euro 4 system workshop

8/19/2019 Euro 4 System Workshop

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Euro 4 System

Workshop



Cummins Confidential

Agenda

Brief Introductions

Component Overview

Application Guideline DiscussionTruck Upfit Simulation

Light Duty Upfit Simulation




SCR System: OverviewSCR System: Overview

Urea Aqueous Solution or AdBlue AdBlue storage tank

Urea Pump

System function lamps

Compressed

Air supply

TurboExhaust

UreaInjectionTemperature Sensors

Tailpipe Decomposition Area

Dosing Unit

SCR Brick

SCR System DiagramSCR System Diagram

Air Inlet Mass flow Sensor

NOx Sensor N

2

+ H H

2

O

Too much Ammonia =Too much Ammonia = Ammonia Ammonia“Slip

lip

”

Usage around

sage around

5 of Fuel

of Fuel


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Switched

Battery

Battery

Urea

Tank

Heater

Relay

Battery +

Battery -

Heater

Battery

Urea

Level MIL

OEM

Connector

ECM

Line

Heaters

J1939 (Public)

Level/Temp Sensor

Exhaust

Flow

•Engine maps

•Engine data

•Nox Estimator

•Algorithm

•Sensor I/O

•System OBD

Urea Dosing Unit

3.5” ½ Marmon Clamp Connection

Injector

Nozzle

Vehicle OEM

responsible for

pink box.

Truck Dash

Lamps

Catalyst Inlet

TemperatureCatalyst Outlet

Temperature

Aftertreatment Device

(Catalyzed Muffler)

NOx Sensor



MSCR Dosing Unit Atomization

Nozzle



Exhaust BrakeExhaust Brake

Typical Right hand Mount with softTypical Right hand Mount with soft

mountings on the EGPmountings on the EGP

NozzleNozzle

Soft MountsSoft MountsRadialRadial

OutletOutlet

No JointNo Joint – – Fully WeldedFully Welded



Typical Left Hand Mounting withTypical Left Hand Mounting withHard Mounts on EGPHard Mounts on EGP

Flex SectionFlex Section

Support BracketSupport Bracket

ThermistorsThermistors

JointJoint



Exhaust Gas Processor (EGP)

Integrated catalyst and acoustic unit inone sealed stainless steel housing

Weight: Significantly heavier than a traditional muffler, the strength of

he current muffler mounting system needs to be reviewed andupgraded if necessary

Temperature: The EGP should be located as close as possible to the

ngine as the chemical process in the catalyst is temperatureependant (2000C min.), The inlet face of the catalyst must be located

between 1 - 4m from the turbocharger exhaust outlet.

Vibration: The catalyst in the EGP must be protected from vibration.

his can be achieved by the use of a flexible section of piping fitted

between the turbocharger outlet and the EGP. CES 10g load tested



Exhaust PipeworkThe exhaust pipe work from 200mm upstream of the

AdBlue nozzle and all the way downstream to the

EGP must be stainless steel grade 304 or 439. Nobrass, copper, mild steel or zinc should be used inareas where AdBlue is present.

The maximum total system back pressure measuredat the turbo exhaust outlet at full load rated speed

should not exceed the value quoted on the enginedata sheet. Typically, EGP < 7kpa, total exhaustsystem < 15 kpa




Dosing UnitThe dosing unit (DU) is a high accuracy unit for injectinghe required AdBlue quantity into the exhaust after-treatment

ystemSolid mounting the DU to the chassis is acceptable. TheDU can only be mounted in one

orientation and must be locatedin the chassis with the ‘Z’ axis vertical

The DU does not contain any

erviceable items and it shall not

be disassembled.

DU Connector




Urea Tank

The supply tank should be sized to suit an operational

use of AdBlue equivalent to 5% of fuel consumption for

Euro 4 installations

The vehicle manufacturer must provide level andemperature sensing for the AdBlue supply tank.

The AdBlue tank and all connections and lines to androm the dosing unit must be internally clean when

assembled.




Climate Consideration

Urea starts to freeze at –11oC , some form of heating will berequired for cold weather operation.

Heating can be provided by means of suitably placed electricalelements or by means of engine coolant. Whatever means ischosen, the heating system must be thermatically regulated. Therecommended maximum temperature for urea is 50 oC

The parts of the system most vulnerable to freezing are theexternal lines and fittings between tank and dosing unit.Regardless of whether tank heating is provided, exposed linesand fittings will freeze and prevent urea flowing and carefulattention must be given to heating and insulation.




Electrical Wiring Harness

It is the OEM’s responsibility to develop

a wiring harness to the DU. The DU isitted with a 7 pin Tyco Connector.




Electrical Wiring Harness

Will update

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