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Real world driving conditions and tightening legislations require improved performance of aftertreatment systems at lower temperatures. Electric heat has been shown to be an effective method of heating exhaust, but having a practical means to provide power and control for the heater has been a barrier for implementation. Recent testing has demonstrated the ability of a 24Vdc heating and control system to effectively heat exhaust using only conventional alternator and battery power sources. Results from transient cycles show the effectiveness of the electrical system and the extent of exhaust heating.

Tightening regulations throughout the world demand a reduction in fuel consumption and NOX emission levels, creating an increasing need for additional heat for SCR aftertreatment. A durable and low cost heating system is needed for vehicles with hybrid or 24Vdc electricity. Recent development efforts have resulted in much smaller and lower cost heating systems for electrical systems ranging from 400 to 24Vdc. Test results demonstrate the feasibility of reducing the size of the heater and the relationship of heater power to the amount of time required to heat the exhaust. Intelligent solid state switching enables the heater to be smaller without compromising durability.

Modifications have been made to the calibration and control of Diesel engines to increase the temperature of the exhaust especially in cold weather and part load operation. The main purpose for this advanced calibration is to enable the reduction of emissions by improving catalytic activity. An alternative method for increasing exhaust temperature is providing electric heat. Test results show the feasibility of applying various amounts of electric heat and the related increases in exhaust temperature as well as speed of heating. Simulation modeling extends the application of electric heat to a complete engine map and explores the potential impact on engine performance and emission reduction benefits.

SCR cold-start effects are increasingly important for meeting today's emission requirements [1]. A significant challenge toward quickly achieving NOx abatement is the presence of moisture in the catalyst at lower temperatures [1]. This paper describes the ability of an electric heater to effectively raise the temperature of the exhaust and overcome the effect of moisture and low exhaust temperature, allowing NOx conversion to begin sooner. A model of the moisture storage and removal is presented, along with results from engine tests. Results show that it is possible to achieve high NOx conversion temperatures quickly with robust heater technology that is suited for diesel applications.

A family of active thermocouples was developed for high temperature exhaust gas temperature measurement. A combination of thermocouple material improvements, package design and integral signal conditioning vastly improve accuracy and durability performance for diesel emission control. Sensors were developed to withstand temperatures from -40 to +1200°C and vibration levels of 30 GRMS with immersion lengths over 85mm. Signal conditioning supplies an interface to engine control units and provides an accuracy of up to ±1% from 500 to 1000°C, depending on output type and sensor construction. Results are presented for accuracy, vibration, high temperature stability and time response. System accuracy factors are discussed for various output types.