Accumulator for an engine exhaust treatment system
10054021 ยท 2018-08-21
Assignee
Inventors
Cpc classification
F01N2610/1413
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2610/144
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/208
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2900/1808
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2610/1466
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
In accordance with one aspect of the present disclosure, an accumulator is provided for an engine exhaust treatment system. The accumulator includes a container, an inlet portion for receiving exhaust treatment fluid, a conduit in communication with the inlet portion of the container to withdraw exhaust treatment fluid from the inlet portion, and an outlet portion configured to receive exhaust treatment fluid from the inlet portion and having an outlet for discharging exhaust treatment fluid. The accumulator includes a weir separating the inlet portion and the outlet portion that permits exhaust treatment fluid in the inlet portion to flow into the outlet portion.
Claims
1. An exhaust treatment system for an engine, the system comprising: a bulk tank for storing exhaust treatment fluid; a transfer pump configured to pump exhaust treatment fluid from the bulk tank; an accumulator having an inlet portion that receives exhaust treatment fluid from the transfer pump; an exhaust treatment fluid injector; a dosing pump configured to withdraw exhaust treatment fluid from the inlet portion of the accumulator and provide exhaust treatment fluid to the exhaust treatment fluid injector; an outlet portion of the accumulator operably coupled to the bulk tank to permit exhaust treatment fluid to return to the bulk tank; and a weir of the accumulator separating the inlet and outlet portions of the accumulator and permitting exhaust treatment fluid in the inlet portion to flow to the outlet portion.
2. The system of claim 1 wherein the accumulator includes a vent in communication with the atmosphere.
3. The system of claim 2 further comprising a conduit coupling the vent of the accumulator to the bulk tank, and the bulk tank includes a breather valve.
4. The system of claim 1 wherein the inlet portion of the accumulator is operably coupled to the bulk tank to permit exhaust treatment fluid to return to the bulk tank.
5. The system of claim 1 wherein the accumulator includes a conduit extending into the inlet portion of the accumulator, the dosing pump being coupled to the conduit and configured to withdraw exhaust treatment fluid from the inlet portion of the accumulator.
6. The system of claim 1 wherein the dosing pump has a maximum flow rate and the transfer pump has a maximum flow rate greater than the maximum flow rate of the dosing pump.
7. The system of claim 1 wherein the weir includes an upper edge configured to permit exhaust treatment fluid to flow over the weir and into the outlet portion.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
DETAILED DESCRIPTION
(6) In
(7) With reference to
(8) With reference to
(9) Turning to
(10) The inlet portion 90 receives DEF 15 from the transfer pump 18 and permits the dosing pump 22 to withdraw the DEF 15 from the inlet portion 90. The weir 21 controls the maximum volume of DEF 15 within the inlet portion 90 of accumulator 20 by permitting DEF 15 to flow into the outlet portion 130 once the DEF has reached a predetermined height within the inlet portion 90, as discussed in greater detail below. The outlet portion 130 receives DEF 15 from the inlet portion 90 and includes a first outlet, such as a return opening 32, coupled to a return line 34 (see
(11) With reference to
(12) With reference to
(13) With reference to
(14) Turning to
(15) With reference to
(16) With reference to
Q.sub.150=Q.sub.152+Q.sub.154+Q.sub.156
(17) In other words, the flow rate of the inlet flow 150 of the DEF 15 from the transfer pump 18 equals the sum of the flow rates of the DEF 15 exiting the accumulator 20 by way of the dosing pump flow 152, the drain flow 154, and the return flow 156. For example, the transfer pump 18 may have a maximum Q.sub.150 of 100 liters per hour and the dosing pump 22 may have a maximum Q.sub.152 of 60 liters per hour. For this maximum flow rate example, the sum of Q.sub.154 and Q.sub.156 would equal 40 liters per hour.
(18) When the dosing pump 22 draws little or no DEF 15 from the inlet portion 90, i.e., Q.sub.152 is close to zero, the transfer pump 18 may continue to provide a constant Q.sub.150. In this situation, the DEF from inlet flow 150 fills the inlet portion 90, flows in direction 160 over the weir 21, into the outlet portion 130, and returns to the bulk tank 16. Though drain opening 36 is relatively small such that the Q.sub.154 is also small, at least some of the DEF 15 in the inlet portion 90 exits the inlet portion 90 by way of the drain flow 154.
(19) When the dosing pump 22 withdraws DEF 15 from the inlet portion 90 at a high rate, i.e., Q.sub.152 is high, the transfer pump 18 continues to provide a constant Q.sub.150 and the Q.sub.154 remains small. The high Q.sub.152 may lower the level of DEF 15 in the inlet portion 90 below the height 132 such that the DEF 15 no longer flows over the weir 21 in direction 160 into outlet portion 130. Instead, the DEF 15 in the inlet portion 90 exits the inlet portion 90 in the dosing pump flow 152 or the drain flow 154. If the Q.sub.152 remains high for an extended period of time, any remaining DEF 15 in the outlet portion 130 may completely drain from the outlet portion 130 through the return opening 32. Once Q.sub.152 decreases, for example the engine 12 is no longer under a heavy load, the Q.sub.150 remains constant and the Q.sub.154 remains small such that the inlet portion 90 may fill again to the height 132 and begin to flow over the weir 21 and into the outlet portion 130.
(20) The transfer pump 18 may be operated to provide a constant Q.sub.150 of the inlet flow 150 of the DEF 15 in the inlet portion 90. In other approaches, the transfer pump 18 may be operated to vary the Q.sub.150. For example, the transfer pump 18 may decrease Q.sub.150 when the dosing pump 22 has been withdrawing the DEF 15 at a low Q.sub.152 for an extended period of time.
(21) Referring to
Q=0.266cB(2g).sup.0.5H.sup.1.5
(22) where:
(23) Q is equal to the flow rate (m.sup.3/s)
(24) c is equal to the discharge coefficient, which may be averaged as 0.62
(25) B is equal to the width 190 (m)
(26) g is equal to a gravitational constant, 9.81 m/s.sup.2
(27) H is equal to the height 192 (m)
(28) With this flow rate Q, the weir 21 may be configured for a particular application including the size of the transfer pump 18 and the dosing pump 22. The drain opening 36 may be permanently open, or selectively opened, but in general has a small flow rate and is used primarily to ensure that all of the DEF 15 in the inlet portion 90 drains from the inlet portion 90 upon shutdown of the exhaust treatment system 10. Thus, the transfer pump 18, dosing pump 22, and drain opening 36 are sized to ensure that the dosing pump 22 is provided with a sufficient supply of DEF 15 in the inlet portion 90 during operation of the engine 12.
(29) The accumulator 20 and the other components of the dosing system 40 are made from materials that resist corrosion by the DEF 15 and are sufficiently strong to handle the pressures and flow of the DEF 15 during operation of the machine 11. For example, the container 80 including the weir 21 may be made of roto molded nylon plastic. In another form, the container 80 and the weir 21 may be made of stainless steel, for example a 300 series grade stainless steel such as a 304 grade stainless steel.
(30) With reference to
(31) The method 200 includes drawing 204 exhaust treatment fluid, such as DEF 15, from the accumulator 20 to the dosing pump 22. The pumping 202 and the drawing 204 may be performed independently of each other. Specifically, the transfer pump 18 may be operated at a constant flow rate while the dosing pump 22 is operated only as needed to supply DEF 15 to the exhaust treatment fluid injector 66. Unused DEF 15 in the accumulator 20 exits the accumulator 20 through the return opening 32 or the drain opening 36 and returns to bulk tank 16. In this manner, the flow rate of the dosing pump 22 can be closely tailored to the current and changing demands of the engine 12 while the transfer pump 18 operates at a constant flow rate, such as a flow rate where the transfer pump 18 operates at or near its maximum efficiency.
(32) The method 200 further includes returning 206 exhaust treatment fluid, such as DEF 15, from the accumulator 20 to the bulk tank 16. In one form, the returning 206 includes returning the DEF 15 from the accumulator 20 to the bulk tank 16 while pumping DEF 15 from the bulk tank 16 to the accumulator 20 via the transfer pump 18. The returning 206 may include removing the DEF 15 from the accumulator 20 to the bulk tank 16 via the return opening 32 and the drain opening 36. The method 200 may therefore include removing the DEF 15 from the accumulator via two openings, the return opening 32 and the drain opening 36. As noted above, the drain opening 36 can be relatively small for emptying the inlet portion 90 upon shut down of the machine 11 and the return opening 32 may be much larger to ensure that the DEF 15 in the outlet portion 130 empties quickly via the return opening 32.
(33) The method 200 further includes injecting 208 the DEF 15 into the engine exhaust pipe 14 via the exhaust treatment fluid injector 66. The DEF 15 mixes with the exhaust stream from the engine 12 and decomposes into ammonia (NH.sub.3) and carbon dioxide (CO.sub.2). As the NO.sub.x from the exhaust stream and ammonia pass over the catalyst of selective catalytic reduction system 70, the NO.sub.x and ammonia react to produce nitrogen (N.sub.2) and water.
(34) The method 200 may also include flowing the exhaust treatment fluid, such as DEF 15, over the weir 21 (see
(35) In some approaches, the pumping 202 of the exhaust treatment fluid from the bulk tank 16 to the accumulator 20 includes pumping the DEF 15 from the bulk tank 16 to the accumulator at a first flow rate, e.g., Q.sub.150 discussed above. Further, the returning 206 of the DEF 15 from the accumulator 20 to the bulk tank may include returning the DEF 15 from the accumulator 20 to the bulk tank 16 at a second flow rate, e.g., the sum of Q.sub.154 and Q.sub.156 discussed above, which is less than the first flow rate Q.sub.150. Still further, the drawing 204 of the DEF 15 from the accumulator 20 to the dosing pump 22 may include drawing the DEF 15 from the accumulator 20 to the dosing pump 22 at a third flow rate, e.g., Q.sub.152 discussed above, which is less than the first flow rate.
INDUSTRIAL APPLICABILITY
(36) The industrial applicability of the embodiments of an accumulator and method described herein will be readily appreciated from the foregoing discussion. The disclosed accumulator and method may be used in a variety of exhaust treatment systems, and particularly in diesel exhaust systems utilizing urea-based diesel exhaust fluid (DEF). Embodiments of the accumulator may find potential application in machines used for construction, aerospace, mining, railroad, forestry, power generation, marine, farming, or similar industries. The machines may be stationary machines, self-propelled vehicles, or vehicles intended to be pushed or pulled by another machine. Exemplary machines include locomotives, stationary power generators, gas turbines, tractors, on- or off-highway trucks, cars, earth moving equipment, material handlers, pumps, or logging machines.
(37) An exhaust treatment system for an engine generally includes a dosing system that receives air from an air compressor, DEF from the accumulator via a supply line, and signals from an engine electronic control module (ECM). The dosing system includes a dosing pump, a dosing system ECM, and a DEF manifold. The components of the dosing system are operably configured to provide metered amounts of DEF to an injector via an injector line. The injector injects the DEF into the exhaust pipe upstream of a catalyst of a selective catalytic reduction system. The dosing system may also return DEF to the bulk tank via a return line.
(38) In general, an accumulator is disclosed that may be utilized with exhaust treatment systems to improve the performance of the dosing system and provide increased protection against DEF freezing in cold operating conditions. In one aspect of the present disclosure, the accumulator includes a container, an inlet portion of the container for receiving exhaust treatment fluid, a conduit in communication with the inlet portion to withdraw exhaust treatment fluid from the inlet portion, and an outlet portion of the container configured to receive exhaust treatment fluid from the inlet portion The accumulator further includes means, such as a weir, for separating the inlet and outlet portions and permitting exhaust treatment fluid in the inlet portion to flow into the outlet portion. In one form, the weir is configured to permit exhaust treatment fluid to flow into the outlet portion once the exhaust treatment fluid has reached a predetermined height within the inlet portion. The height is selected to provide a sufficient volume of exhaust treatment fluid within the inlet portion for being withdrawn via the conduit even under sudden, high-load operation of the engine.
(39) In at least one embodiment, the accumulator has a vent between the container and the atmosphere which generally maintains air within the container at atmospheric pressure. This inhibits the buildup of pressure or creation of a vacuum within the container during operation which, in turn, makes it easier for a dosing pump connected to the conduit to withdraw fluid from the inlet portion of the container. Further, the dosing pump may operate more accurately because the volume of exhaust treatment fluid pumped with each cycle of the dosing pump is not disrupted by pressure or vacuum within the container.
(40) Various embodiments of the accumulator includes a first outlet of the outlet portion for discharging exhaust treatment fluid from the outlet portion back to a source of the exhaust treatment fluid, such as bulk tank. The first outlet of the outlet portion thereby allows for recirculation of exhaust treatment fluid between the accumulator and the bulk tank. The recirculation of the exhaust treatment fluid may reduce the risk of the exhaust treatment fluid freezing during cold operating conditions. The recirculation may also allow for further filtering to remove particulates from the DEF prior to being drawn out of the accumulator with the dosing pump. For example, the DEF may pass through an inline filter when the DEF is pumped by the transfer pump from the bulk tank to the accumulator.
(41) In one form, the inlet portion of the container includes a second outlet that permits exhaust treatment fluid to be removed from the inlet portion upon shut down of the machine. Upon shutdown of the machine, the exhaust treatment fluid in the inlet portion of the container may exit the container through the second outlet and the exhaust treatment fluid in the outlet portion of the container may exit the container through the first outlet. In this manner, the container empties upon shutdown of the machine which may further limit the risk of exhaust treatment fluid freezing within the accumulator during cold operating conditions.
(42) In another embodiment, a method of operating an exhaust treatment system for an engine is provided. The method includes pumping exhaust treatment fluid from a bulk tank into an accumulator and drawing exhaust treatment fluid from the accumulator to a dosing pump. The method further includes returning exhaust treatment fluid from the accumulator to the bulk tank and injecting exhaust treatment fluid into an exhaust stream of the engine. By returning exhaust treatment fluid from the accumulator to the bulk tank, the exhaust treatment fluid may be constantly recirculated within the exhaust treatment system which may reduce the likelihood of freezing. Further, returning exhaust treatment fluid from the accumulator to the bulk tank permits pumping of exhaust treatment fluid from the bulk tank to the accumulator at a constant, steady flow rate while the dosing pump withdraws only the exhaust treatment fluid needed for injection into the exhaust stream. This enables the dosing pump to operate with high accuracy since it is withdrawing only the volume of exhaust treatment needed to be injected into the exhaust stream. The method may further include maintaining a portion of an internal volume of the accumulator at atmospheric pressure. This further enhances the accuracy of the dosing pump because the exhaust treatment fluid being withdrawn from the accumulator is not pressurized or under a vacuum.
(43) Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments, and that such modifications, alterations, and combinations, are to be viewed as being within the scope of the disclosure. Methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.