Title of Invention	AN EXHAUST SYSTEM HAVING HEATING ELEMENT TO INTRODUCE THERMAL ENERGY INTO AN EXHAUST AND A SELECTIVE CATALYST REDUCTION (SCR) UNIT TO FILTER NITROGEN OXIDES (NOX) FROM THE EXHAUST
Abstract	An exhaust system includes a heating element that is disposed downstream from an engine and that introduces thermal energy into an exhaust of the engine. A selective catalyst reduction (SCR) unit is disposed downstream from the heating element and filters nitrogen oxides (NOx) within the exhaust. A control module is in communication with and energizes the heating element based on temperature of the SCR unit.

Title of Invention

AN EXHAUST SYSTEM HAVING HEATING ELEMENT TO INTRODUCE THERMAL ENERGY INTO AN EXHAUST AND A SELECTIVE CATALYST REDUCTION (SCR) UNIT TO FILTER NITROGEN OXIDES (NOX) FROM THE EXHAUST

Abstract

An exhaust system includes a heating element that is disposed downstream from an engine and that introduces thermal energy into an exhaust of the engine. A selective catalyst reduction (SCR) unit is disposed downstream from the heating element and filters nitrogen oxides (NOx) within the exhaust. A control module is in communication with and energizes the heating element based on temperature of the SCR unit.

Full Text	1 SCR COLD START HEATING SYSTEM FOR A DIESEL EXHAUST FIELD [0001] The present disclosure relates to exhaust systems, and more particularly to emission reduction techniques associated therewith. BACKGROUND [0002] The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure. [0003] Exhaust systems for automobiles are used to filter and reduce the emission of nitrogen oxides (NOx). Several technologies have been developed to decrease NOx emissions. The technologies include passive methods that use catalysts and active methods, such as electrochemical catalysis and photocatalytical, plasma, and laser techniques. For example, rich-burning engines use a three-way catalyst to reduce NOx emissions. The three-way catalyst typically includes a combination of noble metals deposited on a stabilized alumina carrier. The three-way catalyst works with a feedback system that directs an engine to blend air and fuel in stoichiometric proportions. By controlling an air-to-fuel ratio of the engine, hydrocarbons (HCs) and carbon monoxide (CO) are produced to convert NOx and HCs to carbon dioxide, water, hydrogen gas, and/or nitrogen gas. [0004] The NOx reducing performance of the three-way catalyst, which is the standard NOx abatement technology for gasoline engines, deteriorates rapidly in the presence of oxygen. Thus, this technology is ineffective in controlling NOx emissions in lean exhaust gases. Approaches that control NOx emissions in lean-burn engines, i.e., engines such as diesel 2 engines that burn fuel in excess oxygen, include catalytic decomposition of nitrogen monoxide (NO) units and selective catalytic reduction (SCR) units. [0005] The decomposition of NOx in a diesel exhaust requires high activation energy and thus is inhibited. Therefore, a catalyst is necessary to lower this activation energy in order to facilitate the decomposition. Various catalysts have been used to decompose NOx, including precious metals, metallic oxides, zeolites-based catalysts and copper ion-exchanged zeolite. [0006] Although the use of a catalyst aids in the reduction of the activation energy, present diesel engines at startup and when moderately operated tend to exhibit cool exhaust temperatures. This delays effectiveness of an SCR unit. An SCR unit needs to reach a minimum operating temperature to effectively filter NOx. Typically, an SCR unit does not efficiently clean an exhaust until several minutes after an engine is started. SUMMARY [0007] Accordingly, an exhaust system is provided that includes a heating element that is disposed downstream from an engine and that introduces thermal energy into an exhaust of the engine. A selective catalyst reduction (SCR) unit is disposed downstream from the heating element and filters nitrogen oxides (NOx) within the exhaust. A control module is in communication with and energizes the heating element based on temperature of the SCR unit. [0008] In other features, a diesel exhaust system is provided and includes a heating element that is disposed downstream from a diesel engine and that introduces thermal energy into an exhaust of the diesel engine. A diesel oxidation catalyst is disposed downstream from the heating element and removes at least one of hydrocarbons and carbon monoxide from the exhaust. A selective catalyst reduction (SCR) unit is disposed downstream from the diesel oxidation catalyst and filters nitrogen oxides (NOx) within the exhaust. A control module is in communication with and energizes the heating element based on temperature of the SCR unit. 3 [0009] In still other features, a method of operating an exhaust system is provided and includes generating an engine startup signal. An electrically heated catalyst (EHC), which is disposed downstream from a diesel engine and that introduces thermal energy into an exhaust of the diesel engine, is energized based on the engine startup signal. Nitrogen oxides (NOx) within the exhaust system are filtered via a selective catalyst reduction (SCR) unit that is disposed downstream from the EHC. [0010] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. DRAWINGS [0011] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein: [0012] FIG. 1 is a functional block diagram of a portion of an exemplary diesel engine system incorporating a selective catalyst reduction heating system having an electrically heated catalyst (EHC) and a selective catalyst reduction (SCR) unit in accordance with an embodiment of the present invention; [0013] FIG. 2 is functional block diagram of another portion of the exemplary diesel engine system of FIG. 1; [0014] FIG. 3 is a thermal flow diagram of an exothermic reaction according to an embodiment of the present disclosure; and [0015] FIG. 4 is a logic flow diagram illustrating a method of operating an exhaust system in accordance with another embodiment of the present invention. 4 DETAILED DESCRIPTION [0016] The following description is merely exemplary in nature and is in no way intended to limit the disclosure, 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 execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical or. It should be understood that steps within a method may be executed in different order without altering the principles of the present disclosure. [0017] Referring to FIGs. 1-2, functional block diagrams of portions of an exemplary diesel engine system 10 of a vehicle 11 including a selective catalyst reduction (SCR) heating system 12 is shown. It is appreciated that the diesel engine system 10 is merely exemplary in nature and that the SCR heating system 12 described herein may be implemented in various engine systems that have a SCR unit. Such engine systems may include, but are not limited to, gasoline direct injection engine systems and homogeneous charge compression ignition engine systems. [0018] The engine system 10 includes a diesel engine 14, an air intake system 16, a fuel injection system 18, a glow plug system 20 (or ignition system when applied to a gasoline spark ignition engine), and an exhaust system 22. In a simplified embodiment, the SCR heating system 12 includes a control module 24, an SCR unit 26, and an electrically heated catalyst (EHC) 28. The EHC 28 is disposed upstream from the SCR unit 26. In more involved embodiments, the SCR heating system 12 may include the air intake system 16, the fuel injection system 18, the glow plug system 20, the exhaust system 22, and related elements, components and systems thereof. 5 [0019] The SCR heating system 12 heats the SCR unit 26 early in an engine startup process. This allows temperature of the SCR unit 26 to increase to an active operating temperature earlier in federal test procedure (FTP) cycles, which in turn reduces exhaust emissions. Traditional diesel engines startup and operate with cool exhaust temperatures. From initial startup until a time at which catalyst aftertreatment systems reach an active operating temperature, traditional exhaust systems are inefficient in preventing exhaust emissions. The time frame between startup and the point in time at which the exhaust system reaches efficient active operation can be several minutes. When operating at temperatures below the active operating temperature, which for some SCR units is approximately 200°C, untreated exhaust can be emitted. The embodiments disclosed and described herein increase the temperature of the aftertreatment systems quickly and early on in an engine startup to significantly reduce exhaust emissions. [0020] The engine 14 combusts an air/fuel mixture to produce drive torque. The engine 14 includes eight cylinders 40 configured in adjacent cylinder banks 42, 44 in V-type layout. Although Figure 1 depicts eight cylinders (N = 8), it can be appreciated that the engine 14 may include additional or fewer cylinders. For example, engines that have 2, 4, 5, 6, 8, 10, 12 and 16 cylinders are contemplated. It is also anticipated that the SCR heating system 12 may be implemented and associated with in an inline-type or another type of cylinder configuration. [0021] The air intake system 16 may include a throttle plate 46 and/or other air flow controlling devices 48. The throttle plate 46 may be located proximate to or in an intake manifold 50. The intake manifold 50 is mounted on the engine 14. [0022] The fuel injection system 18 may be in the form of a common rail fuel injection system, as shown. The fuel injection system 18 includes fuel injectors 52. Each fuel injector 52 is associated with one of the cylinders 40. The fuel system 18 provides fuel to engine 14, which may be mixed with air and ignited via compression and heat and/or by the glow plug system 20. 6 Ignition of the air/fuel mixture provides power for the engine 14 to propel the vehicle 11. [0023] The glow plug system 20 includes glow plugs 60 (or spark plugs when applied to a gasoline spark ignition engine). Glow plugs 60 may be used on a diesel engine to initiate an ignition processes during startup. The purpose of the glow plug system 20 is to pre-heat the cylinders 40 or to pre-heat combustion pre-chambers in an indirect injection engine for easier starting when the engine 14 is cold. [0024] A switch 62 starts the operation of control module 24. The switch 62 may be an ignition switch, a manually controlled switch, a control switch, a solid-state switch, a switch within the control module 24, or some other switch. The control module 24 cranks the engine 14 by signaling a starter 64 to turn a flywheel 66, which cranks a crankshaft 68. The crankshaft 68 operates a timing chain 70, which turns camshafts 72. The control module 24 synchronizes the SCR heating system 12, the engine 14, the air intake system 16, the fuel system 18 and the glow plug system 20. The control module 24 may use timing sensors 80, such as crankshaft position and camshaft position sensors 82 to determine locations of pistons 84 within each of the cylinders 40, as well as to determine ignition stroke timing and other timing parameters. The positions of the crankshaft 68 and camshafts 72 may determine the position of each piston 84 in each of the cylinders 40. In general, the position of the camshafts 72 determines whether the pistons 84, in each of the cylinders 40, are on an intake or a compression stroke. [0025] Air is drawn into the intake manifold 50 across the throttle plate 46. Air is drawn into the cylinders 40 from the intake manifold 50 and is compressed therein. Fuel is injected into cylinders 40 by the fuel injection system 18 and thermal energy (heat) of the compressed air and/or from the glow plug system 20 ignites the air/fuel mixture. Exhaust gases are exhausted from the cylinders 40 into the exhaust system 22. In some instances, the engine system 10 can include a turbocharger 88 that uses an exhaust driven turbine 90 to drive a compressor 92 that compresses the air 7 entering the intake manifold 50. The compressed air typically passes through an air cooler before entering into the intake manifold 50. [0026] In a 4-stroke cycle engine, as illustrated for an embodiment of the present invention, each piston 84 has four strokes: an intake stroke, a compression stroke, an expansion or power stroke, and an exhaust stroke. The positions of the crankshaft 68 and camshafts 72 allow the control module 24 to determine when a piston is beginning an intake stroke or ending a compression stroke. When a piston is near the beginning of an intake stroke the control module 24 signals the fuel injectors 52 to operate. The fuel injectors 52 inject fuel into the intake manifold 50, which is followed by the engine cylinders 40. Although the fuel is described as being injected into the intake manifold 50, it may also be directly injected into the cylinders 40. When ending a compression stroke heat within the cylinders 40 ignites the air/fuel mixture, which was allowed to enter the engine cylinder during the intake stroke, to create a power stroke to drive the crankshaft 68. After the fuel has been ignited in an engine cylinder, resulting exhaust is released on the exhaust stroke through exhaust system 22. [0027] The exhaust system 22 includes exhaust manifolds 100, 102, exhaust conduits 96, 104, 106 and the SCR heating system 12, which for the embodiment shown may be referred to as or included as part of a diesel exhaust filtering system. The exhaust manifolds 100, 102 direct the exhaust exiting the corresponding cylinder banks 40, 44 into the exhaust conduits 96, 104, 106. Optionally, an EGR valve 110 may recirculate a portion of the exhaust back into the intake manifold 50. The remainder of the exhaust is directed into the turbocharger 88 to drive the turbine 90. The turbine 90 facilitates the compression of the fresh air received from the intake manifold 50. A combined exhaust stream flows from the turbocharger 88 through the exhaust conduit 96. 8 [0028] The filtering system 12 includes the SCR unit 26, the EHC 28, a mixer 120, a diesel oxidizing catalyst (DOC) 122, and a gaseous or liquid reductant injector system 124. The mixer 120 is disposed upstream from the SCR unit 26. The DOC 122 is disposed upstream from the mixer 120. The EHC 28 is disposed upstream from the DOC 122. The positional order shown of the SCR unit 26, the EHC 28, the mixer 120, and the DOC 122 is for example purposes only, other arrangements may be implemented. For the example shown, the SCR unit 26 and the mixer 120 are part of and packaged within a first canister 128. The EHC 28 and DOC 122 are part of and packaged within a second canister 130. The second canister 130 is disposed upstream from the first canister 128 and is coupled between the turbine 90 and the first canister 128. [0029] The DOC 122 may have a core substrate with multiple layers including one or more catalyst layers and a washcoat layer, which increases surface area of the core substrate. The core substrate may be formed of a honeycomb of ceramic or stainless steel and coated with one or more precious metals. Examples of precious metals are platinum, palladium, rhodium, cerium, iron, manganese, nickel, and copper. The washcoat may include silicon or aluminum. [0030] The reductant injector system 124 includes a reagent tank 140, a filter 142, and a pump 144. The reagent tank 140 holds a reagent, such as ammonia or urea, which is filtered and pumped into the exhaust upstream from the SCR unit 26 via a reagent injector 146. The reagent mixes with the exhaust gas and decomposes prior to passing through at least one exhaust catalyst bed in the SCR unit 26. Once in the exhaust the reagent vaporizes, mixes with oxides of nitrogen and passes over a catalyst, which turns ozone-forming oxides on nitrogen (NOx) into water, nitrogen and carbon dioxide CO2. The exhaust gas may be mixed by means of the mixer prior to passing through to the SCR catalyst beds. There may be multiple catalyst layers within the first canister 128 to ensure adequate NOx conversion. The SCR catalyst beds may be based on titanium oxide with additions of metal 9 oxides such as, for example, vanadium, molybdenum, tungsten oxide, and/or zeolite, which reacts with the ammonia and NOx to form environmentally harmless nitrogen, oxygen, and water. The SCR catalyst beds may alternatively be based on other materials as is commonly known in the art. [0031] The control module 24 regulates operation of the diesel engine system 10 including management of the SCR heating system 12, the air intake system 16, the fuel injection system 18, the glow plug system 20 and the exhaust system 22. For this reason, the control module 24 is considered part of each of the systems 16, 18, 20, 22. The control module 24 manages the diesel engine system 10 to quickly and efficiently increase the temperatures of the exhaust system 22, including temperatures of the DOC 122 and the SCR unit 26, upon engine startup. In one embodiment, the control module 24 supplies current to the EHC 28 upon engine startup. In another embodiment of the present invention, the control module 24 supplies current to the EHC 28 prior to engine startup. The control module 24 may predict, estimate, and/or determine that a startup procedure is to begin in the near future, such as in approximately 1-3 minutes. When it is determined that a startup procedure is to occur, the control module 24 may preheat the EHC 28, thereby allowing for the SCR unit 26 and the DOC 122 to more quickly increase in temperature upon startup. [0032] Current to the EHC 28 is controlled and provided via the control module 24, switches 148 and a power source 150 to begin a heating process. The current from the power source 150 may be supplied directly to the EHC 28, as shown, or supplied to the control module 24 prior to being received by the EHC 28. The duration of the heating process varies. It is anticipated, that the heating process can last between 1-4 minutes. More specifically, electric energy heats the EHC 28 for a threshold period (e.g., 1-3 minutes). Exhaust passing through the EHC 28 is heated. [0033] Referring now also to FIG. 3 in which a thermal flow diagram of an exothermic reaction is shown. The thermal flow diagram illustrates an EHC exhaust energy leveraging technique. The EHC 28 performs as a low 10 mass catalyzed heating element and igniter. The EHC 28 heats and/or ignites exhaust, represented by arrow 160, which is passed into the DOC 122. The exhaust 160 includes combustion products, such as hydrogen (H2), hydrocarbons (HC), carbon monoxide (CO) and oxygen (02). Electrical energy in the form of current, represented by arrow 162, is provided to the EHC 28. The current 162 increases the temperature of the EHC 28, which increases thermal energy of the exhaust 160 to generate a first activation energy q1 exotherm and a second activation energy q2 that is electric based. The first activation energy q1 exotherm represents the exothermic energy of the exhaust products. The first activation energy q1 and the second activation energy q2 are represented by arrows 164 and 166. The DOC 122 performs as a catalytic combustor. [0034] The first activation energy q1 and the second activation energy q2 are provided to and activate the DOC 122, which provides a large thermal output, which is represented by a third activation energy q3 exotherm arrow 168. Thermal energy out of the DOC 122 is significantly larger than that out of the EHC 28. The large thermal output quickly increases temperature of the SCR unit 26. The above thermal reaction may be referred to as a fast converter light off, which provides low cold start emissions. In other words, emission output is decreased due to quick and efficient increase in DOC and SCR unit temperatures. [0035] As an example, the temperature of the EHC 28 may be equal to a start temperature S, of the exhaust plus the energy E, added to the EHC 28 divided by the exhaust mass Em minus heat loss H,, as provided by equation 1. [0036] The energy added to the EHC E, divided by the exhaust mass £ equals the voltage V across terminals of the EHC 28 multiple by the 11 current C supplied to the EHC 28 and the amount of time that current is supplied to the EHC 28, divided by the mass EHCm of the EHC, as shown by equation 2. [0037] Since the mass EHCm and electrical resistance of the EHC 28 are constant the energy added E, divided by the exhaust mass Em may be set equal to a first constant AT, multiplied by the square of the voltage V multiplied by time T, as provided in equation 3. [0038] Heat loss may be set equal to a second constant K2 multiplied by exhaust flow Ef multiplied by the start temperature S,, as provided in equation 4. The exhaust flow Ef is measured in flow units per unit time. [0039] The control module 24 may have a central processing unit, memory (RAM and/or ROM), and associated input and output buses or be of some other module form. The control module 24 may be a portion of a central vehicle main control unit, an interactive vehicle dynamics module, a power control module, an ignition controller, a control circuit having a power supply, combined into a single integrated controller, or may be a stand-alone controller as shown. [0040] The diesel engine system 10 may include various sensors 170, which may be part of or shared by the SCR heating system 12, the air intake system 16, the fuel injection system 18, the glow plug system 20, the exhaust system 20 or other vehicle systems. The sensors 170 may include the timing sensors 80, as well as intake and exhaust sensors 172, air and fuel sensors 174, and other vehicle sensors. 12 [0041] The intake and exhaust sensors 172 may include temperature sensors 180, such as an EHC temperature sensor 182 and an SCR temperature sensor 184. The intake and exhaust sensors 172 may also include an EHC current sensor 186, pressure sensors 188, flow sensors 190, oxygen sensors 192, NOx sensors 194, and other exhaust sensors. The air and fuel sensors 174 may include air and fuel pressure sensors 196, air and fuel flow sensors 198 and other air and fuel sensors. The timing sensors 80, in addition to the crankshaft and camshaft sensors 82, may include a transmission sensor, a drivetrain sensor, or some other timing sensor. The sensors 170 may be used for status determination and control of the diesel engine system 10. The control module 24 determines when exhaust heating is to be performed and controls engine operation to facilitate efficient heating based on information received from the sensors 170. [0042] Referring now to Figure 4, a flow chart illustrating a method of operating an exhaust system is shown. A control routine used to manage performance of the described method may be executed by the control module of FIGs. 1-2. Although the following steps are primarily described with respect to the embodiments of FIGs. 1 and 2, they may be easily applied to and/or modified for other embodiments of the present invention. [0043] In step 200, the EHC 28 may be preheated prior to engine startup. The control module 24 may receive an engine startup signal and based thereon activate the SCR heating system 12 and supply current to energize the EHC 24. The startup signal may be based on state of the switch 62. [0044] In step 202, the engine 14 is started. Air-intake, fuel, and glow plug systems are initialized. The control module 24 determines the position of the crankshaft 68 and the camshafts 72 using the crankshaft and camshaft sensors 82. Ignition reference and injection reference engine cylinders are determined in response to the crankshaft and camshaft positions, respectively. The ignition reference engine cylinder is that in which a piston is nearing the end of a compression stroke. The injection reference 13 cylinder is that in which the piston is nearing the beginning of an intake stroke. Synchronization values, such as an ignition system synchronization value, a fuel system synchronization value, air flow synchronization values, and other synchronization values, may be determined. The synchronization values may be determined based on the positions of the crankshaft 68 and camshafts 72. [0045] In step 204, the SCR heating system 12 is activated when not previously activated, such as in step 200. [0046] In step 206, the control module 24 reduces and/or minimizes exhaust flow. An EHC start-up strategy algorithm may be enabled to reduce exhaust flow and improve heating performance of the EHC 28. To reduce exhaust flow, the control module 24 may generate lean fuel pulses prior to top dead center of the pistons 84. The control module 24 may also reduce air intake, via the air intake system 16. When an idle air control valve is utilized, position thereof may be adjusted. The revolutions-per-minute (RPM) of the engine 14 may be reduced, which reduces exhaust flow and allows the EHC 28 to heat up more quickly. The EHC 28 may be heated to approximately 400-500°C. [0047] In step 208, the control module 24 receives or generates an EHC temperature signal. The EHC temperature signal may be generated directly by the EHC sensor 182 or generated indirectly. When generated indirectly, the EHC temperature signal may be estimated or determined based on temperature of the exhaust, flow of the exhaust, power supplied to the EHC 28, or other parameters. [0048] In step 210, when the EHC 28 reaches a predetermined temperature, the control module 24 proceeds to steps 212 and 214. The predetermined value is associated with a temperature at which exhaust product are consumed. In step 212, the control module 24 deenergizes the EHC 28. 14 [0049] In step 214, an exhaust exothermic energy control strategy is initiated to increase production output of exhaust products, such as hydrocarbons and carbon monoxide, of the engine 14. The air intake system 16 and the fuel injection system 18 are adjusted to increase exhaust product output. For example, air intake and fuel injection may be increased. As another example, the fuel to air ratio may be increased to provide a rich intake pulse in the associate engine cycle, such as prior to top-dead-center of a piston cycle. Fuel may also be injected in an exhaust stroke to increase exhaust product output. The exhaust products generate an exothermic reaction when in contact with a heated element and/or a hot catalyst. This reaction generates a large amount of thermal energy that enables exhaust aftertreatment technologies to operate efficiently and sooner. The heated exhaust through the EHC 28 enables the DOC 122 and the SCR unit 26 to become fully active. [0050] In step 216, an SCR temperature signal is generated. The SCR temperature signal may be directly generated via the SCR temperature sensor or indirectly. The SCR temperature may also be indirectly estimated or determined based on temperature of the exhaust, flow of the exhaust, power supplied to the EHC 28, or other parameters. When the SCR unit 26 reaches a second predetermined temperature, such as approximately 200°C, the SCR unit 26 is in an active state. When the temperature of the SCR unit 26 is less than 200°C, the SCR unit 26 is in an inactive state or partially active state. [0051] In step 218, when the SCR unit 26 reaches the second predetermined temperature, the control module 24 proceeds to steps 220. In step 220, the exhaust product output may be decreased to provide a normal output for a current engine operating or driving condition. In step 222, when the SCR unit 26 reaches the second predetermined temperature, a gaseous and/or liquid reductant injection may be initiated into the exhaust via the reductant injector system 124. 15 [0052] The above-described steps are meant to be illustrative examples; the steps may be performed sequentially, synchronously, simultaneously, or in a different order depending upon the application. Note that one or more of the above-steps may be repeated or performed during operation of the engine when temperature of the SCR unit 26 drops below or is below the second predetermined temperature. As such, the control module 24 operates the SCR heating system 12 to maintain the SCR unit 26 at the second predetermined temperature. This maintains efficient and effective filtering of the exhaust system 22. [0053] The above-disclosed embodiments include integrated engine control and leverage exhaust energy to provide low tailpipe emissions during and upon startup of an engine. [0054] Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification, and the following claims. 16 CLAIMS What is claimed is: 1. An exhaust system comprising: a heating element that is disposed downstream from an engine and that introduces thermal energy into an exhaust of said engine; a selective catalyst reduction (SCR) unit that is disposed downstream from said heating element and that filters nitrogen oxides (NOx) within said exhaust; and a control module that is in communication with and that energizes said heating element based on a first temperature of said SCR unit. 2. The exhaust system of claim 1 wherein said control module energizes said heating element based on activation of said engine. 3. The exhaust system of claim 1 wherein said control module operates said engine to reduce flow of said exhaust based on a second temperature of said heating element. 4. The exhaust system of claim 3 wherein said control module determines said second temperature based on at least one of flow rate of said exhaust, power to said heating element, and exhaust temperature. 5. The exhaust system of claim 3 further comprising a temperature sensor generating a temperature signal, said control module determining said second temperature based on said temperature signal. 6. The exhaust system of claim 1 wherein said control module deenergizes said heating element based on temperature of said heating element and operates said engine to increase output of at least one of hydrocarbons and carbon monoxide. 17 7. The exhaust system of claim 6 further wherein said control module operates said engine to increase said output until said first temperature is greater than or equal to a predetermined temperature. 8. The exhaust system of claim 1 wherein said heating element includes an electrically heated catalyst. 9. The exhaust system of claim 1 further comprising a diesel oxidization catalyst disposed downstream from said heating element. 10. The exhaust system of claim 1 wherein said SCR unit includes a catalyst substrate that reduces activation energy of said exhaust. 11. A diesel exhaust system comprising: a heating element that is disposed downstream from a diesel engine and that introduces thermal energy into an exhaust of said diesel engine; a diesel oxidation catalyst that is disposed downstream from said heating element and that removes at least one of hydrocarbons and carbon monoxide from said exhaust; a selective catalyst reduction (SCR) unit that is disposed downstream from said diesel oxidation catalyst and that filters nitrogen oxides (NOx) within said exhaust; and a control module that is in communication with and that energizes said heating element based on a first temperature of said SCR unit. 12. The exhaust system of claim 11 wherein said control module energizes said heating element based on activation of said diesel engine. 18 13. The exhaust system of claim 11 wherein said control module energizes said EHC during a time period selected from at least one of a first time period and a second time period, wherein said first time period is prior to startup of said diesel engine and said second time period begins during a startup process of said diesel engine. 14. A method of operating an exhaust system comprising: generating an engine startup signal; energizing an electrically heated catalyst (EHC), which is disposed downstream from a diesel engine and that introduces thermal energy into an exhaust of said diesel engine, based on said engine startup signal; and filtering nitrogen oxides (NOx) within said exhaust system via a selective catalyst reduction (SCR) unit that is disposed downstream from said EHC. 15. The method of claim 14 wherein energizing said EHC is performed during a time period selected from at least one of a first time period and a second time period, wherein said first time period is prior to startup of said diesel engine and said second time period that begins during a startup process of said diesel engine. 16. The method of claim 14 further comprising: generating an EHC temperature signal; and reducing exhaust product generation based on said engine startup signal and said EHC temperature signal. 17. The method of claim 14 further comprising: generating an EHC temperature signal; and deenergizing said EHC based on said EHC temperature signal; 19 18. The method of claim 14 further comprising: generating an EHC temperature signal; and increasing exhaust product output of said diesel engine based on said EHC temperature signal. 19. The method of claim 18 further comprising: generating an SCR temperature signal; decreasing said exhaust product output based on said SCR temperature signal. 20. The method of claim 18 further comprising: generating an SCR temperature signal; and initiating at least one of gaseous reductant and liquid reductant injection into said exhaust based on said SCR temperature signal. An exhaust system includes a heating element that is disposed downstream from an engine and that introduces thermal energy into an exhaust of the engine. A selective catalyst reduction (SCR) unit is disposed downstream from the heating element and filters nitrogen oxides (NOx) within the exhaust. A control module is in communication with and energizes the heating element based on temperature of the SCR unit.

Full Text

1
SCR COLD START HEATING SYSTEM FOR A DIESEL EXHAUST
FIELD
[0001] The present disclosure relates to exhaust systems, and more
particularly to emission reduction techniques associated therewith.
BACKGROUND
[0002] The background description provided herein is for the
purpose of generally presenting the context of the disclosure. Work of the
presently named inventors, to the extent it is described in this background
section, as well as aspects of the description that may not otherwise qualify as
prior art at the time of filing, are neither expressly nor impliedly admitted as
prior art against the present disclosure.
[0003] Exhaust systems for automobiles are used to filter and
reduce the emission of nitrogen oxides (NOx). Several technologies have
been developed to decrease NOx emissions. The technologies include
passive methods that use catalysts and active methods, such as
electrochemical catalysis and photocatalytical, plasma, and laser techniques.
For example, rich-burning engines use a three-way catalyst to reduce NOx
emissions. The three-way catalyst typically includes a combination of noble
metals deposited on a stabilized alumina carrier. The three-way catalyst
works with a feedback system that directs an engine to blend air and fuel in
stoichiometric proportions. By controlling an air-to-fuel ratio of the engine,
hydrocarbons (HCs) and carbon monoxide (CO) are produced to convert NOx
and HCs to carbon dioxide, water, hydrogen gas, and/or nitrogen gas.
[0004] The NOx reducing performance of the three-way catalyst,
which is the standard NOx abatement technology for gasoline engines,
deteriorates rapidly in the presence of oxygen. Thus, this technology is
ineffective in controlling NOx emissions in lean exhaust gases. Approaches
that control NOx emissions in lean-burn engines, i.e., engines such as diesel

2
engines that burn fuel in excess oxygen, include catalytic decomposition of
nitrogen monoxide (NO) units and selective catalytic reduction (SCR) units.
[0005] The decomposition of NOx in a diesel exhaust requires high
activation energy and thus is inhibited. Therefore, a catalyst is necessary to
lower this activation energy in order to facilitate the decomposition. Various
catalysts have been used to decompose NOx, including precious metals,
metallic oxides, zeolites-based catalysts and copper ion-exchanged zeolite.
[0006] Although the use of a catalyst aids in the reduction of the
activation energy, present diesel engines at startup and when moderately
operated tend to exhibit cool exhaust temperatures. This delays effectiveness
of an SCR unit. An SCR unit needs to reach a minimum operating
temperature to effectively filter NOx. Typically, an SCR unit does not
efficiently clean an exhaust until several minutes after an engine is started.
SUMMARY
[0007] Accordingly, an exhaust system is provided that includes a
heating element that is disposed downstream from an engine and that
introduces thermal energy into an exhaust of the engine. A selective catalyst
reduction (SCR) unit is disposed downstream from the heating element and
filters nitrogen oxides (NOx) within the exhaust. A control module is in
communication with and energizes the heating element based on temperature
of the SCR unit.
[0008] In other features, a diesel exhaust system is provided and
includes a heating element that is disposed downstream from a diesel engine
and that introduces thermal energy into an exhaust of the diesel engine. A
diesel oxidation catalyst is disposed downstream from the heating element
and removes at least one of hydrocarbons and carbon monoxide from the
exhaust. A selective catalyst reduction (SCR) unit is disposed downstream
from the diesel oxidation catalyst and filters nitrogen oxides (NOx) within the
exhaust. A control module is in communication with and energizes the
heating element based on temperature of the SCR unit.

3
[0009] In still other features, a method of operating an exhaust
system is provided and includes generating an engine startup signal. An
electrically heated catalyst (EHC), which is disposed downstream from a
diesel engine and that introduces thermal energy into an exhaust of the diesel
engine, is energized based on the engine startup signal. Nitrogen oxides
(NOx) within the exhaust system are filtered via a selective catalyst reduction
(SCR) unit that is disposed downstream from the EHC.
[0010] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the description and
specific examples are intended for purposes of illustration only and are not
intended to limit the scope of the present disclosure.
DRAWINGS
[0011] The present disclosure will become more fully understood
from the detailed description and the accompanying drawings, wherein:
[0012] FIG. 1 is a functional block diagram of a portion of an
exemplary diesel engine system incorporating a selective catalyst reduction
heating system having an electrically heated catalyst (EHC) and a selective
catalyst reduction (SCR) unit in accordance with an embodiment of the
present invention;
[0013] FIG. 2 is functional block diagram of another portion of the
exemplary diesel engine system of FIG. 1;
[0014] FIG. 3 is a thermal flow diagram of an exothermic reaction
according to an embodiment of the present disclosure; and
[0015] FIG. 4 is a logic flow diagram illustrating a method of
operating an exhaust system in accordance with another embodiment of the
present invention.

4
DETAILED DESCRIPTION
[0016] The following description is merely exemplary in nature and
is in no way intended to limit the disclosure, 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 execute one or
more software or firmware programs, a combinational logic circuit, and/or
other suitable components that provide the described functionality. As used
herein, the phrase at least one of A, B, and C should be construed to mean a
logical (A or B or C), using a non-exclusive logical or. It should be understood
that steps within a method may be executed in different order without altering
the principles of the present disclosure.
[0017] Referring to FIGs. 1-2, functional block diagrams of portions
of an exemplary diesel engine system 10 of a vehicle 11 including a selective
catalyst reduction (SCR) heating system 12 is shown. It is appreciated that
the diesel engine system 10 is merely exemplary in nature and that the SCR
heating system 12 described herein may be implemented in various engine
systems that have a SCR unit. Such engine systems may include, but are not
limited to, gasoline direct injection engine systems and homogeneous charge
compression ignition engine systems.
[0018] The engine system 10 includes a diesel engine 14, an air
intake system 16, a fuel injection system 18, a glow plug system 20 (or
ignition system when applied to a gasoline spark ignition engine), and an
exhaust system 22. In a simplified embodiment, the SCR heating system 12
includes a control module 24, an SCR unit 26, and an electrically heated
catalyst (EHC) 28. The EHC 28 is disposed upstream from the SCR unit 26.
In more involved embodiments, the SCR heating system 12 may include the
air intake system 16, the fuel injection system 18, the glow plug system 20,
the exhaust system 22, and related elements, components and systems
thereof.

5
[0019] The SCR heating system 12 heats the SCR unit 26 early in
an engine startup process. This allows temperature of the SCR unit 26 to
increase to an active operating temperature earlier in federal test procedure
(FTP) cycles, which in turn reduces exhaust emissions. Traditional diesel
engines startup and operate with cool exhaust temperatures. From initial
startup until a time at which catalyst aftertreatment systems reach an active
operating temperature, traditional exhaust systems are inefficient in
preventing exhaust emissions. The time frame between startup and the point
in time at which the exhaust system reaches efficient active operation can be
several minutes. When operating at temperatures below the active operating
temperature, which for some SCR units is approximately 200°C, untreated
exhaust can be emitted. The embodiments disclosed and described herein
increase the temperature of the aftertreatment systems quickly and early on in
an engine startup to significantly reduce exhaust emissions.
[0020] The engine 14 combusts an air/fuel mixture to produce drive
torque. The engine 14 includes eight cylinders 40 configured in adjacent
cylinder banks 42, 44 in V-type layout. Although Figure 1 depicts eight
cylinders (N = 8), it can be appreciated that the engine 14 may include
additional or fewer cylinders. For example, engines that have 2, 4, 5, 6, 8, 10,
12 and 16 cylinders are contemplated. It is also anticipated that the SCR
heating system 12 may be implemented and associated with in an inline-type
or another type of cylinder configuration.
[0021] The air intake system 16 may include a throttle plate 46
and/or other air flow controlling devices 48. The throttle plate 46 may be
located proximate to or in an intake manifold 50. The intake manifold 50 is
mounted on the engine 14.
[0022] The fuel injection system 18 may be in the form of a common
rail fuel injection system, as shown. The fuel injection system 18 includes fuel
injectors 52. Each fuel injector 52 is associated with one of the cylinders 40.
The fuel system 18 provides fuel to engine 14, which may be mixed with air
and ignited via compression and heat and/or by the glow plug system 20.

6
Ignition of the air/fuel mixture provides power for the engine 14 to propel the
vehicle 11.
[0023] The glow plug system 20 includes glow plugs 60 (or spark
plugs when applied to a gasoline spark ignition engine). Glow plugs 60 may
be used on a diesel engine to initiate an ignition processes during startup.
The purpose of the glow plug system 20 is to pre-heat the cylinders 40 or to
pre-heat combustion pre-chambers in an indirect injection engine for easier
starting when the engine 14 is cold.
[0024] A switch 62 starts the operation of control module 24. The
switch 62 may be an ignition switch, a manually controlled switch, a control
switch, a solid-state switch, a switch within the control module 24, or some
other switch. The control module 24 cranks the engine 14 by signaling a
starter 64 to turn a flywheel 66, which cranks a crankshaft 68. The crankshaft
68 operates a timing chain 70, which turns camshafts 72. The control module
24 synchronizes the SCR heating system 12, the engine 14, the air intake
system 16, the fuel system 18 and the glow plug system 20. The control
module 24 may use timing sensors 80, such as crankshaft position and
camshaft position sensors 82 to determine locations of pistons 84 within each
of the cylinders 40, as well as to determine ignition stroke timing and other
timing parameters. The positions of the crankshaft 68 and camshafts 72 may
determine the position of each piston 84 in each of the cylinders 40. In
general, the position of the camshafts 72 determines whether the pistons 84,
in each of the cylinders 40, are on an intake or a compression stroke.
[0025] Air is drawn into the intake manifold 50 across the throttle
plate 46. Air is drawn into the cylinders 40 from the intake manifold 50 and is
compressed therein. Fuel is injected into cylinders 40 by the fuel injection
system 18 and thermal energy (heat) of the compressed air and/or from the
glow plug system 20 ignites the air/fuel mixture. Exhaust gases are
exhausted from the cylinders 40 into the exhaust system 22. In some
instances, the engine system 10 can include a turbocharger 88 that uses an
exhaust driven turbine 90 to drive a compressor 92 that compresses the air

7
entering the intake manifold 50. The compressed air typically passes through
an air cooler before entering into the intake manifold 50.
[0026] In a 4-stroke cycle engine, as illustrated for an embodiment
of the present invention, each piston 84 has four strokes: an intake stroke, a
compression stroke, an expansion or power stroke, and an exhaust stroke.
The positions of the crankshaft 68 and camshafts 72 allow the control module
24 to determine when a piston is beginning an intake stroke or ending a
compression stroke. When a piston is near the beginning of an intake stroke
the control module 24 signals the fuel injectors 52 to operate. The fuel
injectors 52 inject fuel into the intake manifold 50, which is followed by the
engine cylinders 40. Although the fuel is described as being injected into the
intake manifold 50, it may also be directly injected into the cylinders 40.
When ending a compression stroke heat within the cylinders 40 ignites the
air/fuel mixture, which was allowed to enter the engine cylinder during the
intake stroke, to create a power stroke to drive the crankshaft 68. After the
fuel has been ignited in an engine cylinder, resulting exhaust is released on
the exhaust stroke through exhaust system 22.
[0027] The exhaust system 22 includes exhaust manifolds 100, 102,
exhaust conduits 96, 104, 106 and the SCR heating system 12, which for the
embodiment shown may be referred to as or included as part of a diesel
exhaust filtering system. The exhaust manifolds 100, 102 direct the exhaust
exiting the corresponding cylinder banks 40, 44 into the exhaust conduits 96,
104, 106. Optionally, an EGR valve 110 may recirculate a portion of the
exhaust back into the intake manifold 50. The remainder of the exhaust is
directed into the turbocharger 88 to drive the turbine 90. The turbine 90
facilitates the compression of the fresh air received from the intake manifold
50. A combined exhaust stream flows from the turbocharger 88 through the
exhaust conduit 96.

8
[0028] The filtering system 12 includes the SCR unit 26, the EHC
28, a mixer 120, a diesel oxidizing catalyst (DOC) 122, and a gaseous or
liquid reductant injector system 124. The mixer 120 is disposed upstream
from the SCR unit 26. The DOC 122 is disposed upstream from the mixer
120. The EHC 28 is disposed upstream from the DOC 122. The positional
order shown of the SCR unit 26, the EHC 28, the mixer 120, and the DOC
122 is for example purposes only, other arrangements may be implemented.
For the example shown, the SCR unit 26 and the mixer 120 are part of and
packaged within a first canister 128. The EHC 28 and DOC 122 are part of
and packaged within a second canister 130. The second canister 130 is
disposed upstream from the first canister 128 and is coupled between the
turbine 90 and the first canister 128.
[0029] The DOC 122 may have a core substrate with multiple layers
including one or more catalyst layers and a washcoat layer, which increases
surface area of the core substrate. The core substrate may be formed of a
honeycomb of ceramic or stainless steel and coated with one or more
precious metals. Examples of precious metals are platinum, palladium,
rhodium, cerium, iron, manganese, nickel, and copper. The washcoat may
include silicon or aluminum.
[0030] The reductant injector system 124 includes a reagent tank
140, a filter 142, and a pump 144. The reagent tank 140 holds a reagent,
such as ammonia or urea, which is filtered and pumped into the exhaust
upstream from the SCR unit 26 via a reagent injector 146. The reagent mixes
with the exhaust gas and decomposes prior to passing through at least one
exhaust catalyst bed in the SCR unit 26. Once in the exhaust the reagent
vaporizes, mixes with oxides of nitrogen and passes over a catalyst, which
turns ozone-forming oxides on nitrogen (NOx) into water, nitrogen and carbon
dioxide CO2. The exhaust gas may be mixed by means of the mixer prior to
passing through to the SCR catalyst beds. There may be multiple catalyst
layers within the first canister 128 to ensure adequate NOx conversion. The
SCR catalyst beds may be based on titanium oxide with additions of metal

9
oxides such as, for example, vanadium, molybdenum, tungsten oxide, and/or
zeolite, which reacts with the ammonia and NOx to form environmentally
harmless nitrogen, oxygen, and water. The SCR catalyst beds may
alternatively be based on other materials as is commonly known in the art.
[0031] The control module 24 regulates operation of the diesel
engine system 10 including management of the SCR heating system 12, the
air intake system 16, the fuel injection system 18, the glow plug system 20
and the exhaust system 22. For this reason, the control module 24 is
considered part of each of the systems 16, 18, 20, 22. The control module 24
manages the diesel engine system 10 to quickly and efficiently increase the
temperatures of the exhaust system 22, including temperatures of the DOC
122 and the SCR unit 26, upon engine startup. In one embodiment, the
control module 24 supplies current to the EHC 28 upon engine startup. In
another embodiment of the present invention, the control module 24 supplies
current to the EHC 28 prior to engine startup. The control module 24 may
predict, estimate, and/or determine that a startup procedure is to begin in the
near future, such as in approximately 1-3 minutes. When it is determined that
a startup procedure is to occur, the control module 24 may preheat the EHC
28, thereby allowing for the SCR unit 26 and the DOC 122 to more quickly
increase in temperature upon startup.
[0032] Current to the EHC 28 is controlled and provided via the
control module 24, switches 148 and a power source 150 to begin a heating
process. The current from the power source 150 may be supplied directly to
the EHC 28, as shown, or supplied to the control module 24 prior to being
received by the EHC 28. The duration of the heating process varies. It is
anticipated, that the heating process can last between 1-4 minutes. More
specifically, electric energy heats the EHC 28 for a threshold period (e.g., 1-3
minutes). Exhaust passing through the EHC 28 is heated.
[0033] Referring now also to FIG. 3 in which a thermal flow diagram
of an exothermic reaction is shown. The thermal flow diagram illustrates an
EHC exhaust energy leveraging technique. The EHC 28 performs as a low

10
mass catalyzed heating element and igniter. The EHC 28 heats and/or ignites
exhaust, represented by arrow 160, which is passed into the DOC 122. The
exhaust 160 includes combustion products, such as hydrogen (H2),
hydrocarbons (HC), carbon monoxide (CO) and oxygen (02). Electrical
energy in the form of current, represented by arrow 162, is provided to the
EHC 28. The current 162 increases the temperature of the EHC 28, which
increases thermal energy of the exhaust 160 to generate a first activation
energy q1 exotherm and a second activation energy q2 that is electric based.
The first activation energy q1 exotherm represents the exothermic energy of
the exhaust products.
The first activation energy q1 and the second activation energy q2 are
represented by arrows 164 and 166. The DOC 122 performs as a catalytic
combustor.
[0034] The first activation energy q1 and the second activation
energy q2 are provided to and activate the DOC 122, which provides a large
thermal output, which is represented by a third activation energy q3 exotherm
arrow 168. Thermal energy out of the DOC 122 is significantly larger than
that out of the EHC 28. The large thermal output quickly increases
temperature of the SCR unit 26. The above thermal reaction may be referred
to as a fast converter light off, which provides low cold start emissions. In
other words, emission output is decreased due to quick and efficient increase
in DOC and SCR unit temperatures.
[0035] As an example, the temperature of the EHC 28 may be equal
to a start temperature S, of the exhaust plus the energy E, added to the EHC
28 divided by the exhaust mass Em minus heat loss H,, as provided by
equation 1.

[0036] The energy added to the EHC E, divided by the exhaust
mass £ equals the voltage V across terminals of the EHC 28 multiple by the

11
current C supplied to the EHC 28 and the amount of time that current is
supplied to the EHC 28, divided by the mass EHCm of the EHC, as shown by
equation 2.

[0037] Since the mass EHCm and electrical resistance of the EHC
28 are constant the energy added E, divided by the exhaust mass Em may be
set equal to a first constant AT, multiplied by the square of the voltage
V multiplied by time T, as provided in equation 3.

[0038] Heat loss may be set equal to a second constant K2
multiplied by exhaust flow Ef multiplied by the start temperature S,, as
provided in equation 4. The exhaust flow Ef is measured in flow units per unit
time.

[0039] The control module 24 may have a central processing unit,
memory (RAM and/or ROM), and associated input and output buses or be of
some other module form. The control module 24 may be a portion of a
central vehicle main control unit, an interactive vehicle dynamics module, a
power control module, an ignition controller, a control circuit having a power
supply, combined into a single integrated controller, or may be a stand-alone
controller as shown.
[0040] The diesel engine system 10 may include various sensors
170, which may be part of or shared by the SCR heating system 12, the air
intake system 16, the fuel injection system 18, the glow plug system 20, the
exhaust system 20 or other vehicle systems. The sensors 170 may include
the timing sensors 80, as well as intake and exhaust sensors 172, air and fuel
sensors 174, and other vehicle sensors.

12
[0041] The intake and exhaust sensors 172 may include
temperature sensors 180, such as an EHC temperature sensor 182 and an
SCR temperature sensor 184. The intake and exhaust sensors 172 may also
include an EHC current sensor 186, pressure sensors 188, flow sensors 190,
oxygen sensors 192, NOx sensors 194, and other exhaust sensors. The air
and fuel sensors 174 may include air and fuel pressure sensors 196, air and
fuel flow sensors 198 and other air and fuel sensors. The timing sensors 80,
in addition to the crankshaft and camshaft sensors 82, may include a
transmission sensor, a drivetrain sensor, or some other timing sensor. The
sensors 170 may be used for status determination and control of the diesel
engine system 10. The control module 24 determines when exhaust heating
is to be performed and controls engine operation to facilitate efficient heating
based on information received from the sensors 170.
[0042] Referring now to Figure 4, a flow chart illustrating a method
of operating an exhaust system is shown. A control routine used to manage
performance of the described method may be executed by the control module
of FIGs. 1-2. Although the following steps are primarily described with respect
to the embodiments of FIGs. 1 and 2, they may be easily applied to and/or
modified for other embodiments of the present invention.
[0043] In step 200, the EHC 28 may be preheated prior to engine
startup. The control module 24 may receive an engine startup signal and
based thereon activate the SCR heating system 12 and supply current to
energize the EHC 24. The startup signal may be based on state of the switch
62.
[0044] In step 202, the engine 14 is started. Air-intake, fuel, and
glow plug systems are initialized. The control module 24 determines the
position of the crankshaft 68 and the camshafts 72 using the crankshaft and
camshaft sensors 82. Ignition reference and injection reference engine
cylinders are determined in response to the crankshaft and camshaft
positions, respectively. The ignition reference engine cylinder is that in which
a piston is nearing the end of a compression stroke. The injection reference

13
cylinder is that in which the piston is nearing the beginning of an intake stroke.
Synchronization values, such as an ignition system synchronization value, a
fuel system synchronization value, air flow synchronization values, and other
synchronization values, may be determined. The synchronization values may
be determined based on the positions of the crankshaft 68 and camshafts 72.
[0045] In step 204, the SCR heating system 12 is activated when
not previously activated, such as in step 200.
[0046] In step 206, the control module 24 reduces and/or minimizes
exhaust flow. An EHC start-up strategy algorithm may be enabled to reduce
exhaust flow and improve heating performance of the EHC 28. To reduce
exhaust flow, the control module 24 may generate lean fuel pulses prior to top
dead center of the pistons 84. The control module 24 may also reduce air
intake, via the air intake system 16. When an idle air control valve is utilized,
position thereof may be adjusted. The revolutions-per-minute (RPM) of the
engine 14 may be reduced, which reduces exhaust flow and allows the EHC
28 to heat up more quickly. The EHC 28 may be heated to approximately
400-500°C.
[0047] In step 208, the control module 24 receives or generates an
EHC temperature signal. The EHC temperature signal may be generated
directly by the EHC sensor 182 or generated indirectly. When generated
indirectly, the EHC temperature signal may be estimated or determined based
on temperature of the exhaust, flow of the exhaust, power supplied to the
EHC 28, or other parameters.
[0048] In step 210, when the EHC 28 reaches a predetermined
temperature, the control module 24 proceeds to steps 212 and 214. The
predetermined value is associated with a temperature at which exhaust
product are consumed. In step 212, the control module 24 deenergizes the
EHC 28.

14
[0049] In step 214, an exhaust exothermic energy control strategy is
initiated to increase production output of exhaust products, such as
hydrocarbons and carbon monoxide, of the engine 14. The air intake system
16 and the fuel injection system 18 are adjusted to increase exhaust product
output. For example, air intake and fuel injection may be increased. As
another example, the fuel to air ratio may be increased to provide a rich intake
pulse in the associate engine cycle, such as prior to top-dead-center of a
piston cycle. Fuel may also be injected in an exhaust stroke to increase
exhaust product output. The exhaust products generate an exothermic
reaction when in contact with a heated element and/or a hot catalyst. This
reaction generates a large amount of thermal energy that enables exhaust
aftertreatment technologies to operate efficiently and sooner. The heated
exhaust through the EHC 28 enables the DOC 122 and the SCR unit 26 to
become fully active.
[0050] In step 216, an SCR temperature signal is generated. The
SCR temperature signal may be directly generated via the SCR temperature
sensor or indirectly. The SCR temperature may also be indirectly estimated
or determined based on temperature of the exhaust, flow of the exhaust,
power supplied to the EHC 28, or other parameters. When the SCR unit 26
reaches a second predetermined temperature, such as approximately 200°C,
the SCR unit 26 is in an active state. When the temperature of the SCR unit
26 is less than 200°C, the SCR unit 26 is in an inactive state or partially active
state.
[0051] In step 218, when the SCR unit 26 reaches the second
predetermined temperature, the control module 24 proceeds to steps 220. In
step 220, the exhaust product output may be decreased to provide a normal
output for a current engine operating or driving condition. In step 222, when
the SCR unit 26 reaches the second predetermined temperature, a gaseous
and/or liquid reductant injection may be initiated into the exhaust via the
reductant injector system 124.

15
[0052] The above-described steps are meant to be illustrative
examples; the steps may be performed sequentially, synchronously,
simultaneously, or in a different order depending upon the application. Note
that one or more of the above-steps may be repeated or performed during
operation of the engine when temperature of the SCR unit 26 drops below or
is below the second predetermined temperature. As such, the control module
24 operates the SCR heating system 12 to maintain the SCR unit 26 at the
second predetermined temperature. This maintains efficient and effective
filtering of the exhaust system 22.
[0053] The above-disclosed embodiments include integrated engine
control and leverage exhaust energy to provide low tailpipe emissions during
and upon startup of an engine.
[0054] Those skilled in the art can now appreciate from the
foregoing description that the broad teachings of the disclosure can be
implemented in a variety of forms. Therefore, while this disclosure includes
particular examples, the true scope of the disclosure should not be so limited
since other modifications will become apparent to the skilled practitioner upon
a study of the drawings, the specification, and the following claims.

16
CLAIMS
What is claimed is:
1. An exhaust system comprising:
a heating element that is disposed downstream from an engine and
that introduces thermal energy into an exhaust of said engine;
a selective catalyst reduction (SCR) unit that is disposed downstream
from said heating element and that filters nitrogen oxides (NOx) within said
exhaust; and
a control module that is in communication with and that energizes said
heating element based on a first temperature of said SCR unit.
2. The exhaust system of claim 1 wherein said control module
energizes said heating element based on activation of said engine.
3. The exhaust system of claim 1 wherein said control module
operates said engine to reduce flow of said exhaust based on a second
temperature of said heating element.
4. The exhaust system of claim 3 wherein said control module
determines said second temperature based on at least one of flow rate of said
exhaust, power to said heating element, and exhaust temperature.
5. The exhaust system of claim 3 further comprising a temperature
sensor generating a temperature signal, said control module determining said
second temperature based on said temperature signal.
6. The exhaust system of claim 1 wherein said control module
deenergizes said heating element based on temperature of said heating
element and operates said engine to increase output of at least one of
hydrocarbons and carbon monoxide.

17
7. The exhaust system of claim 6 further wherein said control
module operates said engine to increase said output until said first
temperature is greater than or equal to a predetermined temperature.
8. The exhaust system of claim 1 wherein said heating element
includes an electrically heated catalyst.
9. The exhaust system of claim 1 further comprising a diesel
oxidization catalyst disposed downstream from said heating element.
10. The exhaust system of claim 1 wherein said SCR unit includes a
catalyst substrate that reduces activation energy of said exhaust.
11. A diesel exhaust system comprising:
a heating element that is disposed downstream from a diesel engine
and that introduces thermal energy into an exhaust of said diesel engine;
a diesel oxidation catalyst that is disposed downstream from said
heating element and that removes at least one of hydrocarbons and carbon
monoxide from said exhaust;
a selective catalyst reduction (SCR) unit that is disposed downstream
from said diesel oxidation catalyst and that filters nitrogen oxides (NOx) within
said exhaust; and
a control module that is in communication with and that energizes said
heating element based on a first temperature of said SCR unit.
12. The exhaust system of claim 11 wherein said control module
energizes said heating element based on activation of said diesel engine.

18
13. The exhaust system of claim 11 wherein said control module
energizes said EHC during a time period selected from at least one of a first
time period and a second time period, wherein said first time period is prior to
startup of said diesel engine and said second time period begins during a
startup process of said diesel engine.
14. A method of operating an exhaust system comprising:
generating an engine startup signal;
energizing an electrically heated catalyst (EHC), which is disposed
downstream from a diesel engine and that introduces thermal energy into an
exhaust of said diesel engine, based on said engine startup signal; and
filtering nitrogen oxides (NOx) within said exhaust system via a
selective catalyst reduction (SCR) unit that is disposed downstream from said
EHC.
15. The method of claim 14 wherein energizing said EHC is
performed during a time period selected from at least one of a first time period
and a second time period, wherein said first time period is prior to startup of
said diesel engine and said second time period that begins during a startup
process of said diesel engine.
16. The method of claim 14 further comprising:
generating an EHC temperature signal; and
reducing exhaust product generation based on said engine startup
signal and said EHC temperature signal.
17. The method of claim 14 further comprising:
generating an EHC temperature signal; and
deenergizing said EHC based on said EHC temperature signal;

19
18. The method of claim 14 further comprising:
generating an EHC temperature signal; and
increasing exhaust product output of said diesel engine based on said
EHC temperature signal.
19. The method of claim 18 further comprising:
generating an SCR temperature signal;
decreasing said exhaust product output based on said SCR
temperature signal.
20. The method of claim 18 further comprising:
generating an SCR temperature signal; and
initiating at least one of gaseous reductant and liquid reductant
injection into said exhaust based on said SCR temperature signal.

An exhaust system includes a heating element that is disposed
downstream from an engine and that introduces thermal energy into an
exhaust of the engine. A selective catalyst reduction (SCR) unit is disposed
downstream from the heating element and filters nitrogen oxides (NOx) within
the exhaust. A control module is in communication with and energizes the
heating element based on temperature of the SCR unit.

AN EXHAUST SYSTEM HAVING HEATING ELEMENT TO INTRODUCE THERMAL ENERGY INTO AN EXHAUST AND A SELECTIVE CATALYST REDUCTION (SCR) UNIT TO FILTER NITROGEN OXIDES (NOX) FROM THE EXHAUST

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