CN110714816B - 尿素浓度传感器反射器 - Google Patents

尿素浓度传感器反射器 Download PDF

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CN110714816B
CN110714816B CN201910434527.8A CN201910434527A CN110714816B CN 110714816 B CN110714816 B CN 110714816B CN 201910434527 A CN201910434527 A CN 201910434527A CN 110714816 B CN110714816 B CN 110714816B
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reflector
urea
concentration sensor
urea concentration
legs
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CN110714816A (zh
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A·卡皮尼萨恩
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GM Global Technology Operations LLC
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Abstract

一种尿素浓度传感器反射器系统包括尿素浓度传感器反射器组件，该尿素浓度传感器反射器组件包括具有向上凸起的圆顶形状的反射器，该反射器一体连接到多个支腿并由多个支腿支撑。反射器包括凹形内表面。多个支腿连接到尿素浓度传感器反射器组件并将尿素浓度传感器反射器组件支撑到尿素储存罐的底部罐壁的向上定向的表面。声波发生器和接收器固定到直接位于反射器下方并与反射器中心对准的底部罐壁上。声波发生器和接收器产生朝反射器向上定向的超声波。基于超声波传播到反射器并作为回波信号返回到声波发生器和接收器的时间，以及液态尿素的温度，确定尿素储存罐中液态尿素的浓度。

Description

尿素浓度传感器反射器
技术领域
本公开涉及包括尿素浓度感测的柴油发动机车辆尿素控制系统。
背景技术
具有柴油发动机的车辆需要对排气进行额外处理以满足环境法规。一种方法是将液态尿素喷射到排气系统中以减轻由于使用柴油燃料而产生的过量燃烧副产物，例如升高的NOx。液态尿素通常储存在车上，并通过由发动机电子控制模块控制的定量喷射阀以浓缩形式泵送。使用尿素溶液的排气处理的有效性取决于流体定量给料和浓度比之间的紧密相关性。当尿素储存罐被装满时，通常没有可用的系统来确定尿素的浓度，因此车辆通常配备有尿素浓度传感器。
已知的尿素浓度传感器基于超声波在尿素溶液中行进预定距离所需的时间跨度的测量来操作。已知的传感器通过将与反射器相对的收发器定位在盘状水平板上而使用水平声音传播方向。发送和接收的信号之间的测量时间范围受收发器和反射器之间的距离变化以及尿素溶液的温度的影响。因为尿素储存罐通常由适于容纳尿素的聚合材料制成，例如高密度聚乙烯，收发器和反射器在聚合材料罐壁上的定位非常容易受到温度变化的影响，温度变化导致反射器和收发器未对准。为了补偿这种已知的灵敏度，温度与尿素浓度表必须是可用的并且被访问以确定近似的尿素浓度，这导致浓度解释中的误差。
因此，虽然当前的尿素浓度传感器实现了它们的预期目的，但是需要一种新的改进的尿素浓度传感器和反射器组件。
发明内容
根据多个方面，一种尿素浓度传感器组件包括反射器，该反射器具有一体地连接到主传感器主体并由多个腿部支撑的圆顶形状。反射器包括凹形内表面。多个支腿连接到尿素浓度传感器组件并将尿素浓度传感器组件支撑到尿素储存罐底部罐壁的向上定向的表面。声波发生器和接收器固定到直接位于反射器下方并与反射器中心对准的底部罐壁上。声波发生器和接收器产生朝反射器向上定向的超声波。
在本公开的另一方面中，多个支腿包括第一支腿、第二支腿、第三支腿和第四支腿，每个支腿与多个支腿中的连续支腿等距地间隔开。
在本公开的另一方面中，多个支腿的数量是三个支腿中的一个或多于四个支腿，每个支腿相对于底部罐壁成角度地定向。
在本公开的另一方面中，底部罐壁除了直接在反射器下方之外大致上是平面的。
在本公开的另一方面中，直接在反射器下方的底部罐壁限定了向上定向的凸起圆顶表面，使得在底部罐壁处形成的尿素晶体或颗粒能够通过重力向外移动并离开圆顶表面。
在本公开的另一方面中，声波发生器和接收器是陶瓷压电元件。
在本公开的另一方面中，支腿中的每一个包括一个支腿部分，该支腿部分的大小被确定成摩擦地容纳在形成于该底部罐壁中的对应形状的槽中。
在本公开的另一方面中，声波发生器和接收器产生朝反射器向上定向的超声声波，反射器包括凹形内表面，凹形内表面限定向下定向的超声波聚焦区，超声波聚焦区接收并回射超声波。
在本公开的另一方面中，凹形内表面将超声波反射并重新构造成圆锥形超声波锥体，该圆锥形超声波锥体将反射的超声波集中，从而基本上沿着声波发生器和接收器的中心轴线在声波发生器和接收器的接收器部分处相遇。
在本公开的另一方面中，尿素浓度传感器组件的固定高度保持在凹形内表面的顶点和底部罐壁的平面上表面之间。通过使用在支腿中的每一个的相同位置处形成的凹口表面来保持固定高度，该凹口表面直接抵靠在平面上表面上。在尿素浓度传感器组件的安装位置，支腿中的每一个相对于平面上表面以共同的角度阿尔法(α)定向。
根据多个方面，一种尿素浓度传感器系统包括尿素浓度传感器组件，该尿素浓度传感器组件具有反射器，该反射器具有一体连接到多个支腿并由多个支腿支撑的向上凸起的圆顶形状。反射器包括凹形内表面。多个支腿连接到尿素浓度传感器组件并将尿素浓度传感器组件支撑到尿素储存罐的底部罐壁的向上定向的表面上。声波发生器和接收器固定到直接位于反射器下方并与反射器中心对准的底部罐壁上。声波发生器和接收器产生朝反射器向上定向的超声波。基于超声波传播到反射器并作为回波信号返回到声波发生器和接收器的时间，确定尿素储存罐中液态尿素的浓度读数。
在本公开的另一方面中，加热器壁被定位成邻近尿素储存罐中的尿素浓度传感器组件，该加热器壁被通电以防止至少邻近尿素浓度传感器组件的区域冻结。
在本公开的另一方面中，柴油机排气处理液加热系统定位在尿素储存罐中，控制加热器壁的运行。
在本公开的另一方面中，反射器和尿素浓度传感器组件的多个支腿是不锈钢或对尿素溶液具有耐腐蚀性并且具有类似于不锈钢的热膨胀的材料。
在本公开的另一方面中，直接在反射器下方的底部罐壁限定向上定向的凸起圆顶表面。反射器包括凹形内表面，该凹形内表面限定向下定向的超声波聚焦区，该超声波聚焦区接收超声波并将超声波向声波发生器和接收器反向反射。
在本公开的另一方面中，尿素浓度传感器组件的固定高度通过使用在每个支腿中的相同位置处产生的凹口表面来保持，该凹口表面直接抵靠在向上定向的表面上。
根据多个方面，一种确定尿素浓度的方法包括：将具有向上凸起的圆顶形状和凹形内表面的反射器连接到多个支腿以创建尿素浓度传感器组件；将尿素浓度传感器组件定位在尿素储存罐中，包括将多个支腿固定到尿素储存罐的底部储罐壁的向上指向的表面上，或固定到安装在该尿素储存罐中的传感器部件的本体上；将声波发生器和接收器附接到直接位于反射器下方且与反射器中心对准的底部罐壁；操作声波发生器和接收器以产生朝反射器向上定向的超声波；以及基于超声波传播到反射器并作为回波信号返回到声波发生器和接收器的时间，以及液态尿素的温度，确定尿素储存罐中液态尿素的浓度。
在本公开的另一方面中，该方法包括：使用DEF泵通过DEF喷射器定量阀将尿素泵送出尿素储存罐；以及将尿素喷射到催化转换器上游的混合器中。
在本公开的另一方面中，该方法包括：在确定步骤之前，使用凹形内表面将超声波反射和重新配置成圆锥形超声波锥体，以集中反射的超声波，从而基本上沿着声波发生器和接收器的中心轴线在声波发生器和接收器的接收器部分相遇。
从本文提供的细节描述，进一步的适用性领域将变得明。应当理解的是，描述和具体示例仅用于说明的目的，并不旨在限制本公开的范围。
附图说明
本文描述的附图仅用于说明目的，并不旨在以任何方式限制本公开的范围。
图1是根据示例性实施例的尿素浓度传感器组件的顶部透视图；
图2是在图1的截面2处截取的前立面剖视图；
图3是类似于图2的前立面剖视图，其被修改以添加罐和加热器；以及
图4是采用图1的尿素浓度传感器组件的DEF系统的图示。
具体实施方式
以下描述本质上仅仅是示例性的，并不旨在限制本公开、应用或用途。
参照图1，尿素浓度传感器和反射器系统10包括尿素浓度传感器反射器组件12，尿素浓度传感器反射器组件12例如由金属(比如不锈钢)制成，其抵抗尿素液体的腐蚀作用。尿素浓度传感器反射器组件12包括向上凸起的圆顶形的反射器14，反射器14连接到多个支腿并由多个支腿支撑，根据多个方面，多个支腿包括第一支腿16、第二支腿18、第三支腿20和第四支腿22。如图所示，支腿16、18、20、22中的每一个可以与连续支腿等距离地间隔开，或者支腿可以彼此具有不同的间隔。支腿16、18、20、22的数量也可以不同于所示的示例性的四根支腿，例如可以是三根支腿或根据设计者的判断多于四根支腿。在所示的尿素浓度传感器反射器组件12的安装位置中，支腿16、18、20、22相对于尿素储存底部罐壁28的向上定向的表面26或者相对于安装在参照图3所示和所述的尿素储存罐68中的传感器部件的主体，连接到并支撑尿素浓度传感器反射器组件12。底部罐壁28除了直接在反射器14下面之外大致上是平面的，这将参考图2更详细地描述。声波发生器和接收器30固定在底部罐壁28上，底部罐壁28直接位于反射器14下方并与反射器14中心对准。根据几个方面，声波发生器和接收器30是已知设计的陶瓷压电元件。
参照图2并再次参照图1，支腿16、18、20、22中的每一个包括支腿部分32，该支腿部分32的尺寸设置成摩擦地容纳在形成于底部罐壁28中的相应形状的槽34中，并且支腿部分32的一部分可从底部罐壁28向外(如图2所示向下)延伸。根据几个方面，凸形壁部分36直接位于反射器14下方。凸形壁部分36包括向上定向的弯曲或圆顶表面38，弯曲或圆顶表面38的功能包括使得可能在底部罐壁28处形成的尿素污染物的晶体或颗粒能够通过重力向外移动并离开圆顶表面38，从而有助于在声波发生器和接收器30的区域中使得这些晶体保持离开圆顶表面38。在车辆行驶和发动机运行期间发生的正常振动也将有助于使尿素晶体振动，从而有助于晶体重力位移离开圆顶表面38。
声波发生器和接收器30固定到底部罐壁28的下表面40，并且可以如图所示部分地嵌入到底罐壁28内。电力和感测线42保持在下表面40之下最大可能的程度，以将电力和感测线42保持在容纳尿素液体的罐的内部之外，该罐的内部由底部罐壁28界定。在运行中，声波发生器和接收器30产生朝反射器14向上定向的超声波44。反射器14包括凹形内表面46，该凹形内表面46限定了向下定向的超声波聚焦区48或反射表面，该反射表面接收并回射超声波44。凹形内表面46将超声波反射并重新构造成圆锥形超声波锥体50，该圆锥形超声波锥体50将反射的超声波集中，从而基本上沿着声波发生器和接收器30的中心轴线54，在声波发生器和接收器30的接收器部分52处相遇。根据几个方面，声波发生器和接收器30的中心轴线54也与凹形内表面46的中心轴线56同轴定向。
尿素储存罐中液态尿素的浓度可以基于超声波传播到反射器14并作为回波信号返回到声波发生器和接收器30的时间以及液态尿素的温度来确定。参照图4讨论尿素储存罐中使用的温度传感器。为了使该确定中的任何时间偏差最小化，尿素浓度传感器反射器组件12的固定高度58被保持在例如凹形内表面46的顶点与底部罐壁28的平面上表面60之间。通过使用在支腿16、18、20、22中的每一个的相同位置处形成的凹口表面62来保持固定高度58，凹口表面62直接抵靠在平面上表面60上。此外，在安装位置，支腿16、18、20、22中的每一个相对于平面上表面60以共同的角度阿尔法(α)定向。为了保持固定高度58，支腿16、18、20、22中的每一个也可以使用诸如环氧树脂的粘合剂固定到平面上表面60上。
参照图3，使用参照图4讨论的液位传感器监测尿素储存罐68中的液态尿素66的液位64。加热器壁70设置在尿素浓度传感器反射器组件12附近，该加热器壁70被通电以至少在尿素浓度传感器反射器组件12的附近区域中防止尿素66冻结。加热器壁70使用电力电缆72连接到电源(未示出)，电力电缆72与参考图2讨论的电力和感测线42一起保持在底部罐壁28的下表面40下方的电子干燥区域74内。
参照图4并再次参照图1至图3，为了控制尿素浓度传感器和反射器系统10的运行以及柴油发动机操作的车辆的排放，尿素作为柴油机排气处理液(DEF)被注入到柴油发动机车辆的排气流中以将NOx排放物分解成氮气和水。DEF约为32.5％的尿素和67.5％的去离子水。柴油发动机可以以稀燃烧空燃比(过化学计量比)运行，以确保烟灰的完全燃烧并防止排出未燃烧的燃料。过量的空气导致从空气中的氮产生氮氧化物(NOx)污染物。选择性催化还原(SCR)催化转换器76中的选择性催化还原(SCR)用于减少释放到大气中的NOx的量。尿素作为柴油机排气处理液(DEF)从单独的尿素储存罐68提供并喷射到排气系统78中，在排气系统78中，含水尿素蒸发并分解以形成氨和二氧化碳。在SCR催化剂内，NOx被氨(NH3)催化还原为水(H2O)和氮气(N2)，水和氮气通过排气系统排出部分80释放。
一组排放要求82和提供多个当前驱动条件84(例如车辆速度、环境温度等)的传感器信号被馈送到车辆电子控制模块86中，车辆电子控制模块86可以包括处理器。电子控制模块86与DEF控制模块88通信，DEF控制模块88直接控制DEF泵90的运行以将DEF流体泵送出尿素储存罐68。DEF控制模块88和DEF泵90形成DEF部件管理系统92的一部分。DEF分配系统94包括一组DEF供应线加热器96和多个DEF供应线98。尿素储存罐68包括DEF加热系统100，DEF加热系统100控制参考图3讨论的加热器壁70的运行，尿素浓度传感器反射器组件12、DEF压力传感器102、DEF温度传感器104和DEF液位传感器106中的每个均由DEF部件管理系统92控制。
使用从车辆电子控制模块86和DEF部件管理系统92接收的控制信号，使用DEF泵90通过DEF分配系统94将尿素泵送出尿素储存罐68，并引导通过DEF喷射器定量阀，该DEF喷射器定量阀使用DEF定量控制器110进行控制并被喷射到SCR催化转换器76上游的混合器112中。第一NOx传感器114可以位于SCR催化转换器76的上游，第二NOx传感器116可以位于SCR催化转换器76的下游。温度传感器118也位于SCR催化转换器76的上游。
参考用于确定在柴油发动机车辆的尿素喷射或DEF系统中使用的尿素浓度，描述了本公开的尿素浓度传感器和反射器系统10。尿素浓度传感器反射器组件12还可适于通过首先确定超声波44对于特定期望液体的反射时间并根据需要修改固定高度58来测量基本上任何液体的浓度。
本公开的尿素浓度传感器和反射器系统10提供了若干优点。这些优点包括在声波发生器和接收器30的顶部提供具有向上定向的凸起圆顶表面38的凸形壁部分36，该凸形圆顶表面38为靠近声波发生器和接收器30的底部罐壁28的区域提供自然重力感应的自清洁功能。对于尿素浓度梯度形成的情况，从声波发生器和接收器30到反射器14以及从反射器14提供垂直声音传播方向促进了平均函数的集中。使用不锈钢作为尿素浓度传感器反射器组件12或者使用具有类似热膨胀系数且能够在尿素浓度中起作用的材料，使硬件热生长对超声波传播时间的影响减少了超过80％。这简化或消除了对温度对尿素浓度表的需要。附接尿素浓度传感器反射器组件12和反射器14的形状的本方法还减轻了由于主体的热变形引起的回波损耗状况。
本公开的描述本质上仅仅是示例性的，并且不脱离本公开的要点的变化旨在落在本公开的范围内。这些变化不应被视为偏离本发明的精神和范围。

Claims (7)

1.一种尿素浓度传感器反射器组件，包括：
反射器，具有圆顶形状，所述圆顶形状一体地连接到多个支腿上并且由所述多个支腿支撑，所述反射器包括凹形内表面；
所述多个支腿，连接到所述尿素浓度传感器反射器组件的所述反射器并将所述尿素浓度传感器反射器组件的所述反射器支撑到尿素储存罐底部罐壁的向上定向的表面；以及
固定到所述底部罐壁的声波发生器和接收器，所述底部罐壁直接位于所述反射器下方并与所述反射器中心对准，所述声波发生器和接收器产生朝所述反射器向上定向的超声波；
其中，直接在所述反射器下方的所述底部罐壁限定了向上定向的凸起圆顶表面，使得在所述底部罐壁处形成的尿素晶体或颗粒能够通过重力向外移动并离开所述圆顶表面。
2.根据权利要求1所述的尿素浓度传感器反射器组件，其中，所述多个支腿包括第一支腿、第二支腿、第三支腿和第四支腿，所述多个支腿之间彼此等距地间隔开。
3.根据权利要求1所述的尿素浓度传感器反射器组件，其中，所述底部罐壁除了直接在所述反射器下方之外大致上是平面的。
4.根据权利要求1所述的尿素浓度传感器反射器组件，其中，所述支腿中的每一个包括支腿部分，所述支腿部分的大小被确定成摩擦地容纳在所述底部罐壁中产生的对应形状的槽中。
5.根据权利要求1所述的尿素浓度传感器反射器组件，其中，所述凹形内表面限定向下定向的超声波聚焦区，所述向下定向的超声波聚焦区接收并回射所述超声波。
6.根据权利要求5所述的尿素浓度传感器反射器组件，其中，所述凹形内表面将所述超声波反射并重新构造成圆锥形超声波锥体，所述圆锥形超声波锥体将所述反射的超声波集中，以基本上沿着所述声波发生器和接收器的中心轴线在所述声波发生器和接收器的接收器部分处相遇。
7.根据权利要求1所述的尿素浓度传感器反射器组件，其中：
所述尿素浓度传感器反射器组件的固定高度保持在所述凹形内表面的顶点和所述底部罐壁的平面上表面之间；
通过使用在所述支腿中的每一个的相同位置处形成的凹口表面来保持所述固定高度，所述凹口表面直接抵靠在所述平面上表面上；以及
在所述尿素浓度传感器反射器组件的安装位置，支腿中的每一个相对于所述平面上表面以共同的角度阿尔法（α）来取向。
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