# US 7,412,335 B2 · Component evaluations using non-engine based test system

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- Number: US 7,412,335 B2
- Document ID: US7412335B2
- Status: Granted
- Kind: B2
- Application number: 10/918,330
- Filed: 2004-08-12
- Published: 2005-03-10
- Granted: 2008-08-12
- Earliest claimed: 2002-08-06
- Assignees: Southwest Research Institute
- Inventors: Andy Morris Anderson; Gordon James Johnston; Cynthia Chaffin Webb; Martin John Heimrich; Thomas Ray Gabehart; Bruce Bruno Bykowski
- Web page: https://patentgrep.com/patent/US7412335B2

## CPC

- G01M 7/02: Vibration-testing {by means of a shake table}
- F23D 11/103: {with means creating a swirl inside the mixing chamber}
- F23D 11/107: {at least one of both being subjected to a swirling motion}
- G01M 99/002: {Thermal testing (flaw detection G01N25/72)}
- F01N 11/00: Monitoring or diagnostic devices for exhaust-gas treatment apparatus
- F01N 2550/20: Monitoring artificially aged exhaust systems
- F23N 2237/12: catalytic burners
- G01M: TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- F23D: BURNERS
- 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)
- F23N: REGULATING OR CONTROLLING COMBUSTION (control devices specially adapted for combustion apparatus in which combustion takes place in a fluidised bed of fuel or other particles F23C10/28; condition responsive controls for regulating combustion in domestic stoves with open fires for solid fuel F24B1/187)

## Abstract

A burner-based system for producing exhaust that simulates the exhaust produced by a production type internal combustion engine. The system is computer controlled so that parameters such as the composition of the exhaust, its rate of flow, and its temperature can be specified. This permits various engine operating conditions to be simulated. An emissions control device can be installed to receive the exhaust, and to thereby undergo rigorous testing. Various tests for durability can be performed.

## Claims

### Claim 1

A method for using a burner-based automotive exhaust gas simulation system to test an automotive exhaust system component, comprising:
providing a burner system having at least a burner for receiving air and fuel having an air-fuel ratio and for combusting fuel to produce simulated engine exhaust; an exhaust line for carrying the exhaust from the burner to the component; and a heat exchanger for cooling the exhaust gas downstream the burner;
placing the component in the exhaust line downstream the heat exchanger;
using a computerized control system to control the ratio of fuel and air combusted by the burner, and to control the temperature of the exhaust at the input to the component; and
using the component to treat the exhaust during specified operating conditions of temperature and air-fuel ratio;
exposing the component to vibration during the step of using the component; and
evaluating the effect of the vibration on the component.

### Claim 2 (depends on 1)

The method of claim 1, wherein the burner system is operable to maintain stable operation at an air to fuel ratio of from about 10:1 to 40:1.

### Claim 3 (depends on 1)

The method of claim 1, further comprising providing supplemental oxygen into the exhaust.

### Claim 4 (depends on 1)

The method of claim 1, wherein the supplemental oxygen is controlled to provide the exhaust with an oxygen content of at least 3%.

### Claim 5 (depends on 1)

The method of claim 1, wherein the air-fuel ratio is controlled to provide the exhaust with a carbon monoxide component of the exhaust of at least 3%.

### Claim 6 (depends on 1)

The method of claim 1, wherein the burner is operable to produce exhaust having a temperature up to 900 degrees C.

### Claim 7 (depends on 6)

The method of claim 6, wherein the component has a thermal gradient between its internal and external temperature, and wherein the exhaust gas temperature is incrementally increased to produce a number of thermal gradient states.

### Claim 8 (depends on 1)

The method of claim 1, wherein at least one of the following group of operating conditions is also specified: exhaust gas temperature, time interval between changes in temperature, and air-fuel ratio.

### Claim 9 (depends on 7)

The method of claim 7, wherein the air-fuel ratio is varied to a number of air-fuel ratios, each achieving steady state condition.

### Claim 10 (depends on 7)

The method of claim 7, wherein the air-fuel ratio is continuously varied at a predetermined rate.

### Claim 11 (depends on 1)

The method of claim 1 wherein at least one of the following group of operating conditions is held constant: exhaust gas temperature and air-fuel ratio.

### Claim 12 (depends on 1)

The method of claim 1, wherein the exposing step is performed during steady state stoichiometric conditions.

### Claim 13

A method for using a burner-based automotive exhaust gas simulation system to test an automotive exhaust system component, comprising:
providing a burner system having at least a burner for receiving air and fuel having an air-fuel ratio and for combusting fuel to produce simulated engine exhaust; an exhaust line for carrying the exhaust from the burner to the component; and a heat exchanger for cooling the exhaust gas downstream the burner;
placing the component in the exhaust line downstream the heat exchanger;
using a computerized control system to control the A/F ratio of fuel and air combusted by the burner, and to control the temperature of the exhaust at the input to the component; and
exposing the component to the exhaust during an air-fuel ratio sweep;
wherein the air-fuel ratio sweep is a continuous sweep at a predetermined rate of change of the air-fuel ratio.

### Claim 14 (depends on 13)

The method of claim 13, wherein the air-fuel ratio sweep is a stepped sweep, such that each air-fuel ratio is maintained until steady state conditions are achieved.

### Claim 15 (depends on 13)

The method of claim 13, wherein the air-fuel ratio is varied between lean and rich conditions.

### Claim 16 (depends on 13)

The method of claim 13, wherein the air-fuel ratio may be varied in a range of air-fuel ratios between 10:1 and 40:1.

### Claim 17

A method for using a burner-based automotive exhaust gas simulation system to age an emissions control device in the exhaust line of an internal combustion engine, comprising:
providing a burner for receiving air and fuel and for combusting a fuel feedstream to produce simulated engine exhaust;
providing an exhaust line for carrying the exhaust from the burner to the emissions control device;
providing a cooling device for cooling the exhaust gas downstream the burner;
placing the emissions control device on the exhaust line downstream the cooling device;
providing an air injection device for injecting air into the exhaust line between the burner and the emissions control device;
using a control system to simulate a number of engine cycles, each cycle having a succession of engine operating modes, by controlling at least the following engine operating parameters: the ratio of air and fuel received by the burner, the rate of flow of exhaust from the burner; and the temperature of the exhaust gas at the inlet to the emissions control device;
wherein the simulated operating modes are at least the following modes: closed loop stoichiometric, open loop rich without air injection, open loop rich with air injection, closed loop stoichiometric with air injection; and
exposing the emissions control device to the exhaust gas for a number of engine cycles; and
varying the exhaust gas flowrate.

### Claim 18 (depends on 17)

The method of claim 17, further comprising the step of varying the exhaust gas temperature at the input to the emissions control device.

### Claim 19 (depends on 17)

The method of claim 17, further comprising the step of varying the exhaust gas stoichiometry from a range of 10:1 to 20:1.

### Claim 20 (depends on 17)

The method of claim 17, further comprising the step of varying the exhaust gas stoichiometry from a range of 10:1 to 40:1.

### Claim 21

A method for using a burner-based automotive exhaust gas simulation system to test an automotive exhaust system component, comprising:
providing a burner system having at least a burner for receiving air and fuel having an air-fuel ratio and for combusting fuel to produce simulated engine exhaust; an exhaust line for carrying the exhaust from the burner to the component; and a heat exchanger for cooling the exhaust gas downstream the burner;
placing the component in the exhaust line downstream the heat exchanger;
using a computerized control system to control the ratio of fuel and air combusted by the burner, and to control the temperature of the exhaust at the input to the component;
using the component to treat the exhaust during specified operating conditions of temperature and air-fuel ratio;
providing supplemental oxygen into the exhaust, wherein the supplement oxygen is controlled to provide the exhaust with an oxygen content of at least 3%; and evaluating the effect of the exposing steps on the component.

### Claim 22

A method for using a burner-based automotive exhaust gas simulation system to test an automotive exhaust system component, comprising:
providing a burner system having at least a burner for receiving air and fuel having an air-fuel ratio and for combusting fuel to produce simulated engine exhaust; an exhaust line for carrying the exhaust from the burner to the component; and a heat exchanger for cooling the exhaust gas downstream the burner;
placing the component in the exhaust line downstream the heat exchanger;
using a computerized control system to control the ratio of fuel and air combusted by the burner, and to control the temperature of the exhaust at the input to the component; and
using the component to treat the exhaust during specified operating conditions of temperature and air-fuel ratio;
wherein the air-fuel ratio is controlled to provide the exhaust with a carbon monoxide content of at least 3%; and
evaluating the effect of the exposing steps on the component.

### Claim 23

A method for using a burner-based automotive exhaust gas simulation system to test an automotive exhaust system component, comprising:
providing a burner system having at least a burner for receiving air and fuel having an air-fuel ratio and for combusting fuel to produce simulated engine exhaust; an exhaust line for carrying the exhaust from the burner to the component; and a heat exchanger for cooling the exhaust gas downstream the burner;
placing the component in the exhaust line downstream the heat exchanger;
using a computerized control system to control the ratio of fuel and air combusted by the burner, and to control the temperature of the exhaust at the input to the component;
using the component to treat the exhaust during specified operating conditions of temperature and air-fuel ratio;
exposing the component to liquid applied to the external surface of the component, during the step of using the component; and
evaluating the effect of the exposing steps on the component.