranges from three
hundred degrees Celsius to nine hundred degrees Celsius. An exemplary
control band is indicated at 220. The control band indicates the range at
which the oxygen levels should be maintained in order to control the
temperature of the DPF and to completely burn the accumulated soot.
[0021] Referring back to Figure 2, as regeneration occurs in step
140, the soot mass is reduced over a period of time. The time for complete
regeneration of the stored soot mass can be estimated from the known DPF
conditions. A maximum regeneration time can be pre-determined for the
particular system. If the DPF outlet temperature in step 150 remains above a

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minimum temperature (e.g., 550 degrees Celsius) and the regeneration time
in step 160 is greater than the regeneration time max ( e.g., 7 minutes), the
filter is clean and regeneration is complete. Control proceeds to the end. If
the DPF outlet temperature is above the minimum temperature, but for
insufficient time, control loops back to step 100 and regeneration will continue
to complete the soot oxidation process.
[0022] Those skilled in the art can now appreciate from the
foregoing description that the broad teachings of the present invention can be
implemented in a variety of forms. Therefore, while this invention has been
described in connection with particular examples thereof, the true scope of the
invention should not be so limited since other modifications will become
apparent to the skilled practitioner upon a study of the drawings, specification,
and the following claims.

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CLAIMS
What is claimed is:
1. A system for controlling regeneration of a participate filter,
comprising:
an outlet temperature sensor that senses a temperature at an
outlet of the particulate filter and that generates a temperature signal based
on said outlet temperature;
an air fuel sensor that senses an oxygen level in exhaust flowing
from the particulate filter and generates an oxygen signal based on said
oxygen level; and
a control module that receives said outlet temperature signal
and said oxygen signal and controls regeneration of said particulate filter
based on said outlet temperature signal and said oxygen signal.
2. The system of claim 1 wherein said temperature sensor senses
a substrate temperature at said outlet of said particulate filter.
3. The system of claim 1 wherein said temperature sensor senses
a gas temperature flowing through said outlet of said particulate filter.
4. The system of claim 1 wherein said control module controls at
least one of airflow and fuel to maintain a desired oxygen level in said
exhaust, wherein said desired oxygen level is defined by a control band, and
wherein said control band is defined by a plurality of selectable ranges for a
plurality of selectable temperatures.
5. The system of claim 4 wherein said selectable temperatures are
between five hundred and nine hundred degrees Celsius and said selectable
ranges are between zero and ten percent oxygen.

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6. The system of claim 1 wherein said control module estimates an
accumulation of soot in said particulate filter and controls regeneration based
on said estimation.
7. The system of claim 6 further including an inlet exhaust
temperature sensor that senses a temperature of exhaust flowing into said
particulate filter and generates an exhaust temperature signal based on said
temperature of exhaust flowing into said particulate filter and wherein said
control module initiates regeneration by commanding engine operation such
that said exhaust temperature flowing into said particulate filter is above a
soot light-off threshold.
8. The system of claim 1 wherein when said temperature signal
indicates a temperature above a selectable threshold, said control module
controls regeneration based on said oxygen signal and said temperature
signal.
9. The system of claim 8 wherein said threshold is five hundred
degrees Celsius.
10. A particulate filter regeneration method for an internal combustion
engine system, comprising:
receiving an outlet temperature signal corresponding to a
temperature at an outlet of a particulate filter;
receiving an oxygen signal corresponding to an oxygen level in
exhaust flowing from said particulate filter; and
controlling at least one of airflow and fuel based on said oxygen
level such that said outlet temperature is within a desired range.
11. The method of claim 10 further comprising estimating an
accumulation of soot in said particulate filter and wherein said step of
controlling is performed if said estimated accumulation exceeds an
accumulation threshold.

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12. The method of claim 11 further comprising receiving a
temperature signal corresponding to an inlet temperature of said particulate
filter and controlling at least one of airflow and fuel to said engine such that
said inlet temperature is above a soot light-off threshold when said estimated
accumulation exceeds an accumulation threshold.
13. The method of claim 10 wherein said receiving comprises
receiving an outlet temperature signal corresponding to a temperature of
particulate filter substrate at said outlet of said particulate filter.
14. The method of claim 10 wherein said receiving comprises
receiving an outlet temperature signal corresponding to a temperature of
gases flowing from said outlet of said particulate filter.
15. The method of claim 10 wherein said desired range for said
outlet temperature is between five hundred and nine hundred degrees
Celsius.
16. The method of claim 10 wherein said oxygen level is controlled
to be within a desired range for a given outlet temperature.
17. The method of claim 16 wherein said desired range for said
oxygen level is between zero and ten percent oxygen.
18. The method of claim 10 wherein said step of controlling at least
one of airflow and fuel based on said oxygen level continues as long as soot
is available to be burned.

A particulate filter regeneration method for an internal combustion
engine system is provided. The method includes: receiving an outlet
temperature signal corresponding to a temperature at an outlet of a particulate
filter; receiving an oxygen signal corresponding to an oxygen level in exhaust
flowing from said particulate filter; and controlling at least one of airflow and
fuel based on said oxygen level such that said outlet temperature is within a
desired range.

Documents:

01217-kol-2007-abstract.pdf

01217-kol-2007-assignment.pdf

01217-kol-2007-claims.pdf

01217-kol-2007-correspondence 1.2.pdf

01217-kol-2007-correspondence others 1.1.pdf

01217-kol-2007-correspondence others.pdf

01217-kol-2007-description complete.pdf

01217-kol-2007-drawings.pdf

01217-kol-2007-form 1.pdf

01217-kol-2007-form 2.pdf

01217-kol-2007-form 3.pdf

01217-kol-2007-form 5.pdf

01217-kol-2007-priority document.pdf

1217-KOL-2007-(01-09-2011)-ASSIGNMENT.pdf

1217-KOL-2007-(01-09-2011)-FORM 16.pdf

1217-KOL-2007-(01-09-2011)-PA.pdf

1217-KOL-2007-ABSTRACT-1.1.pdf

1217-KOL-2007-ASSIGNMENT.pdf

1217-KOL-2007-CANCELLED DOCOMENT.pdf

1217-KOL-2007-CLAIMS-1.1.pdf

1217-kol-2007-CORRESPONDENCE 1.3.pdf

1217-KOL-2007-CORRESPONDENCE 1.4.pdf

1217-KOL-2007-CORRESPONDENCE OTHERS 1.3.pdf

1217-KOL-2007-CORRESPONDENCE OTHERS 1.4.pdf

1217-KOL-2007-CORRESPONDENCE OTHERS 1.5.pdf

1217-KOL-2007-DESCRIPTION COMPLETE-1.1.pdf

1217-KOL-2007-FORM 1-1.1.pdf

1217-KOL-2007-FORM 18.pdf

1217-KOL-2007-FORM 2-1.1.pdf

1217-KOL-2007-FORM 26.pdf

1217-KOL-2007-FORM 27.pdf

1217-kol-2007-OTHERS.pdf

1217-kol-2007-PETITION UNDER RULE 137.pdf

1217-KOL-2007-REPLY TO EXAMINATION REPORT.pdf

1217-kol-2007-SCHEDUAL-FORM 3.pdf

abstract-01217-kol-2007.jpg


Patent Number 241173
Indian Patent Application Number 1217/KOL/2007
PG Journal Number 26/2010
Publication Date 25-Jun-2010
Grant Date 22-Jun-2010
Date of Filing 31-Aug-2007
Name of Patentee GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Applicant Address 300 GM RENAISSANCE CENTER, DETROIT, MICHIGAN
Inventors:
# Inventor's Name Inventor's Address
1 FRANK AMENT 1681 ROLLING WOODS DRIVE, TROY MICHIGAN 48098
2 DAVID B. BROWN 3681 OLDE DOMINION, BRIGHTON, MICHIGAN 48114
PCT International Classification Number F01N3/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 11/539904 2006-10-10 U.S.A.