# US 2017/0256104 A1 · Virtual sensing system

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- Number: US 2017/0256104 A1
- Document ID: US20170256104A1
- Status: Published application
- Kind: A1
- Application number: 15/447,942
- Filed: 2017-03-02
- Published: 2017-09-07
- Earliest claimed: 2016-03-02
- Assignees: Watlow Electric Manufacturing Company
- Applicants: Watlow Electric Manufacturing Company
- Inventors: James N. Pradun; Sanhong Zhang; Jeremy J. Quandt
- Web page: https://patentgrep.com/patent/US20170256104A1

## CPC

- F01N 9/005: {using models instead of sensors to determine operating characteristics of exhaust systems, e.g. calculating catalyst temperature instead of measuring it directly}
- F01N 3/023: using means for regenerating the filters, e.g. by burning trapped particles
- F01N 3/027: using electric or magnetic heating means
- F01N 3/2006: {Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating (by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235)}
- F01N 3/2013: {using electric or magnetic heating means}
- F01N 9/00: Electrical control of exhaust gas treating apparatus (monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00)
- F01N 9/002: {of filter regeneration}
- F01N 11/002: {the diagnostic devices measuring or estimating temperature or pressure in, or downstream of the exhaust apparatus}
- F01N 11/005: {the temperature or pressure being estimated, e.g. by means of a theoretical model}
- F01N 13/0097: {the purifying devices are arranged in a single housing}
- F02D 41/024: {to increase temperature of the exhaust gas treating apparatus}
- F02D 41/1446: {the characteristics being exhaust temperatures}
- F02D 41/1447: {with determination means using an estimation}
- F02D 41/22: Safety or indicating devices for abnormal conditions {(in air/fuel ratio feedback systems F02D41/1495, in electric control linkage F02D11/107, in purge control systems F02M25/0809)}
- F02D 41/222: {relating to the failure of sensors or parameter detection devices}
- G01F 1/68: by using thermal effects
- G01F 1/86: Indirect mass flowmeters, e.g. measuring volume flow and density, temperature or pressure
- G01K 7/16: using resistive elements
- G01M 15/05: by combined monitoring of two or more different engine parameters
- G05D 23/185: with auxiliary non-electric power
- G05D 23/2401: {using a heating element as a sensing element}
- G05D 23/30: Automatic controllers with an auxiliary heating device affecting the sensing element, e.g. for anticipating change of temperature
- G07C 5/0808: {Diagnosing performance data (testing of vehicles G01M17/00; testing of electrical installation on vehicles G01R31/005)}
- H05B 1/0227: {Applications}
- H05B 1/0244: {Heating of fluids (H05B1/0247 takes precedence)}
- H05B 3/0042: {used in motor vehicles}
- H05B 3/141: {Conductive ceramics, e.g. metal oxides, metal carbides, barium titanate, ferrites, zirconia, vitrous compounds}
- H05B 3/18: the conductor being embedded in an insulating material
- H05B 3/20: Heating elements having extended surface area substantially in a two-dimensional [2D] plane, e.g. plate-heater (H05B3/62, H05B3/68, H05B3/78, H05B3/84 take precedence)
- H05B 3/40: Heating elements having the shape of rods or tubes (H05B3/62, H05B3/68, H05B3/78 take precedence)
- F01N 3/021: by means of filters
- F01N 3/0814: {combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts}
- F01N 3/103: {Oxidation catalysts for HC and CO only}
- F01N 3/106: {Auxiliary oxidation catalysts}
- F01N 3/2066: {Selective catalytic reduction [SCR]}
- F01N 2240/10: a heat accumulator
- F01N 2240/16: an electric heater, i.e. a resistance heater
- F01N 2240/36: an exhaust flap
- F01N 2410/00: By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
- F01N 2410/04: during regeneration period, e.g. of particle filter
- F01N 2550/22: of electric heaters for exhaust systems or their power supply
- F01N 2560/06: the means being a temperature sensor
- F01N 2560/07: the means being an exhaust gas flow rate or velocity meter or sensor, intake flow meters only when exclusively used to determine exhaust gas parameters
- F01N 2560/12: Other sensor principles, e.g. using electro conductivity of substrate or radio frequency
- F01N 2560/20: Sensor having heating means
- F01N 2610/102: after addition to exhaust gases, e.g. by a passively or actively heated surface in the exhaust conduit
- F01N 2900/0416: using the state of a sensor, e.g. of an exhaust gas sensor
- F01N 2900/1404: Exhaust gas temperature
- F01N 2900/1406: Exhaust gas pressure
- F01N 2900/1411: Exhaust gas flow rate, e.g. mass flow rate or volumetric flow rate
- F01N 2900/1602: Temperature of exhaust gas apparatus
- F02D 2041/1433: {using a model or simulation of the system}
- F02D 2041/228: {Warning displays}
- F28F 2200/00: Prediction; Simulation; Testing
- G01K 2205/04: for measuring exhaust gas temperature
- H01C 7/02: having positive temperature coefficient
- H01C 7/04: having negative temperature coefficient
- H05B 2203/019: Heaters using heating elements having a negative temperature coefficient
- H05B 2203/021: Heaters specially adapted for heating liquids
- H05B 2203/022: Heaters specially adapted for heating gaseous material
- Y02T 10/12: Improving ICE efficiencies
- Y02T 10/40: Engine management systems
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)
- F02D: CONTROLLING COMBUSTION ENGINES (vehicle fittings, acting on a single sub-unit only, for automatically controlling vehicle speed B60K31/00; conjoint control of vehicle sub-units of different type or different function, road vehicle drive control systems for purposes other than the control of a single sub-unit B60W)
- G01F: MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01K: MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR (radiation pyrometry G01J5/00)
- G01M: TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G05D: SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G07C: TIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
- H05B: ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- F28F: DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION (water and air traps, air venting F16)
- H01C: RESISTORS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A control system for a heating system of an exhaust system is provided. The control system includes at least one electric heater disposed within an exhaust fluid flow pathway, and a control device adapted to receive at least one input selected from the group consisting of mass flow rate of an exhaust fluid flow, mass velocity of an exhaust fluid flow, flow temperature upstream of the at least one electric heater, flow temperature downstream of the at least one electric heater, power input to the at least one electric heater, parameters derived from physical characteristics of the heating system, and combinations thereof. The control device is operable to modulate power to the at least one electric heater based on at least one input.

## Claims

### Claim 1

A control system for a heating system of an exhaust system, the control system comprising:
at least one electric heater disposed within an exhaust fluid flow pathway; and
a control device adapted to receive at least one input selected from the group consisting of mass flow rate of an exhaust fluid flow, mass velocity of an exhaust fluid flow, flow temperature upstream of the at least one electric heater, flow temperature downstream of the at least one electric heater, power input to the at least one electric heater, parameters derived from physical characteristics of the heating system, and combinations thereof,
wherein the control device is operable to modulate power to the at least one electric heater based on at least one input.

### Claim 2 (depends on 1)

The control system according to claim 1, wherein the at least one electric heater is selected from the group consisting of a band heater, a bare wire resistive heating element, a cable heater, a cartridge heater, a layered heater, a strip heater, and a tubular heater.

### Claim 3 (depends on 1)

The control system according to claim 1, wherein the at least one electric heater comprises a sheath having a sheath temperature (Ts) determined by the parameters derived from the physical characteristics of the heating system.

### Claim 4 (depends on 3)

The control system according to claim 3, wherein Ts is determined by a system of equations using inputs of set point, mass flow rate, and inlet temperature to calculate system temperatures.

### Claim 5 (depends on 1)

The control system according to claim 1, wherein the physical characteristics of the heating system are selected from the group consisting of resistance wire diameter, heater insulation thickness, heater sheath thickness, conductivity, specific heat and density of the material of the heater, heat transfer coefficients, emissivity of the heater and exhaust fluid flow pathway, and combinations thereof.

### Claim 6 (depends on 1)

The control system according to claim 1, wherein the control device is operable to predict temperatures associated with the at least one heater without a physical sensor.

### Claim 7 (depends on 1)

The control system according to claim 1, wherein mass flow rate is determined through parameters selected from the group consisting of torque demand, pedal position, increased manifold absolute pressure (MAP), boost timing, engine timing, and combinations thereof.

### Claim 8 (depends on 7)

The control system according to claim 7, wherein the control device is operable to determine desired heater power in advance of when power is needed.

### Claim 9 (depends on 1)

The control system according to claim 1, wherein the control device is operable to receive input associated with radiation effects.

### Claim 10 (depends on 1)

The control system according to claim 1, wherein the mass flow rate is determined by a parameter selected from the group consisting of measured manifold absolute pressure (MAP), combining inlet air mass flow rate with fuel consumption, and combinations thereof.

### Claim 11 (depends on 1)

An engine system comprising the exhaust system according to claim 1.

### Claim 12 (depends on 11)

The engine system according to claim 11, wherein the control device is adapted to receive engine inputs selected from the group consisting of engine parameters, exhaust parameters, electrical power output, heater parameters, and the device is operable to generate output selected from the group consisting of power consumption, exhaust temperature, heater temperature, diagnostics, exhaust mass flow rate, and combinations thereof.

### Claim 13 (depends on 11)

The engine system according to claim 11, wherein the control system is operable to diagnose degrading engine system components.

### Claim 14 (depends on 13)

The engine system according to claim 13, wherein the control system is in communication with an engine control unit and adapted to trigger a diagnostic trouble code when a determined parameter is mismatched with a preset parameter.

### Claim 15 (depends on 1)

The control system according to claim 1, wherein the at least one electric heater includes a resistive heating element, and the control system modulates power to the at least one electric heater based on a calculated temperature of the resistive heating element.

### Claim 16

A method of predicting temperature of at least one location in a fluid flow system having a heater disposed in a heating system for heating fluid, the method comprising:
obtaining a mass flow rate of fluid flow of the fluid flow system;
obtaining at least one of a fluid outlet temperature and a fluid inlet temperature of the heater;
obtaining power provided to the heater; and
calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate and fluid outlet and inlet temperatures.

### Claim 17 (depends on 16)

The method according to claim 16, wherein the at least one location is on a resistive heating element of the heater.

### Claim 18 (depends on 16)

The method according to claim 16, wherein the method is integrated with a model-based design.

### Claim 19 (depends on 16)

The method according to claim 16, wherein the temperature is one of a steady-state temperature and a transient temperature.

### Claim 20

A method of predicting outlet temperature after each of a plurality of resistive heating elements in a heater system disposed in a fluid flow system comprising:
obtaining a mass flow rate of fluid flow;
obtaining a fluid inlet temperature to at least one of the plurality of resistive heating elements;
obtaining power provided to at least one of the plurality of resistive heating elements and characteristics of the fluid flow system that relate power input to at least one of the plurality of resistive heating elements to power transferred to the fluid flow; and
calculating the outlet temperature based on a model of the fluid flow system.