重型卡车SCR排放系统中英文版2015

0,EngineApplicationDepartmentofC2、排气后处理系统的技术类型：TypesofExhaustSolutionSystem:选择催化还原技术简介：选择性催化还原是一项针对柴油发动机排气的NOx控制技术。这个反应需要在一个催化器里向排气中喷入尿素（一种易于分解为氨的氮化合物）。尿素被加热后产生的氨与NOx发生发应，生成无害的氮气(N2)和水(H20)。SCR：SelectiveCatalyticReductionIntroduction:SelectivecatalyticreductionisaNOxcontroltechniquefordieselengineexhaust.TheprocessinvolvestheinjectionofUrea(anitrogenouscompoundwhichreadilydecomposesintoammonia)intotheexhaustoveracatalystconvertor.TheammoniareactswithNOxandproducesharmlessnitrogen(N2)andwater(H20).,一、概述Chapter1Overview,注意：这里所说的添蓝就是指：“尿素”Note:TheAdbluesaidhereis:urea,3,3、排气后处理系统的组成：ComponentsofExhaustSolutionSystem:添蓝供给装置：如添蓝罐、添蓝溶液传感器、添蓝管路、添蓝喷射泵等Adbluesupplydevice:suchasadbluetank、adbluesensor、adbluehose空气供给装置：如储气罐、油气分离器、尼龙管等Airsupplydevice:suchasairtank、oil条件2：氮氧传感器状态值为“正常”；Condition2:thestateofthenitrogenoxygensensorisnormal;条件3：发动机转速大于650rpm；Condition3:enginespeedisgreaterthan650rpm;,原理图Principlefigure,车辆布置图Vehiclelayoutfigure,控制模块Dosingcontrolunit,防冻液电磁阀Coolantcontrolvalve,前温度传感器CatalystinputT-sensor,添蓝溶液传感器Ureasensor,前温度传感器CatalystoutputT-sensor,NOx传感器NOxsensor,二、排气后处理系统原理条件5：大气压力大于90kpa；Condition5:atmosphericpressuregreaterthan90kpa;条件6：排温大于200；Condition6:rowtemperaturegreaterthan200;条件7：发动机水温大于60。Condition7:enginewatertemperatureisgreaterthan60degrees.,原理图Principlefigure,车辆布置图Vehiclelayoutfigure,控制模块Dosingcontrolunit,防冻液电磁阀Coolantcontrolvalve,前温度传感器CatalystinputT-sensor,添蓝溶液传感器Ureasensor,前温度传感器CatalystoutputT-sensor,NOx传感器NOxsensor,二、排气后处理系统原理2.NOxsensorinreal-timemonitoringofNOxemissionsintheexhaustgasemissionsrequirements,andfeedbacktotheDCU,tocalculationparametersforureameasurement.,氮氧传感器NOxsensor,前温度传感器CatalystinputT-sensor,后温度传感器CatalystoutputT-sensor,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,添蓝罐总成（带添蓝溶液传感器）主要结构组成与功能：通气装置：维持罐体内和罐体外压力平衡添蓝溶液传感器：监测尿素液位和温度，密封添蓝罐添蓝罐口盖：密封添蓝罐，便于实现添蓝罐实时的尿素加注要求，加注口集成70m自清洁式过滤器，以防通过加注颈管进入的杂物损坏系统液位观察窗：人工加注尿素时，通过观察窗口液位显示控制尿素加注量，防止尿素加注过满排水孔：定期清理罐体中的残渣和污垢罐体：盛载尿素溶液,Ureatank（integratedureasensor）Mainstructureandfunction:Ventdevice:maintaintankinsideandoutsidepressurebalanceUreasolutionsensor:monitoringofurealiquidlevelandtemperature,sealingUreatankFillingcover:sealingUreatank,itiseasytofilladblueintoUreatankreal-timemeetingfillingrequirements.Thefillerneckofthetankhasafiltersizedat70microntopreventingressofmaterialwhichmaygetinviathefillerneck.Urealevelshow:Whenmanualfillingurea,controlstheureafillingquantitythroughtheurealevelshowwindow,preventstheureafillingoverDrainhole:cleaningtheresidueanddirtofthetankregularlyTankbody:loadingureasolution,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,添蓝罐中的关键总成件-添蓝溶液传感器总成监测罐内尿素溶液温度，通过发动机热水（防冻液）对罐内尿素溶液化冰加热，保证尿素溶液的正常供给；监测罐内液位高度，并按照预设液位高度向后处理系统控制模块发出报警信号；,KeycomponentinUreatank-Ureasolutionsensormonitorthetemperatureofureasolutioninthetank,keeptheureasolutionnormaltemperaturebyheatingthroughenginehotcoolant,andensurethenormalsupplyofureasolutionMonitortheheightofliquidlevelintheUreatank,andsendoutthealarmsignaltotheDCUmoduleaccordingtothepresetparameter,显示液位高低原理：磁化的浮筒感应电子管内的磁簧管开关，改变电阻输出的大小，通过阻值变化反应箱体中的液体高度变化Displayliquidlevelprinciple:changethesizeoftheoutputresistancethroughtheMagneticfloatinducingthemagneticreedswitchintube;TheresistancechangedisplayliquidheightchangeintheUreatank显示液体温度原理：NTC热敏电阻随温度变化，输出不同阻值，通过阻值变化反应罐内溶液的温度变化Displayliquidtemperatureprinciple:TheNTCthermistoroutputdifferentresistancewithdifferenttemperatureoftheUreatanksolution,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,A,B,C,D,E,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,添蓝罐总成（带添蓝溶液传感器）SCR反应所需的氨取自于质量浓度为32.5%的尿素水溶液(AdBlue)。供应罐的尺寸应使AdBlue量相当于燃油消耗量5%（欧4安装类型）的工作用量，而对于欧5估算值约为7%。适用的罐材料有不锈钢、镁铝合金或中高密度的聚乙烯。推荐使用不透明罐，使操作员不能观察液位。这能确保诊断显示空罐时它仍留有足量AdBlue，以免计量泵吸入空气。,Ureatank（Ureasensorintegrated）TheammoniarequiredfortheSCRprocessisobtainedfromasolutionof32.5%(byweight)ureainwater(AdBlue).TheUreatankshouldbesizedtosuitanoperationaluseofureaequivalentto5%offuelconsumptionforEuro4installationsandanestimated7%forEuro5.Suitabletankmaterialsarestainlesssteel,magnesiumaluminiumalloyormedium-highdensitypolyethylene.Itisrecommendedthatthetankisnon-transparentsuchthattheoperatorcannotseethelevel.Thisistoensurethatwhenthetankshowsemptydiagnostically,itwillstillhaveasignificantamountofurealefttoavoidthedosingunitdrawingair.,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,添蓝罐总成（带添蓝溶液传感器）供应罐应与大气保持双向低压通风，使出口接头的液体自由流动，并排出罐内的所有蒸汽或膨胀气体。通气口设计应使其不受罐溅出或蒸发过程中生成的结晶AdBlue导致堵塞的影响。目前还没有发生道路事故时车辆翻倾防溅方面的法规，但是需要关注未来法规的发展。添蓝罐有一个排液孔，以便进行定期维护。,Ureatank（Ureasensorintegrated）Theureatankshouldbeventedatlowpressurebothtoandfromatmospheretoallowfreeflowfromtheoutletconnectionandtoventanyvapourorexpansioninthetank.Theventshouldbedesignedsuchthatitisnotsusceptibletoblockagebycrystallizedureaformedduringtanksloshandevaporation.Thereisnoknownregulationonanti-spillforvehicleroll-overintheeventofaroadaccident;howeverthisneedstobemonitoredforfuturedevelopmentsinthelegislation.TheUreatankhasadrainholeforperiodicservicing.,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,添蓝喷射泵总成添蓝喷射泵泵(DU)是高精度装置，用于将所需尿素溶液量喷入排气后处理系统中。该部件应轻拿轻放。如果跌落可能会损坏。由DCU控制的24V电动泵和计量系统与车辆压缩空气系统送来的空气一起协作，推动雾化的尿素溶液充入排气系统催化器上游的喷嘴中。应注意空气电磁阀是一个直接使用取自加料泵12V电源的12V装置。空气消耗量为17.522L/min。（标准条件）。不论是否加注AdBlue，空气消耗都是持续的。UreadoserUnitThedosingunit(DU)isahighaccuracyunitforinjectingtherequiredAdBluequantityintotheexhaustafter-treatmentsystem.Thiscomponentshouldbehandledwithcare.Itmaybedamagedifdropped.A24velectronicallyoperatedpumpandmeteringsystem(controlledbytheDCU)workincombinationwithairfromthevehiclecompressedairsystemtopropelthe,atomizedAdBluechargethroughanozzleintotheexhaustsystemupstreamofthecatalyst.Itshouldbenotedthattheairvalvesolenoidisa12voltunitwiththe12voltpowersourcecomingfromthedosingpumpdirectly.Theairconsumptionis17.522litres/min.(standardconditions).ThisairconsumptioniscontinuouswhetherAdBlueisbeingdosedornot.,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,1.空气阀（由电磁阀控制）2.4bar压力下的空气压力调节阀3.量孔4.空气单向阀（ACV）5.背压阀（BPV）6.混合室7.出口单向阀（弹簧承载）8.促动膜片9.进口单向阀（弹簧承载）10.压力开关11.空气促动阀空气装置混合阀膜片泵A.与车辆空气系统连接（压缩空气进气管）B.与添蓝喷嘴连接（添蓝喷射管）C.与添蓝罐连接（添蓝进液管）D.与添蓝罐连接（添蓝回液管）,三、主要部件功用及工作原理Chapter3、FunctionsandOperatingPrincipleofMainComponents,1.添蓝喷射泵的4种工作模式-预注模式1.FouroperatingmodesofDUPRIMNGMODE,每次发动机运转，添蓝泵将进入预注阶段。添蓝溶液通过泵循环并流回到添蓝罐中，以便排空添蓝系统中残留的空气与尿素溶液混合物。如果预注阶段成功，将会听到添蓝泵电机全速运转30秒，空气电磁阀将在本阶段末工作。如果预注阶段第一次不成功，空气电磁阀将断电，电机将再全速运转30秒直到预注成功。这一顺序可以重复最多20次。,Everytimetheenginerunning,theDUwillcomeintoprimingmodephase.Ureasolutionthroughthecirculationpumpandflowbacktoureatank,toemptytheremainingairAccidentallyinhalationmaycauseirritationtothenose,throatandupperrespiratorytract.Itcanirritatetheskin,Needtocleanwithwaterorsoapandwaterafterlongtimecontact.Ifgetsintotheeyesmaycauseirritationtotheeyes,shouldbeimmediatelywashedwithplentyofwaterfor10to15minutes;Therewillbepain,headache,nausea,vomiting,dizziness,sleepinessandothercentralnervoussystemeffectsifeatingureasolution.Shouldgotothehospitalimmediately.,四、使用注意事项Chapter4、Useattention,2.燃油硫含量对SCR系统的影响关系2.TheinfluenceoffuelsulfurcontentfortheSCRsystem,四、使用注意事项Chapter4、Useattention,2.燃油硫含量对SCR系统的影响关系2.TheinfluenceoffuelsulfurcontentfortheSCRsystem,四、使用注意事项Chapter4、Useattention,结论：大量试验研究结果显示，350ppm硫含量的柴油对SCR排放控制系统的性能和耐久性没有明显影响。中国国三（欧）柴油硫含量为350ppm，国四（欧）柴油硫含量为350ppm；目前，大多数厂商都开发出了适用350ppm柴油的国四发动机；为满足SCR系统的正常运行，应使用满足350ppm的燃油；注意：使用硫含量过高的燃油，发动机燃烧产生的硫酸盐会很快堵塞SCR系统的催化器载体，导致发动机排气系统背压升高，动力下降，最终可能损坏催化器载体。,Conclusion:Alargenumberofexperimentalresultsshowthat350PPMsulfurcontentofdieselemissionsofSCRcontrolsystemhadnosignificanteffectperformanceanddurability.Chinathree(Europe)dieselsulfurcontentof350PPM,Chinafour(Europe)dieselsulfurcontentof350PPM;Atpresent,mostmanufacturershavedevelopedthefourthemissionstagedieselenginesfor350PPMfuel;InordertomeetthenormaloperationoftheSCRsystem,shouldbeusedtomeet350PPMorlessfuel;Note:SulfateproducedbyenginecombustionwillquicklyblockcatalystsubstrateswhenUsinghighsulfurcontentoffuel.Resultinhigherengineexhaustsystembackpressure,powerdown,andmaydamagethecatalystsubstrateseventually.,四、使用注意事项Chapter4、Useattention,3.清洁度的要求不满足导致杂质进入尿素泵3.ThecleanlinessdoesnotmeetthedemandsofthesystemleadtoimpuritiesintotheDU,EG2:Sawdustincheckvalveleadtolosingaone-wayfunction,EG1:OpenplaceofDU,andnoprotectionforimport,EG3:Beforeinstallingureahose,donotpullthedustcapoftheconnector,四、使用注意事项Chapter4、Useattention,4.材料使用要求不满足导致杂质进入尿素系统4.Materialuserequestdoesnotmeetleadtoimpuritiesintotheureasystem,Donotconformtotherequirementsoftheureahosewillhavethematerialloss,castflowintotheDUwillmakeDUfailure,四、使用注意事项Chapter4、Useattention,5.加注口材料不满足要求导致杂质进入尿素系统5.Materialoffillingcapuserequestdoesnotmeetleadtoimpuritiesintotheureasystem,5.Materialoffillingcapuserequestdoesnotmeet,leadtoseriouscorrosionofureafillingmouthinternal.Aqualifiedmaterialsshallbe304stainlesssteelorothernylonmaterials,四、使用注意事项Chapter4、Useattention,6.喷嘴及管路堵塞6.Nozzleandthepipeblockage,尿素喷嘴堵塞将导致尿素泵电机负荷加大，长时间会损坏尿素泵。大部分情况下喷嘴堵塞导致尿素泵气液混合室压力大于12bar，因此引发尿素泵内部泄露，导致尿素泵工作不正常。一般长时间停车后（超过1个月）需目测检查喷嘴是否堵塞。,UreanozzlecloggingwillleadtomotorofDUloadincrease,candamagetheDUforalongtime.Inmostcases，thenozzleblockagewillcauseDUgas-liquidmixingchamberpressureisgreaterthan12bar,DUinternalleakage,thusraisestotheDUcouldntworknormally.Ingeneral,shouldcheckthenozzleblockagebyvisualinspectionwhenparkingforalongtime(morethan1month).,四、使用注意事项Chapter4、Useattention,7.电器接头密封不良导致故障7.Electricalconnectorsealedleadtofailure,Becausethewaterintotheelectricalconnectors,thepowercordcolumncorrosion,leadtoDUdoesnotwork,四、使用注意事项Chapter4、Useattention,8.尿素传感器密封性差或者未装配到位导致不良后果8.Ureasensorsealingpoorornoassemblyinplaceleadtoadverseconsequences,SensorsealshouldbeachievedbychuckandtypeOsealingring,butifthechuckbenotatthelocation,cancausetheresultonthedrawing:ureacrystaloverflow,dirtintothetank.,四、使用注意事项Chapter4、Useattention,9.加注添蓝（尿素）/添蓝罐开启9.Fillingureasolutionforureatank,1.插入钥匙，逆时针旋转到位后，逆时针方向旋转并取下添蓝罐密封盖；2.取下添蓝罐密封盖，密封盖需防尘、防水和防油；3.加注添蓝，直至添蓝罐额定容积标线处（加注量不要超过额定容积）；4.加注结束后，对准卡槽装上密封盖，并拧紧上锁。,1.Insertthekey,counterclockwisinginplace,counterclockwiseandremoveureatanksealingcovergasket;2.Removethecovergasket,thecovergasketmustbedustproof,waterproofandoilproof;3.Fillingureasolutionuntiltankratedvolumeline(chargingamountdoesnotexceedtheratedvolume);4.Afterthefilling,installedsealingcovergasketintocardslot,andscrewdownthelock.,添蓝罐Ureatank,逆时针方向counterclockwise,四、使用注意事项Chapter4、Useattention,10.添蓝罐保养10.Ureatankmaintenance,1.为保证SCR后处理系统的正常工作，添蓝罐中加注的车用尿素溶液应符合GB29518或者ISO22241-1:2006；2.为避免尿素加注过程中可能存在的杂质和水分对SCR系统零部件的影响，应到正规的尿素加注站点加注尿素；3.添蓝罐口滤网可以防止大碎屑进入罐内。禁止拆除加注口滤网，加注过程需防尘、防水和防油；4.添加尿素前，必须停止发动机；,1.InordertoguaranteethenormalworkoftheSCRsystem,ureasolutionfilledshouldcomplywiththeGB29518orISO22241-1:2006;2.ToavoidimpuritiesandmoistureinureasolutionwiththeprocessoffillinginfluenceforSCRsystemcomponents,shouldbetoanormalchargingureasite;3.Thefillingmouthmeshofureatankcanpreventdebrisintothetank.Forbiddentoteardownfillingmouthmesh,fillingprocessmustbedustproof,waterproofandoilproof;4.Muststoptheenginebeforefillingureasolution.,1.添蓝罐加注口盖2.排水螺塞3.添蓝罐箍带1.Fillingcover2.Drainplug3.Hoopbelt,四、使用注意事项Chapter4、Useattention,10.添蓝罐保养10.Ureatankmaintenance,5.整车行驶首次达到2000公里时须对添蓝罐箍带双螺母进行复紧，第一级螺母复紧扭矩101N.m，锁紧螺母复紧扭矩232N.m；6.每10万公里或1年（先到者为准）应通过添蓝罐放水螺塞清理一次添蓝罐内部，并清洗添蓝溶液液位传感器底部滤芯，以保证罐内部清洁；7.加注量应不超过添蓝罐额定容积。,5.Mustbetoscrewnutsoftankhoopbelttightwhenthevehicledriving2000kmforthefirsttime.Thefirstnuttighteningtorqueto10+1N*m,thesecondnuttighteningtorqueto23+2N*m;6.Mustclearureatankinsidebydrainplugevery50000kmor1year(thefirstpriority),clearthemeshfilteratthebottomoftheureasensoratthesametime,tomakesurethetankinteriorclean;7.Ureasolutionfillingamountshallnotexceedtheratedvolumeofureat