senior design: diesel soot filter measurement cummins 1: tedrick rollings jonathan whitaker partius...
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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