WO2022003709A1

WO2022003709A1 - Exhaust system for a vehicle

Info

Publication number: WO2022003709A1
Application number: PCT/IN2020/050912
Authority: WO
Inventors: Bharaniram Senthilkumar; Boobalan Mani; Balaji Vaidyanathan
Original assignee: Tvs Motor Company Limited
Priority date: 2020-06-30
Filing date: 2020-10-29
Publication date: 2022-01-06
Also published as: CO2022019056A2

Abstract

The present invention relates to a vehicle (100), where said vehicle (100) comprises an exhaust system (200) which includes a single sensor member (202) disposed upstream to and in a predetermined short distance to the first catalytic converter (204). Downstream there is a second catalytic converter (205), preferably within the muffler body (207).

Description

EXHAUST SYSTEM FOR A VEHICLE

TECHNICAL FIELD

[0001] The present subject matter relates to a motor vehicle. More particularly, the present subject matter relates to an exhaust system of the motor vehicle.

BACKGROUND [0002] In recent time, motor vehicle emission reduction has been a major focus area for invention and technology development. This includes On-Board Diagnostics as one of the major means to achieving reduced emission and improves performance. The On Board Diagnostic OBD implies that specific emission related systems on the vehicle should be monitored. The intent of the OBD is to ensure that these systems are functioning as intended, and if the systems have deteriorated, in that case the vehicle operator should be informed through suitable means. For example, a catalytic converter of a motor vehicle is monitored because of its ability to reduce undesirable emissions in exhaust gases from an engine of the motor vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The detailed description is described with reference to an embodiment of a motor vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference like features and components. [0004] Fig.l is a right side view of a saddle type vehicle as per one embodiment of the present invention.

[0005] Fig.2 is a perspective view of an exhaust system as per one embodiment of the present invention

[0006] Fig. 3 is a schematic layout of the exhaust system when substrate of the first catalytic condition is functional as per one embodiment of the present invention. .

[0007] Fig. 3a is a schematic layout of the exhaust system when substrate of the first catalytic condition is damaged as per one embodiment of the present invention. . [0008] Fig. 3b is a graphical representation of output of sensor member when the substrate of first catalytic converter is functional and damaged as per one embodiment of the present invention. .

[0009] Fig. 4 represents a flowchart explaining detection method as per one embodiment of the present invention.

[00010] Fig. 5 is a flowchart explaining the detection method as per another embodiment of the present invention.

[00011] Fig. 6 is a flowchart explaining the detection method as per another embodiment of the present invention.

DETAILED DESCRIPTION

[00012] Generally, in motor vehicles with internal combustion engine, power/torque for the motor vehicle propulsion is produced by combustion of air-fuel mixture provided through an intake system. The resultant gases of the combustion process are removed by an exhaust system. The exhaust system as mentioned includes an exhaust piping to channelize gases from an engine to a muffler. Also, the exhaust system treats the gases before emitting into the atmosphere.

[00013] During the combustion of air-fuel mixture in the engines of motor vehicles, in addition to water and carbon dioxide some other incomplete burnt gases like carbon monoxide (CO), hydro-carbons (HC) and nitrogen oxides (NOx) are also released. These gases as emitted are channelized to the muffler through the exhaust piping. Further, as it is known that these gases are harmful in nature and if they are emitted in an atmosphere without being treated, will increase the level of pollution in the atmosphere. So, to curb this, generally these gases are converted into less harmful gases like carbon dioxide, nitrogen and oxygen etc. by various mechanisms like use of devices for example, catalytic converters. Also, an efficient combustion process is one which has minimal exhaust emissions, therefore enhancing performance is an higher order objective which also results in reduction of emissions.

[00014] The catalytic converters for vehicle exhaust system are well known components which are basically used for treating the harmful exhaust gases emitted from the engine. Such catalytic converters are typically constructed by having a housing within which one or more converter bricks are arranged. Each of the converter bricks has a wash coat containing one or more rare metals typically chosen amongst the elements viz. platinum, rhodium or palladium. The catalytic converter is most often made of precious metal. Platinum is the most active catalyst and is widely used. However, because of unwanted additional reactions and/or cost, Palladium and rhodium are two other precious metals are used. Platinum and rhodium are used as a reduction catalyst, while palladium is used as an oxidization catalyst. Cerium, iron, manganese and nickel are also used, although each has its own limitations

[00015] The washcoat provides a plurality of catalytic reaction sites on which oxygen is temporarily stored. The temporarily stored oxygen within the catalytic converter as a buffer, can undergo catalytic oxidation reactions with one or all of the following gases: carbon monoxide (CO), hydrocarbons (HC) and nitrous oxides (NO) of various types.

[00016] Also, the optimum performance of the catalytic converter is achieved when the catalytic converter reaches optimum temperature at the shortest possible time from the time the engine is ignited. The time taken by the catalytic converter to reach the optimum temperature is often referred as light-off time or activation time. The activation time plays a vital role in reducing emissions.

[00017] Further, in some vehicles the catalytic converter is disposed in the proximity of a muffler body or within the muffler body, which is away from any hot zone such that it is not exposed to be in close contact with excess heat from the combustion chamber as well as to be not affected by environmental factors. Also, a first catalytic converter may be disposed upstream of the aforementioned catalytic converter, that is near exhaust port. However, when the catalytic converter having substrate is disposed closer to the exhaust port, it is inherently vulnerable of being burnt out earlier than required time period, due to exposure to high temperature generated by the emitted exhaust gases. As a result, the durability or life of the catalytic converter is compromised, which could in turn lead to undesirably higher emissions and usage of the vehicle with deteriorated performance. Further, using the vehicle with such deteriorated performance would lead to a major failure of the engine in the long run. Therefore, to prevent such major failures and in order to restore the best performance of the catalytic converter, there is a requirement to replace the burnt out catalytic converter. [00018] Furthermore, taking other factors into consideration, the catalytic converter may deteriorate over time due to factors such as engine misfire, a faulty sensor, positioning in close proximity of heat or prolonged high temperature operation which lead to damaging of substrate present in the catalytic converter. As the catalytic converter deteriorates, it loses its capacity to store the oxygen available in the exhaust gases. This results in transferring of harmful untreated exhaust gases from vehicle to atmosphere, thereby polluting environment at large. Hence, the periodic monitoring of catalytic converter, specifically, substrate of catalytic converter is required, to inform the user about the faulty catalytic converter. This ensures that the catalytic converter is timely replaced and hence, reduces the impact of faulty catalytic converter on the overall vehicle at large.

[00019] In known art, for periodic monitoring of the condition of substrate of catalytic converter, a set of sensors are positioned, one before and one after the catalytic converter. Typical monitoring methods employ plurality of sensors and infer the conversion capability of the catalytic converter using the sensor signals in a closed loop system. One sensor monitors the oxygen level associated with an inlet exhaust stream of the catalytic converter. This inlet sensor is also the primary feedback mechanism that maintains the fuel-to-air (F/A) ratio of the engine at the chemically correct, or stoichiometric Air- Fuel ratio needed to support the catalytic conversion processes. A second or outlet sensor monitors the oxygen level concentration of the exhaust stream exiting the catalytic converter. Excess concentration in the exiting exhaust stream induces a “lean¹ Sensor Signal. A deficit or absence of oxygen in the exiting exhaust stream induces a "rich’ Sensor Signal.

[00020] Traditional monitoring methods relate the empirical relationships that exist between the inlet and outlet sensors to quantify catalyst conversion capability. Further, the measurements are affected by a property of a catalytic converter known as Oxygen Storage Capacity (OSC). OSC refers to the ability of the catalytic converter to store excess oxygen under lean conditions and to release oxygen under rich conditions. The amount of oxygen storage and release decreases as the conversion capability of the catalytic converter is reduced over time.

[00021] The above mentioned monitoring method has its own disadvantages, e.g. the number of components increases owing to use of plurality of sensors etc. Also there is a rise in probability of malfunction of the system due to large number of elements, where failure of any one element would result in giving false data and thereby poor reliability. Moreover, as the sensor members are delicate components and also, output of the sensor members may get affected by various external factors like, surrounding components, location, positioning etc. So, the sensor members may also provide erroneous/faulty data to an electronic control unit regarding a functioning condition of the catalytic converter depending on the position of the sensor member with reference to the catalytic converter. For example, if the sensor member provides error information related to condition of the catalytic converter, it may affect the user or affect the environment. Further, if the sensor member gives false information regarding proper functioning of the catalytic converter, it would turn out to be harmful to the environment. In another scenario, if the system gives false information that the catalytic converter has failed, when in actual the catalytic converter is functioning properly, it unnecessarily leads to a complete change in the exhaust system, which is expensive. Thus while an open loop single sensor system as per known art fails to provide reliable information about the catalytic convertor, a closed loop plural sensor system does the job albeit at compromise on complexity, layout space, complexity, reliability and cost.

[00022] In continuation of the above paragraph, such systems having plurality of sensors are undesirable as it involves complex algorithm and signal commands monitored by control unit to determine and communicate the need for the replacement to the user in a timely manner. However, such systems are also undesirable owing to design complexity involving additional no. of sensors, challenge of packaging in a compact layout space and increased cost. Additional problem also arises like layout constraint to package more sensors in the available space, compromise in potential ground clearance due to the increase in the no. of components, increase in complexity of manufacturing and assembly due to the increased no. of parts.

[00023] It is apparent from above paragraphs that the catalytic converters of the vehicle exhaust system are an important component in the vehicle. The catalytic converter reduces the harmful gases emitted from the vehicle by treating them and converting it to less harmful gases like carbon dioxide etc. and therefore protects the environment at large. As the catalytic converter efficiency is highly affected by the prolonged exposure of the high temperatures etc. So, there is a constant need of periodic monitoring of the life of catalytic converter. In conventional method, this is done by using plurality of sensors which ultimately increases the complexity as well as cost of the vehicle.

[00024] Hence, there exists a challenge to provide a reliable system that is cost effective and additionally capable of providing reliable health condition of the catalytic converter with minimum number of parts and sensor to enable a compact layout of the vehicle.

[00025] Therefore, there is a need for an improved exhaust system with an open loop system, which can effectively monitor and indicate condition of the catalytic converter.

[00026] The present subject matter discloses an exhaust system configured in a counterintuitive manner with a single sensor member which effectively indicates the health condition of the catalytic converter to vehicle ECU and / or the users in a reliable manner while overcoming all the problems cited above and other problems of known art.

[00027] As per one aspect of present invention, a vehicle comprises of an exhaust system. The exhaust system comprises of an exhaust pipe, a plurality of catalytic converters (can be referred as ‘CAT’) and a muffler. The exhaust pipe is attached to an engine, through which emitted gases during exhaust stroke of the engine, are channelized to the muffler. Further, the first catalytic converter is mounted near the exhaust port and second catalytic converter is mounted in the muffler itself. The first catalytic converter is a primary converter and second catalytic converter is a secondary converter. These catalytic converters as disposed converts the harmful gases like carbon monoxide etc. into carbon dioxide, nitrogen, oxygen etc. This ensures that the gases which are emitting in the atmosphere are comparatively less harmful. As per additional embodiment, there may be a tertiary catalytic converter implemented.

[00028] As per one aspect of the present invention, a sensor member is disposed or configured at a predetermined distance with respect to the first catalytic converter in an open loop system. More precisely, the sensor member as located monitors the condition of substrate of the first catalytic converter and sends it to the users through a failure detection system. Further, as per one aspect of the present invention, a failure detection system includes a detection control unit being functionally connected to the sensor member to receive data from the first catalytic converter thereby determining any failure of the first catalytic converter. The first catalytic converter is disposed in proximity of exhaust port. The data from the sensor member as disposed upstream of the first catalytic converter is analysed by the ECU in a predetermined manner based on which the ECU detects the health condition of the first catalytic converter, identifies of any issues and sends the input to the failure detection system in case of any failure. This received input in the detection control unit triggers the malfunction indication to the users leading to timely replacement of faulty/damaged catalytic converter. This configuration ensures that the users are informed about the condition of damaged catalytic converter which helps them to replace the component timely, thereby not affecting the performance of vehicle at large in a known or unknown manner.

[00029] Elaborating further regarding detection method of the condition of the first catalytic converter, the failure detection system includes a detection control unit, i.e. DCU. The detection control unit has predetermined information or signals signature stored in the form of look up table. Further, the sensor member disposed on upstream of the catalytic converter in close proximity to the catalytic converter sends the output signal to the detection control unit. The detection control unit analyzes the output signal as received by the sensor member against the preconfigured signals which are stored in the look up table. The detection control unit determines that whether quantifiable parameter value, eg. amplitude of the received output signal is beyondthe predetermined value of the of the signal stored in the look up table. Further, if the detection control unit finds out that the amplitude of the received output signal is greater than predetermined amplitude of the predetermined signal stored in the look up table, then the detection control unit concludes that the substrate of the first catalytic converter is damaged, hence the first catalytic converter damage indication may be triggered to the user . The detection control unit communicates this to the user through a suitable indication means, for example, in an instrument cluster or to any other connected device, for example, a mobile phone. This achieves a simple and cost effective open loop system to monitor the condition of the first catalytic converter, that is, without calculating or going through the complex algorithm of calculating the data related to before and after treatment of the emitted gases. The current invention is counterintuitive in that it employs a single upstream sensor and thereby ensures the timely replacement of the damaged catalytic converter without affecting the performance of the vehicle at large. [00030] Further, when the substrate of catalytic converter is functional, then the exhaust gases as emitted from the engine are less turbulent. Hence, the output signal generated by the sensor member would be consistent without any peaks. When the substrate of catalytic converter is damaged/nonfunctional/burnt out, then the exhaust gases as emitted from engine tend to become more turbulent, which in turn creates discernable high peaks in the output signal of the sensor member. As per another aspect of the present invention, the detection control unit has predetermined data or preconfigured signals stored in a lookup table. The sensor member sends the generated output signal to the detection control unit, where the sensor member generates the output signal based on the turbulence of the exhaust gases emitted from the engine. The detection control unit analyzes the received signal with respect to the predetermined data or preconfigured signal signature stored in the look up table. The detection control unit determines that whether there is a significant variation in the output signal that is, whether number of spikes are increased in the received output signal as compared to the number of spikes in the predetermined signal stored in look up table and whether they are attributable to the significant deterioration of the catalytic converter. Further, if the detection control unit finds out that the numbers of spikes are increased in the received output signal as compared to the number of spikes in the predetermined reference information or reference signature signal stored in look up table, then the detection control unit concludes that the substrate of first catalytic converter is damaged, hence first catalytic converter is inferred to need a change or service. Then the detection control unit communicates this to the user through a suitable means, for example, in an instrument cluster or any other connected device, for example, a mobile phone. This solution achieves a simple and cost effective open loop system to monitor the condition of the first catalytic converter that is without calculating or going through the complex algorithm of calculating the data related to before and after treatment of the emitted gases as well as without implementing a plurality of sensors. This also enables the timely replacement of the catalytic converter without affecting the performance of the vehicle at large.

[00031] Further, as per another aspect of the invention, the sensor member sends the output signal to the detection control unit. The detection control unit stores the predetermined pattern of signal in a look up table. The detection control unit after receiving the output signal from the sensor member analyzes it against a predetermined pattern of signal, i.e., comparing against the predetermined signal pattern stored in the look up table. Further, the detection control unit determines that whether one or more qantifiable parameters of the input signal e.g. the amplitude or range or peak or frequency etc. of the received output signal from the sensor member is greater than the predetermined threshold or limiting value e.g. predetermined amplitude of the preconfigured signal as stored in the lookup table and if beyond a predetermined limit or range, the DCU infers damage condition of the catalytic converter and triggers a fault intimation to be conveyed to the user for repair and / or service. As per an additional embodiment, if the detection control unit finds out that the quantifiable parameter of the received output signal from the sensor member is greater than a predetermined limit, then subsequently the detection control unit determines that whether there is a significant variation in the output signal, e.g. whether number of spikes are increased in received output signal as compared to predetermined number of spikes of the preconfigured signal stored in the look up table, then the detection control unit concludes that the substrate of the first catalytic converter is damaged. Further, the detection control unit communicates this to the user through a suitable indication means, for example, instrument cluster, or to any other connected device, for example, a mobile phone. This ensures the timely replacement of the catalytic converter without affecting the performance of the vehicle at large.

[00032] In the ensuing exemplary aspects, the vehicle is a two-wheeler saddle type vehicle. However, it is contemplated that the concepts of the present invention may be applied to any of the two wheeler, three wheeler and four wheeler vehicle without defeating the spirit of the invention. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof. [00033] The various other features of the invention are described in detail below with an embodiment of a two wheeler saddle type vehicle with reference to the accompanying drawings. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the corresponding reference number. With reference to the accompanying drawings, wherein the same reference numerals will be used to identify the same or similar elements throughout the several views.

[00034] Further “front” and “rear”, and “left” and “right” referred to in the ensuring description of the illustrated embodiment refer to front and rear, and left and right directions as seen in a state of being seated on a seat of the saddle type vehicle. Furthermore, a longitudinal axis refers to a front to rear axis relative to the vehicle, while a lateral axis refers to a side to side, or left to right axis relative to the vehicle. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[00035] Fig. 1 is a right side view of an exemplary saddle type vehicle. The vehicle (100) has a frame assembly (not shown), which acts as the skeleton for bearing the loads. Instrument cluster (119) is mounted on handle bar assembly (126). The handle bar assembly (126) is disposed over the head tube (not shown) and it includes brake levers (not shown). The handle bar assembly (126) is connected to a front wheel (129) by one or more front suspension(s) (130). A front fender (131) is disposed above the front wheel (129) for covering at least a portion of the front wheel (129). A fuel tank (103) is mounted to the main tube (not shown) of the frame (not shown) and it is disposed in the front portion F of a space of the frame (not shown). The vehicle (100) having lighting means which includes Head lamp (127), Tail lamp (not shown), Turning indicators includes front side indicators (not shown) and rear side indicator (not shown) respectively. The rear fender (138) is projected outwardly of the vehicle systems and protects pillion from mud splash as well as protects the rear wheel (133) from damage from external objects. An engine (125) is mounted to the lower portion of the vehicle (100). In an embodiment, the engine (125) is a single cylinder engine. The fuel tank (103) is functionally connected to the engine (125). The seat (132) is located at the back region of the fuel tank (103) and is extended in a longitudinal direction along the seat frames. As per one embodiment of the present invention, an exhaust system (200) is connected to the engine (125) and extended rearwardly of the vehicle (100).

[00036] Fig. 2 is a perspective view of the exhaust system as per one embodiment of the present invention. As per one embodiment, the exhaust system (200) includes an exhaust port, an exhaust pipe, a plurality of catalytic converters (204, 205), a sensor member (202), a muffler (206) and a muffler body (207). The second catalytic converter (205) is disposed downstream of the first catalytic converter (204). Thus, the exhaust gas flow path covers the first catalytic converter (204) and the second catalytic converter (205). Further, the second catalytic converter (205) can be disposed substantially after a lengthwise mid-portion of the exhaust pipe (201). The first catalytic converter (204) is a primary converter and second catalytic converter (205) is a secondary converter.

[00037] The sensor member (202) is disposed upstream of the first catalytic converter

(204). As per one embodiment, the first treatment device (204) acts as a secondary device having a volume substantially lesser than a volume of the second catalytic converter

(205), which acts as a primary device. This split configuration of the catalytic converter enables designing a compact exhaust system since the function of the catalytic converter is split into primary and secondary catalytic converter thereby enabling reducing size of each catalytic converter. Moreover, first catalytic converter (204) is compactly located within a receiving portion (203) in the exhaust pipe (201) without the need for any major increase the external diameter of the exhaust pipe (201). This maintains the compact structure of the exhaust pipe and overall exhaust system of the vehicle. The second catalytic converter (205) is located in a muffler body (207) of the exhaust system (200). The secondary catalytic converter is provided with a guard to protect the user/rider from the excessive heat as generated in the muffler.

[00038] Fig. 3 is a schematic layout of the exhaust system as per one embodiment of the present invention. As per one embodiment of the present invention, the sensor member (202) is disposed or configured at a predetermined distance with respect to the first catalytic converter (204) in an open loop system. The sensor member (202) is disposed in a predetermined distance (Z) varying between 1 to 2 times diameter D of the first catalytic converter. Beyond 2 times of the outer diameter (D) of the first catalytic converter, the detection of the increase in turbulence, created due to the damage of substrate of the first catalytic converter, would not be accurately detected by the sensor member and can lead to compromised or erroneous inferences. For example, the accuracy can be varying approximately between 90% up to 1 time the diameter (D) to 80% up to 2 times the diameter (D) of the first catalytic converter. Ahead of 2 times the diameter (D) of the first catalytic converter, the accuracy of detection reduces exponentially. As per additional embodiment, the sensor member (202) is disposed on the cylinder head on the side of spark plug. The sensor member as disposed is parallel to a combustion chamber of the engine (125).

[00039] Further, as per one embodiment of the present invention, when substrate of the first catalytic converter (204) is functional, and the exhaust gases are less turbulent, then the output signal of the sensor member (202) would be consistent without any aberration or undesirable peak (as shown by line A, fig, 3b). When the substrate of the first catalytic converter (204) is burnt out/ faulty/damaged, that would tend to obstruct the flow of the exhaust gases, thereby creating a vortex (303) shown in Fig 3a. The vortex (303) as created increases the turbulence in the vicinity of the first catalytic converter, which is created here up to 1 time the diameter (D) of the first catalytic converter (as shown in fig. 3a). Hence, the sensor member is disposed in the proximity to monitor the turbulence generates in normal condition and faulty condition and thereby, generates the required output signal (in faulty case, having high peaks (as shown in B of fig. 3b)). The sensor member (202) monitors the condition of the first catalytic converter (204). More precisely, the sensor member monitors the condition of substrate of the first catalytic converter and sends indication to the users through failure detection system (300). Further, as per one embodiment of the present invention, a failure detection system (300) includes a detection control unit DCU (301) being functionally connected to the sensor member (202) to receive data of the condition of the first catalytic converter (204) thereby determining any failure of the first catalytic converter. The first catalytic converter (204) is disposed in proximity of the exhaust port. The data from the sensor member (202) as disposed upstream of the first catalytic converter (204) is analysed by the ECU in a predetermined manner based on which the ECU detects the health condition or health of the first catalytic converter (204), identifies of any issues and sends the input to the detection control unit (301) in case of any failure. This received input in the detection control unit (301) triggers the malfunction indication (302) to the users leading to timely replacement of faulty/damaged catalytic converter. This configuration ensures that the users are informed timely about the condition of damaged catalytic converter which helps them to replace the component, thereby not affecting the performance of vehicle at large. Subsequent paragraphs further elaborate the detection method of the condition of the first catalytic converter.

[00040] Fig. 4 represents a flowchart explaining detection method as per one embodiment of the present invention. The failure detection system includes a detection control unit, i.e. DCU. The detection control unit has predetermined information or signals or signatures of signals or reference limit values stored in a look up table. At step S401, the sensor member as disposed sends the output signal information to the detection control unit. Further, at step S402, the detection control unit analyzes the output signal information as sent by the sensor member against the preconfigured signal information which are stored in the look up table At step S403, the detection control unit determines that whether quantifiable parameter value, e.g, amplitude of the received output signal is beyond the predetermined value of the signal information stored in the look up table. At this step, if the detection control unit determines that the parameter value of the received output signal is greater than a predetermined value of the signal stored in the look up table, then the detection control unit at step S404 concludes that substrate of first catalytic converter is damaged, hence the first catalytic converter is damaged. Further at step S405, the detection control unit communicates this to the user through a suitable indication means, for example, in an instrument cluster or to any other connected device, for example, a mobile phone. This achieves a simple and cost effective open loop system to monitor the condition of the first catalytic converter, that is, without calculating or going through the complex algorithm of calculating the data related to before and after treatment of the emitted gases with the help of plurality of sensors etc. This also, ensures the timely replacement of the catalytic converter without adversely affecting the performance of the vehicle at large.

[00041] Fig. 5 is a flowchart explaining the detection method as per another embodiment of the present invention. As per another embodiment of the present invention, the detection control unit has predetermined data or preconfigured signals stored in a look up table. At step S501, the sensor member sends the generated output signal to the detection control unit where the sensor member generates the output signal based on the turbulence of the exhaust gases emitted from the engine. At step S502, the detection control unit analyzes the received signal with respect to the preconfigured signal as stored in the look up table) At step S503, the detection control unit determines that whether there is a significant variation in the output signal, that is number of spikes are increased in the received output signal as compared to the number of spikes in the preconfigured signal stored in look up table and whether they are attributable to the significant deterioration of the catalytic converter Further, at step S504, if the detection control unit finds that the number of spikes are increased in the received output signal as compared to the predetermined number of spikes in the preconfigured signal or data stored in look up table, then the detection control unit concludes that the substrate of first catalytic converter is damaged, hence first catalytic converter is damaged. At last, at step S505, the detection control unit communicates this to the user through a suitable means, for example, in an instrument cluster or any other connected device, for example, a mobile phone. This achieves a simple and cost effective open loop system to monitor the condition of the first catalytic converter that is without calculating or going through the complex algorithm of calculating the data related to before and after treatment of the emitted gases with the help of plurality of sensors etc. This also enables the timely replacement of the catalytic converter without affecting the performance of the vehicle at large.

[00042] Fig. 6 is a flowchart explaining the detection method as per another embodiment of the present invention. Further, as per another embodiment of the invention, at step S601, the sensor member sends the output signal to the detection control unit. The detection control unit has the predetermined pattern of signal stored in a look up table. The detection control unit at step S602 after receiving the output signal from the sensor member analyzes it against a predetermined pattern of signal, i.e., comparing against the predetermined signal stored in the look up table. Further, the detection control unit at step S603 determines that whether one or more quantifiable parameters of the input signal e.g., the amplitude or range or peak or frequency etc. of the received output signal from the sensor member is greater than the predetermined threshold or limiting value e.g. predetermined amplitude of the preconfigured signal as stored in the lookup table and if beyond a predetermined limit or range, the DCU infers damage condition of the catalytic converter and triggers a fault intimation to be conveyed to the user for repair and / or service. . As per an additional embodiment, if the detection control unit finds that the quantifiable parameter of the received output signal from the sensor member is greater than a predetermined limit, then subsequently the detection control unit at step S604, determines that whether there is a significant variation in the output signal, that is, e.g. whether number of spikes are increased in received output signal beyond predetermined number of spikes of the preconfigured signal or limiting data stored in the look up table. Based on the determination, the detection control unit at step S605 concludes that the substrate of the first catalytic converter is damaged; hence the first converter is damaged. Further, the detection control unit communicates this to the user through a suitable indication means, for example, instrument cluster, or to any other connected device, for example, a mobile phone (as described step S606). The present invention achieves a simple and cost effective open loop system to monitor the condition of the first catalytic converter without detailed computations or calculations or going through the complex algorithm of calculating the data related to before and after treatment of the emitted gases with the help of plurality of sensors etc. This also ensures the timely replacement of the catalytic converter without affecting the performance of the vehicle at large. As per additional embodiment, the failure detection system can be configured so as to be able to self-calibrate the limit values or limit signal signature by installing a faulty catalytic converter on the exhaust system by providing a suitable self-calibration mode activation.

[00043] The embodiment and methods explained in Fig. 2, Fig. 4, Fig.5 and Fig. 6 of the present invention helps in ensuring monitoring the condition of first catalytic converter as well as overcoming all the problems known in the art.

[00044] Advantageously, the embodiments of the present invention, describes the potential modifications in the location of the sensor member in the exhaust system. This facilitates the cost effective method to monitor the condition of the first catalytic converter in an open loop system. [00045] Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention.

List of reference symbol:

Fig. 1: 100: Saddle type Vehicle

126: Handle Bar Assembly 119: Instrument Cluster 127: Head Lamp 131: Front Fender 129: Front Wheel

130: Front Suspension 125: Engine

103 : Fuel Tank Assembly 134: Seat 138: Rear Fender

133: Rear Wheel 200: Exhaust system

Fig. 2

201: Exhaust Pipe 202: Sensor Member

203: Receiving Portion 204: First Catalytic Converter 205: Second Catalytic Converter.

206: Muffler 207: Muffler Body

Fig. 3:

300: Failure Detection System. 301: Detection Control Unit 302: Malfunction Unit

303: Turbulence Z: Predetermined Range D: Diameter

Fig. 3b

A: Output Signal by sensor member when substrate is normal functioning. B: Output signal when substrate is damaged

Claims

We Claim

1. An exhaust system (200) of an engine (125) for a motor vehicle (100), said exhaust system (200) comprising: a plurality of catalytic converters (204, 205), said first catalytic converter (204) disposed upstream of a second catalytic converter (208) of said exhaust system (200); a sensor member (202) disposed upstream of said first catalytic converter (204) at a turbulence zone (303) and in a predetermine distance Z.

2 The exhaust system (200) as claimed in claim 1, wherein said turbulence zone (303) is up to a distance of 1 time a diameter (D) of said first catalytic converter (204).

3. The exhaust system (200) as claimed in claim 1, wherein said predetermine distance Z is between 1 to 2 times external diameter (D) of said first catalytic converter (202).

4 The exhaust system (200) as claimed in claim 1, wherein said exhaust system (200) includes an exhaust pipe (201) having receiving portion (203), where said first catalytic converter (204) disposed within a receiving portion (203) in said exhaust pipe (204).

5. The exhaust system (200) as claimed in claim 1, wherein said exhaust system (200) includes a muffler body (207), where said second catalytic converter (205) is disposed in said muffler body (207) in said exhaust system (200).

6. The exhaust system (200) as claimed in claim 1, wherein first catalytic converter (204) is a primary catalytic converter and second catalytic converter (205) is a secondary catalytic converter.

7. A failure detection system (300) for an exhaust system (200) of a motor vehicle (100), said failure detection system (300) comprising; a sensor member (202) disposed upstream of a first catalytic converter (204) of plurality of catalytic converters (204, 205) disposed in said exhaust system (200); a detection control unit (301) functionally connected to said sensor member (202) for receiving data and comparing said received data with respect to predetermined data stored in a lookup table of said detection control unit (301) and said detection control unit (301) capable of determining failure of substrate of said first catalytic converter of said exhaust system (200).

8. The failure detection system (300) as claimed in claim 7, wherein said detection system (300) includes a malfunction indicator (302), and said detection control unit (305) capable of triggering said malfunction unit (302) based on detection of failure of substrate of first catalytic converter (204).

9. A method for failure detection of substrate of first catalytic converter (204) of an exhaust system (200) configured based on output signal generated by a sensor member (202), said method comprising steps of: sending output signal generated by a sensor member to detection control unit ; analyzing of said output signal received by said detection control unit against a preconfigured signals which are stored in a look up table of said detection control unit ; determining whether quantifiable parameter value of said received output signal is beyond predetermined value of the signal stored in the look up table of said detection control unit ; determining whether there is a variation in the received output signal; concluding substrate of first catalytic converter damaged; and communicating damaging of substrate of first catalytic converter to the user through a suitable indication means

10. The method for failure detection for substrate of first catalytic converter (204) of an exhaust system (200) as claimed in claim 8, wherein determining whether quantifiable parameter value, that is, a amplitude/frequency/range of said received output signal is beyond predetermined value of the signal stored in the look up table of said detection control unit (S402).

11. The method claim for failure detection for substrate of first catalytic converter (204) of an exhaust system (200) as claimed in claim 8, wherein additionally determining variation is received output signal that is whether number of spikes generated in received output signal increased than the predetermined number of spikes in the preconfigured signal stored in the look up table of said detection control unit (S503).