Senior Design: Diesel Soot Filter MeasurementAgendaSlide 3Problem DescriptionProject OutlineProgression DiagramIndustry SolutionsHoriba -Engine MeasurementsSlide 9Argonne National LaboratoryArgonne – Trans. Tech R&DNGK Insulators, LtdSegmented FilterResearch Project/ProposalConceptual DesignsDecision MatrixFilter Heat-Soot Correlation MethodThermodynamic ModelExperimental Research SetupExperimental Research ProcedureSimulated Data ResultsChallenges FacedLong Term Solution: Temperature Measuring DevicesLong Term Temp. Cont. Stabilized Type K ThermocouplesProblems Encountered & SolutionsConclusionQuestions?Senior Design:Diesel Soot Filter MeasurementCummins 1:Tedrick RollingsJonathan WhitakerPartius RobinsonMichael ErhardtAgenda1. Problem Description1. Problem Description3. Industry Solution3. Industry Solution4. Research Project 4. Research Project 5. Conclusion 5. Conclusion 2. Project Outline/Progress Diagram2. Project Outline/Progress DiagramProblem Description•We are required to design a sensor or a similar system capable of measuring the amount of soot in a diesel soot filter. The sensor has to be able to operate with a soot filter with the following specifications:–8 mm wall thickness–200 cells per unit inch–manufactured with cordierite–Accuracy = +/- 0.5 g of soot per liter of filter.Project Outline•Industry Solutions–Horiba-Engine Measurements•Correspondence•Executive Summary + Proposal Report–Argonne National Laboratory•Correspondence•Executive Summary + Proposal Report–NGK Insulators•Correspondence•Executive Summary + Proposal Report•Research Proposal/Solution–Filter Heat-Soot Correlation Method•Overall Concept•Thermodynamic Modeling•Test Setup•Desired Results•Advanced Temperature Measurement ResearchMethods of Measuring Diesel Soot in DPFShort Term SolutionsLong Term ResearchHoriba-Engine MeasurementsArgonne National LaboratorySegmented FilterTemperature Measurement MethodCorrespondenceExecutive Summary + Proposal ReportCorrespondenceExecutive Summary + Progress ReportCorrespondenceExecutive Summary + Progress ReportOverall ConceptThermodynamic ModelingTest SetupDesired ResultsAdvanced Temperature Measurement ResearchProgression DiagramPhase 1Phase 1Phase 2Phase 2Phase 3Phase 3•Combination of the two ideals•Finalization of project•Long term project research•Thermodynamic formulization•Segmented filter calculations•Industry interaction and research•Short term project research•Collection of ideasIndustry SolutionsCummins Diesel Engine MeasurementProjectHoribaEngineMeasurementsArgonneNationalLabsNGKInsulatorsHoriba -Engine MeasurementsFilter is placed analyzer's furnace and heated in N2 gas flow. SOF and sulfate vaporized by heat in N2 atmosphere Vaporized sulfate is deoxidized to SO2 by heat, measured by SO2 detector. Organic components oxidized by O2 , measured as CO2 by NDIR detector. Output of CO2 detector is integrated while O2 is flowing to determine soot mass. Vaporization and oxidation/deoxidation techniqueHoriba -Engine MeasurementsMexa-1370 PMMeasures soot, sulfate, and total particulate matter in diluted engine exhaust gas 1370 Analyzer and Data Processor Complications• Multiple Part Analysis•Size Issues (2.3 x 1.8 x 2.7 ft)•4 Minute AnalysisArgonne National LaboratoryReal-Time Portable Exhaust AnalyzerLaser-Induced Incandescence Can measure Mean size of the particles Number of particles per cubic centimeter Correlate Exhaust Particle Size/Number and Filter FullnessArgonne – Trans. Tech R&D•Thermophoretic sampling to study diesel PM. •High-Res transmission electron microscope (TEM)–Data recording – Analysis.•Better understand PM–Density–Weight –Specific heat capacityTEM Clip of Diesel Particulate MatterNGK Insulators, Ltd•Pressure Drop of Segmented Diesel Particulate FilterUses the flow resistance of a segmented Diesel particulate filter.Given identical monolithic and segmented filters:•Segmented:–Holds lower filtration wall area –Reduces the filter open frontal area •Resulting in:–Higher flow resistance–Increase in the filter pressure drop •15% Reduction in Filtration Area = 400 Pa Pressure DropSegmented FilterResearch Project/ProposalCumminsCumminsCumminsCumminsCumminsFilter Heat-SootCorrelation MethodConceptual DesignsConstantAppliedVoltageAmmeter(Measures Current)WiringParticulates (Soot)CordieriteFilter Power Supply(Supplies Voltage) Vehicle Stack Exhaust •Concept #1: Force Measuring System•Idea #2: Continuous Dilution Method•Idea #3: Temperature Monitoring•Idea #4: Particulate Measurement through Electrical Current Analysis•Idea #5: Incandescence Soot MeasurementDecision Matrix•Decision Matrix–Factor quantifying system:•1 – Very Poor 2 – Poor 3 – Average 4 – Good 5 – Excellent –Largest Total: Most reasonable idea–“Filter Heat-Soot Correlation Method” was selected to be the most possible idea using the decision matrix.CostProduction TimeIdea ComplexityMass ProductionSpecific Factors1 3 4 3 4 3 172 1 2 3 4 2 123 5 4 5 4 3 214 3 3 4 3 4 175 1 3 2 3 4 13Concept #FACTORS (1 - 5)TOTALFilter Heat-Soot Correlation Method•Thermodynamic Background–Thermal Exchanger System–Thermal Conductivity•Thermodynamic Project Application–Specific Heat Capacity–***Special Thanks to Dr. Chiang Shih and Dr. Juan OrdonezThermodynamic Model•Simplified gradual representation of diesel particulate filter systemExperimental Research Setup•Preliminary Experiment–Specific Heat Capacity of Diesel Soot–Specific Heat Capacity of Diesel Particulate Filter•Main Experiment–Simulated Exhaust SystemExperimental Research Procedure•Assemble Test Equipment •Assemble Temperature Monitoring Equipment•Prepare Mass Measurement Equipment•Phase I Experimental Procedure•Phase II Experimental ProcedureSimulated Data ResultsChallenges Faced•Extraneous Factors–Pressure–Geometry–Altered Density–Non-Constant Mass•Long Term Temperature Measurement–K-Thermocouple FailureLong Term Solution:Temperature Measuring Devices•Type K thermocouples •Composed of a positive Chromel wire and a negative Alumel wire.• Most popular thermocouple•Wide measurement range •Good temp. precision.Long Term Temp. Cont.Stabilized Type K Thermocouples•Controls drift for more stabilized temperature readings for extended periods of time.•Can survive temperature readings of -145 to