Claims:1. A system (100) for cleaning diesel particulate filter comprising:
an apparatus (110), wherein the apparatus (110) comprises:
a first compartment (115) comprising a tank (118) configured to hold fluid;
a second compartment (120) operatively coupled to the first compartment (115), wherein the second compartment (128) comprises a diesel particulate filter (DPF) (112) mounted on a diesel particulate filter (DPF) fixture (130);
a control unit (135) operatively coupled to the apparatus (110), wherein the control unit (135) is configured to:
obtain a plurality of properties associated with at least one of fluid and the diesel particulate filter (DPF) (112) remotely, from a sensing unit, through a transceiver (185);
generate one or more commands by a programmable logic controller (PLC) (140) for calibration of an operation of the apparatus (110) in one or more modes based on a plurality of obtained properties;
a fluid supply unit (150) operatively coupled to the apparatus (110), wherein the fluid supply unit (150) is configured to supply the fluid to clean the diesel particulate filter (DPF) (112) for a predefined period based on one or more generated commands.
2. The system (100) as claimed in claim 1, wherein the first compartment (115) comprises a heating coil (125) operatively coupled to the tank (118), wherein the heating coil (125) is configured to heat the fluid stored in the tank (118).
3. The system (100) as claimed in claim 1, wherein the diesel particulate filter (DPF) (112) comprises a first end (132) configured to supply the fluid into the diesel particulate filter (DPF) (112), wherein the fluid comprises at least one of air and water.
4. The system (100) as claimed in claim 1, wherein the diesel particulate filter (DPF) (112) comprises a second end (130) configured to enable release of diesel particulate matter from the diesel particulate filter (DPF) (112).
5. The system (100) as claimed in claim 1, wherein the sensing unit comprises at least one of a temperature sensor (138), a pressure sensor (138) and a water-level sensor (138), wherein the sensing unit is configured to sense a corresponding plurality of properties associated with the at least one of the fluid and the diesel particulate filter (DPF) (112).
6. The system (100) as claimed in claim 1, wherein the control unit (135) is configured to monitor and control data stored in a database remotely, upon generation of the one or more commands, by using a telemetry or cloud-based technology, wherein the data is representative of the operation of the apparatus (110).
7. The system (100) as claimed in claim 1, wherein the fluid supply unit (150) comprises:
a compressor (152) operatively coupled to the second compartment (128), wherein the compressor (152) is configured to supply air through a solenoid valve (155) into the diesel particulate filter (DPF) (112);
a pump (160) operatively coupled to the tank (112), wherein the pump (160) is configured to circulate water into the diesel particulate filter (DPF) (112) through the solenoid valve (155) upon filtration by using at least two filters (162); and
a blower (165) operatively coupled to the second compartment (128), wherein the blower (165) is configured to supply hot air into the diesel particulate filter (DPF) (112) for drying.
8. The system (100) as claimed in claim 1, further comprising a verification subsystem (170) operatively coupled to the control unit (135), wherein the verification subsystem (170) is configured to:
record the plurality of properties associated with the at least one of the fluid and the diesel particulate filter (DPF) (112), wherein the plurality of properties comprises at least one of water-flow level, pressure of air, pressure of water, back pressure of the diesel particulate filter (DPF) (112), temperature of the water and temperature of the air; and
estimate requirement of a cleaning process of the diesel particulate filter (DPF) (112) based on comparison of a plurality of recorded properties with a predetermined threshold limit of the plurality of properties associated with a reference diesel particulate filter (DPF) (112).
9. The system (100) as claimed in claim 1, further comprising a report generation subsystem (180) operatively coupled to the verification subsystem (170), wherein the report generation subsystem (180) is configured to generate at least one report for depicting values of the plurality of recorded properties.
Dated this 23rd day of August 2019


Vidya Bhaskar Singh Nandiyal
Patent Agent (IN/PA-2912)
Agent for applicant
, Description:BACKGROUND
[0001] Embodiments of the present disclosure relates to, a cleaning system and more particularly to a system for cleaning diesel particulate matter.
[0002] Diesel particulate filter (DPF)is a device which is used to trap and filter harmful diesel particulate emissions from exhaust gas of a diesel engine. The DPF filters out more than 95% of the harmful diesel particulate emissions. Mostly, the DPF is made of ceramic material such as cordierite or Sic and have a honeycomb kind of structure with lot of parallel channels running along the length of the DPF. In passing of the exhaust from the diesel engine through the walls of the channels the soot particles get filtered and deposited in the inlet channels which leads to back pressure on the engine and adversely affects fuel economy. As a result, various systems are essential which cleans the DPF and removes the ash trapped in the DPF physically in an environment friendly manner.
[0003] Conventionally, the system available to clean the DPF includes removal of the soot deposited in the DPF, which if unremoved, leads to back pressure on the diesel engine and adversely affects its fuel economy. So, the filtered particulates or soot have to be burnt or oxidized intermittently. The organic constituents of the particulate emissions are oxidized by raising the exhaust temperature above 600degree Celsius and is removed from the DPF which is known as regeneration of the soot. The regeneration of soot is done every 300-500 kms depending on several different parameters. The inorganic constituents are unable to oxidize and remain trapped in the DPF as ash. Over several thousands of kilometers of running of the vehicle, this can lead to significant amounts of ash in the DPF which again increases backpressure on the engine and adversely affects the fuel economy and also reduces the effective volume available for particulate matter filtering thereby reducing the effectiveness of the device. So, the ash trapped in the DPF has to be physically removed and disposed in an environmentally friendly manner.
[0004] Hence there is need to clean the ash from the DPF so that DPF can be restored to close to its initial state and this can also improve the vehicle fuel economy.
BRIEF DESCRIPTION
[0005] In accordance with an embodiment of the present disclosure, a system for cleaning a diesel particulate filter is disclosed. The system includes an apparatus. The apparatus includes a first compartment which includes a tank configured to hold fluid. The apparatus also includes a second compartment operatively coupled to the first compartment. The second compartment includes a diesel particulate filter (DPF)mounted on a diesel particulate filter (DPF) fixture. The system also includes a control unit operatively coupled to the apparatus. The control unit is configured to obtain a plurality of properties associated with at least one of fluid and the diesel particulate filter (DPF) remotely, from a sensing unit, through a transceiver. The control unit is also configured to generate one or more commands by a programmable logic controller (PLC) for calibration of an operation of the apparatus in one or more modes based on a plurality of obtained properties. The system also includes a fluid supply unit operatively coupled to the apparatus. The fluid supply unit is configured to supply the fluid to clean the diesel particulate filter (DPF) for a predefined period based on one or more generated commands.
[0006] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0007] FIG. 1 is a schematic representation of a system for cleaning a diesel particulate filter in accordance with an embodiment of the present disclosure; and
[0008] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0009] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0010] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0011] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0012] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0013] Embodiments of the present disclosure relate to a system for cleaning a diesel particulate filter (DPF). The system includes an apparatus. The apparatus includes a first compartment which includes a tank configured to hold fluid. The apparatus also includes a second compartment operatively coupled to the first compartment. The second compartment includes a diesel particulate filter (DPF) mounted on a diesel particulate filter (DPF) fixture. The system also includes a control unit operatively coupled to the apparatus. The control unit is configured to obtain a plurality of properties associated with at least one of fluid and the diesel particulate filter (DPF) remotely, from a sensing unit, through a transceiver. The control unit is also configured to generate one or more commands by a programmable logic controller (PLC) for calibration of an operation of the apparatus in one or more modes based on a plurality of obtained properties. The system also includes a fluid supply unit operatively coupled to the apparatus. The fluid supply unit is configured to supply the fluid to clean the diesel particulate filter (DPF) for a predefined period based on one or more generated commands.
[0014] FIG. 1 is a schematic representation of a system (100) for cleaning a diesel particulate filter in accordance with an embodiment of the present disclosure. The system (100) includes an apparatus (110). As used herein, the term ‘apparatus’ is defined as an equipment which includes two separate enclosures, wherein the equipment is designed to serve a specific function by performing one or more operations. The apparatus (110) as described herein ,may be installed at one or more service centers to effectively clean the diesel particulate filter (DPF) (112)in order to get rid of the ash and soot present in the DPF (112).The apparatus (110) includes a first compartment (115) which includes a tank (118) configured to hold fluid.In one embodiment, the tank (118)may include an inlet pipe (120)for supplying the fluid in the tank (118). In another embodiment, the tank (118) may include an outlet pipe (122) to drain the fluid from the tank (118). In one embodiment, the first compartment (115) may include a heating coil (125) operatively coupled to the tank (118), wherein the heating coil (125) is configured to heat the fluid stored in the tank (118). In such embodiment, the heating coil (125) may include at least a copper heating coil, a nickel and chromium(nichrome) heating coil, a kanthal (FeCrAl) heating coil or a cupronickel (CuNi) heating coil.
[0015] The apparatus (110) also includes a second compartment (128) operatively coupled to the first compartment (115). The second compartment (128) includes a diesel particulate filter (DPF) (112) mounted on a diesel particulate filter (DPF) fixture (130). As used herein, the term ‘diesel particulate filter (DPF)’refers to a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine. In one embodiment, the DPF (112) may include a first end (132) configured to supply the fluid into the DPF, wherein the fluid may include at least one of air and water. In some embodiment, the first end may include an outlet end of the DPF, which is connected at a top surface of the DPF through a connector. In another embodiment, the DPF may include a second end (134) configured to enable release of diesel particulate matter from the DPF (112). In such embodiment, the second end (134) may include an inlet end connected at a bottom surface of the DPF (112). In one embodiment, the DPF fixture (130) may include an adjustable fixture.
[0016] The system (100) also includes a control unit (135) operatively coupled to the apparatus (110). The control unit (135) is configured to obtain a plurality of properties associated with at least one of fluid and the DPF (112) remotely, from a sensing unit, through a transceiver. In one embodiment, the control unit (135) may be remotely hosted on a cloud server. In such embodiment, the transceiver may communicate with sensing unit remotely through a wireless communication network. In some embodiment, the wireless communication network may include 2G, 3G, 4G, long term evolution (LTE), high speed downlink packet access (HSDPA), wireless fidelity (Wi-Fi), Bluetooth, Zigbee, Low Power wide area network (LP-WAN) and the like. In another embodiment, the control unit (135) may be locally mounted on the apparatus (110). In one embodiment, the plurality of properties associated with the fluid and the DPF (112) may include at least one of water-flow level, pressure of the air, pressure of the water, back pressure of the DPF (112), temperature of the water and temperature of the air.
[0017] In some embodiment, the sensing unit may be configured to sense a corresponding plurality of properties associated with the at least one of the fluid and the DPF (112). In such embodiment, the sensing unit may include at least one of a temperature sensor (138), a pressure sensor (138) and a water-level sensor (138). In some embodiment, the temperature sensor (138) may be coupled with the tank (118) and an outlet side piping of the DPF (112). In such embodiment, the temperature sensor (138) may be used to sense the temperature of the fluid. In another embodiment, the pressure sensor (138) may be used to sense the pressure generated across the DPF (112). In some embodiment, the pressure sensor (138) may also be used to sense the pressure generated by the fluid. In one embodiment, the water-level sensor (138) may be coupled with the tank (118) to detect level of one or more substances of the fluid which may tend to flow.
[0018] The control unit (135) is also configured to generate one or more commands by a programmable logic controller (PLC) (140) for calibration of an operation of the apparatus (110) in one or more modes based on a plurality of obtained properties. In one embodiment, the one or more modes may include a manual mode of operation. In another embodiment, the one or more modes may also include an automatic mode of operation. In such embodiment, the control unit (135) may also include a miniature circuit breaker (MCB) (142) for the automatic mode of operation to protect an electrical circuit from damage caused by excess current from an overload or short circuit. The control unit (135) is also configured to monitor, and control data stored in a database remotely, upon generation of the one or more commands, by using a telemetry or cloud-based technology, wherein the data is representative of the operation of the apparatus. In one embodiment, the control unit (135) may include one or more controllers (145) that communicate with the sensing unit to obtain one or more inputs corresponding to the plurality of properties associated with the at least one of the fluid and the DPF (112).In some embodiment, the control unit (135) may include a human machine interface (HMI) (148) to enable an operator to provide one or more requests manually.
[0019] The system (100) also includes a fluid supply unit (150) operatively coupled to the apparatus (110). The fluid supply unit (150) is configured to supply the fluid to clean the diesel particulate filter (DPF) (112) for a predefined period based on one or more generated commands. In one embodiment, the fluid supply unit (150) may include a compressor (152) operatively coupled to the second compartment (128). In such embodiment, the compressor (152) may be configured to supply air through a solenoid valve (155) into the DPF (112). The solenoid valve (155) opens, and closes based on amount of the air supplied by the compressor (152).
[0020] In some embodiment, the fluid supply unit (150) may also include a pump (160) operatively coupled to the tank (118). In such embodiment, the pump (160) is configured to circulate water into the DPF (112) through the solenoid valve (155) upon filtration by using at least two filters (162). In one embodiment, the pump (160) may include a water pump to pump the water through the at least two filters (162) and combines with the air supplied by the compressor (152). In some embodiment, the water pump (160) may generate a predefined pressure of 13 bars and a flow rate of 300 litre per minute (L/min). The pressure of the pump (160) is adjusted automatically by the one or more generated commands of the PLC based on the back pressure across the DPF (112)generated due to clogging so that the DPF (112) does not get exposed to excessive forces during a cleaning process which may either damage the DPF (112) or may push the DPF (112) out of the DPF fixture (130).
[0021] In one embodiment, the fluid supply unit (150) may also include a blower (165) operatively coupled to the second compartment (128). In such embodiment, the blower (165) is configured to supply hot air into the DPF (112) for drying. In one embodiment, the temperature of the hot air coming from the blower (165) may be controlled to ensure optimum drying of the DPF (112) so that the DPF (112) may be readily assembled on a vehicle upon drying.
[0022] In a specific embodiment, the system (100) further includes a verification subsystem (170) operatively coupled to the control unit (135). The verification subsystem (170) is configured to record the plurality of properties associated with the at least one of the fluid and the DPF (112). The verification subsystem (170) is also configured to estimate requirement of a cleaning process of the DPF (112) based on comparison of a plurality of recorded properties with a predetermined threshold limit of the plurality of properties associated with a reference DPF (112). As used herein, the term ‘predefined threshold limit’ is defined as a safety limit set in the PLC, so that any if any of the plurality of properties associated with the at least one of the fluid and the DPF (112) crosses beyond the safety limit, the apparatus (110) may be switched off to prevent any damage. In one embodiment, the cleaning process of the DPF (112) may include one or more phases, wherein the one or more phases may include at least one of a rinsing phase, a washing phase and a drying phase.
[0023] In a preferred embodiment, the system (100) further includes a report generation subsystem (180) operatively coupled to the verification subsystem (170). The report generation subsystem (180) is configured to generate at least one report for depicting values of the plurality of recorded properties. In such embodiment, the at least one report may be generated to alert one or more users regarding the plurality of recorded properties and the requirement of the cleaning process of the DPF. In such embodiment, at least one generated report may be printed by using a printer.
[0024] In operation, the system (100) for cleaning the DPF is shown is utilized to clean the apparatus (110) which includes the DPF (112) in order to get rid of the ash and the soot present in the DPF (112). The apparatus (110) for performing one or more operations uses a combination of the fluid such as the air and the water at a relatively low pressure in conjunction with a cleaning solvent to remove both the ash and the soot from the DPF (112). The apparatus (110) is automated and once the DPF (112) is equipped on the apparatus (110) in a designed enclosure, the cleaning process is performed with minimal intervention from the operator.
[0025] The apparatus (110) initially measures the backpressure of the DPF (112) by using the pressure sensor (138). Once, the backpressure is recorded, estimation of the requirement of the cleaning process is checked to initiate the cleaning process. To initiate the cleaning process, firstly, a rinsing phase is performed, wherein only the water stored in the tank (118) is supplied to the DPF (112). The water stored in the tank (118) is heated by using the heating coil and such heated water is supplied to the pump (160). The pump (160) upon completion of filtration of the heated water using the at least two filter units (162), circulates the heated water to the DPF (112) through the solenoid valve (155). The rinsing phase is performed for approximately 3-5 minutes time interval.
[0026] The solenoid valve (155) opens, and closes based on the pressure of the fluid coming from the compressor (152) and the pump (160). Once, the rinsing phase is completed, a washing phase is followed, wherein both the water and the air is used to clean the DPF (112). Here, the pressurized reverse osmosis (RO) water and the air may be pressurized air. The washing phase includes multiple washing cycles of predefined time intervals such as 20 seconds each. Here, the compressor (152) supplies the pressurized air into the DPF (112) through the solenoid valve (155) for the predetermined time interval of 5-7 seconds in each of the 20 second washing cycles. Also, the water from the pump is mixed with the pressurized air. The mixture of the RO water and the pressurized air at about 6 bar pressure dislodges the soot and ash from the inlet end (130) of the DPF (112) which is at the bottom surface facing the tank (118). The washing phase is performed for approximately 30-40 mins.
[0027] Again, the drying phase is followed by the washing phase, wherein only the hot air from the blower (165) is supplied through the DPF (112). The drying phase continues for approximately 15-20 minutes. Once, the drying phase is completed, the backpressure across the DPF (112) is again recorded. If the backpressure is normally 50mbar, then the DPF (112) needs to be again cleaned, if the backpressure is above 100mbar, then such reading indicates that the DPF (112) is heavily clogged and needs to be cleaned in multiple cycles. Also, if the backpressure is normally below 10 mbar, then such reading indicates that the DPF (112) is properly cleaned and upon complete drying, may be fitted on the DPF fixture (130).
[0028] Various embodiments of the present disclosure provide the apparatus which may be installed at the vehicle service centers and is used to effectively clean the DPF to get rid of the ash and also the soot present in the DPF.
[0029] Moreover, the present disclosed system enables remote monitoring and controlling the cleaning process of the DPF using cloud-based and telemetry-based technology.
[0030] Furthermore, the present disclosed system provides the apparatus in which cleaning fluid is re-circulated and used for multiple cleanings, wherein the cleaning fluid is filtered using set of high efficiency filters and re-used for subsequent cleaning cycles.
[0031] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[0032] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[0033] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.