Senior Design:Diesel Soot Filter Measurement

Cummins 1:

Tedrick Rollings

Jonathan Whitaker

Partius Robinson

Michael Erhardt

Agenda

1. Problem Description1. Problem Description

3. Industry Solution3. Industry Solution

4. Research Project 4. Research Project

5. Conclusion 5. Conclusion

2. Project Outline/Progress Diagram2. Project Outline/Progress Diagram

Problem Description

• We are required to design a sensor or a similar system capable of measuring the amount of soot in a diesel soot filter. The sensor has to be able to operate with a soot filter with the following specifications:

– 8 mm wall thickness– 200 cells per unit inch– manufactured with cordierite– Accuracy = +/- 0.5 g of soot per liter of filter.

Project Outline

• Industry Solutions– Horiba-Engine Measurements

• Correspondence• Executive Summary + Proposal

Report– Argonne National Laboratory

• Correspondence• Executive Summary + Proposal

Report– NGK Insulators

• Correspondence• Executive Summary + Proposal

Report

• Research Proposal/Solution– Filter Heat-Soot Correlation

Method• Overall Concept• Thermodynamic Modeling• Test Setup• Desired Results• Advanced Temperature

Measurement Research

Methods of Measuring

Diesel Soot in DPF

Short Term Solutions

Long Term Research

Horiba-Engine Measurements

Argonne National

Laboratory

Segmented Filter

Temperature Measurement

Method

Correspondence

Executive Summary +

Proposal Report

Correspondence

Executive Summary +

Progress Report

Correspondence

Executive Summary +

Progress Report

Overall Concept

Thermodynamic Modeling

Test Setup

Desired Results

Advanced Temperature Measurement

Research

Progression Diagram

Phase 1Phase 1 Phase 2Phase 2 Phase 3Phase 3

•Combination of the two ideals

•Finalization of project

•Long term project research

•Thermodynamic formulization

•Segmented filter calculations

•Industry interaction and research

•Short term project research

•Collection of ideas

Industry Solutions

Cummins Diesel Engine MeasurementProject

HoribaEngine

Measurements

ArgonneNational

Labs

NGKInsulators

Horiba -Engine Measurements

Filter is placed analyzer's furnace and heated in N2 gas flow.

SOF and sulfate vaporized by heat in N2 atmosphere

Vaporized sulfate is deoxidized to SO2 by heat, measured by SO2 detector.

Organic components oxidized by O2 , measured as CO2 by NDIR detector.

Output of CO2 detector is integrated while O2 is flowing to determine soot mass.

Vaporization and oxidation/deoxidation technique

Horiba -Engine Measurements

Mexa-1370 PM

Measures soot, sulfate, and total particulate matter in diluted engine exhaust gas

1370 Analyzer and Data Processor

Complications• Multiple Part Analysis•Size Issues (2.3 x 1.8 x 2.7 ft)•4 Minute Analysis

Argonne National Laboratory

Real-Time Portable Exhaust Analyzer

Laser-Induced Incandescence

Can measure Mean size of the particles Number of particles per

cubic centimeter

Correlate Exhaust Particle Size/Number and Filter Fullness

Argonne – Trans. Tech R&D

• Thermophoretic sampling to study diesel PM.

• High-Res transmission electron microscope (TEM)– Data recording – Analysis.

• Better understand PM– Density– Weight – Specific heat capacity

TEM Clip of Diesel Particulate Matter

NGK Insulators, Ltd

•Pressure Drop of Segmented Diesel Particulate Filter

Uses the flow resistance of a segmented Diesel particulate filter.

Given identical monolithic and segmented filters:

• Segmented:– Holds lower filtration wall area – Reduces the filter open frontal area

• Resulting in:– Higher flow resistance– Increase in the filter pressure drop

• 15% Reduction in Filtration Area = 400 Pa Pressure Drop

Segmented Filter

Research Project/Proposal

Cummins

Cummins

Cummins

CumminsCummins

Filter Heat-SootCorrelation Method

Conceptual Designs

ConstantAppliedVoltage

Ammeter(Measures Current)

Wiring

Particulates (Soot)

CordieriteFilter

Power Supply(Supplies Voltage)

Vehicle Stack

Exhaust • Concept #1: Force Measuring System

• Idea #2: Continuous Dilution Method

• Idea #3: Temperature Monitoring

• Idea #4: Particulate Measurement through Electrical Current Analysis

• Idea #5: Incandescence Soot Measurement

Decision Matrix

• Decision Matrix– Factor quantifying system:

• 1 – Very Poor 2 – Poor 3 – Average 4 – Good 5 – Excellent – Largest Total: Most reasonable idea– “Filter Heat-Soot Correlation Method” was selected to be the most

possible idea using the decision matrix.

Cost

Production

Time

Idea

Complexity

Mass

Production

Specific

Factors

1 3 4 3 4 3 17

2 1 2 3 4 2 12

3 5 4 5 4 3 21

4 3 3 4 3 4 17

5 1 3 2 3 4 13

Concept #

FACTORS (1 - 5)

TOTAL

Filter Heat-Soot Correlation Method

• Thermodynamic Background– Thermal Exchanger

System– Thermal Conductivity

• Thermodynamic Project Application– Specific Heat Capacity– ***Special Thanks to

Dr. Chiang Shih and Dr. Juan Ordonez

Thermodynamic Model

• Simplified gradual representation of diesel particulate filter system

Experimental Research Setup

• Preliminary Experiment– Specific Heat Capacity

of Diesel Soot– Specific Heat Capacity

of Diesel Particulate Filter

• Main Experiment– Simulated Exhaust

System

Experimental Research Procedure

• Assemble Test Equipment

• Assemble Temperature Monitoring Equipment

• Prepare Mass Measurement Equipment

• Phase I Experimental Procedure

• Phase II Experimental Procedure

Simulated Data Results

Soot Content-Specific Heat Correlation

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

5.5

6

6.5

7

7.5

8

8.5

9

9.5

10

10.5

01234567891011121314

Specific Heat (kJ/K)

So

ot

Co

nte

nt

(g)

Challenges Faced

• Extraneous Factors– Pressure– Geometry– Altered Density– Non-Constant Mass

• Long Term Temperature Measurement– K-Thermocouple

Failure

Long Term Solution:Temperature Measuring Devices

• Type K thermocouples

• Composed of a positive Chromel wire and a negative Alumel wire.

• Most popular thermocouple

• Wide measurement range

• Good temp. precision.

Long Term Temp. Cont.Stabilized Type K Thermocouples

• Controls drift for more stabilized temperature readings for extended periods of time.

• Can survive temperature readings of -145 to 2500°F.

• Not just heat treated, but reinforced by heat resistance material that locks in the heat calibration.

Type K Wire Thermocouple

Problems Encountered & Solutions

Lack of

Industry

ResponseInitia

l

Calculatio

n

Difficulty

Initial

Sponsor

Discontent Temp.

Measuring

Device

•Persistence

•More Persistence

•In-Depth

Research

•Collaboration

•Revised Plan of Action

•New Division of Labor

•More “realistic” goal setting

•Research and discovery of Type K Thermocouples

Conclusion

1. Cummins and other industry leaders aremaking progress towards a viable solution

1. Cummins and other industry leaders aremaking progress towards a viable solution

2. The research project/proposal is a viable solution to the problem at hand.

2. The research project/proposal is a viable solution to the problem at hand.

3. Goals were achieved…3. Goals were achieved…

Questions?

MichaelErhardt

JonathanWhitaker

PatriusRobinson

TedrickRollings

CumminsCumminsCumminsCummins