Diesel Particulate Filters

Diesel Particulate Filter

Canning Design for Diesel Particulate Filters

  • LIBAK ApS can assist you with the designing and documentation, of Your new range of Diesel Particulate Filters
  • Emission After Treatment systems for Retrofit as well as OE, designed by LIBAK ApS, cleaning the exhaust of more than 8000 Diesel engine, around the world.
  • Database with OE muffler dimensions - You need a new direct fit DPF for OE no. 81151010335 MAN TGA, or 9424902701 Actros? Give us a call! we have all dimensions needed, and can start right away

Designs made for all types of Diesel powered vehicles and applications:

  • On-road: Light-, Medium- and Heavy Duty vehicles
  • Stationary equipment/ Gen-sets
  • Rail applications
  • Agricultural equipment
  • Construction and Mining equipment
  • Inland vessels/ Yachts (ULSD)

Designs made for different EAT technologies:

  • Passive-/ Active-/ Continuously Regeneration of soot traps
  • PM Coated Substrates
  • FBC systems - Fuel Borne Catalyst (lowering soot ignition temp. with fuel additives
  • DOC - Diesel Oxidation Catalyzer with HC injection
  • SCR - Selective Catalytic Reduction systems
  • SiC (Silicon Carbide substrates), Cordierite, Compressed Wire Mesh and Metal Foam substrates
  • Online/ Offline Electrical heating
  • Burner Regeneration

Cut Time to Market!!

MAN dpfLet LIBAK ApS assist with the designing and documentation, of Your new range of Diesel Particulate Filters, and YOU’ll get designs that’s made to:

  • Last longer – FEA is applied to analyze design for thermal expansion, stress and fatigue from backpressure, accelerations, vibration etc.
  • Function better – CFD analysis is applied to minimize system back pressure, optimize HC/ Urea mixing or burner functionality etc.
  • Be cost effective – by always using standard components and manufacturing methods.
  • Be easy in fitting and maintenance, with standard brackets and clamps, and easy access to internal replacement parts etc.
  • Meet your specifications e.g. regarding noise attenuation, mounting brackets, heat shields etc.

The design process:

First time:

  • Exchange of info/ dimensions on your filter substrates, flanging interfaces, v‐clamps, back pressure/ temp. measuring connectors etc.
  • We discuss your manufacturing facilities (Important in the following DFM process ‐ design for manufacturing)

Every time:

  • We receive drawings/ dimensions of OE exhaust system ‐We might already have the dimensions for the DPF system you want to make – just ask!
  • If no OE drawings exist, We’ll make a 3D scanning of the OE exhaust system, or the application that is to be fitted with DPF. The 3D scanning is then used as a base for the modeling of the new DPF system.
  • Based on 1) or 2), We’ll make a preliminary design proposal in 3D, optimized with: Flow‐ and FE Analysis etc. and every time, made to match your production facilities.
  • After a design review, modifications are made accordingly, and a new 3D model is forwarded for approval.
  • When agreed on a design, the final detail design, complete with BOM’s, manufacturing documentation, illustrations for installation and maintenance etc. is done.
  • Photorealistic 3D product illustrations, animations and 3D PDF files is made for your marketing use.

The following shows the stages of a typical design process

1) 3D Scanning of the OE exhaust silencer:

actrosscanTo make sure that the new DPF has the exact same dimensions as the OE muffler, a 3D scanning is used. The 3D scanned geometry contains the precise geometry of the scanned object. The scanned geometry is then imported into the CAD system, and the new design can be an exact replication of the outer dimension of the original muffler. If the Particulate filter is made as a Retrofit part to replace an OE Exhaust Silencer, it is very important that it's a perfect fit in the original brackets, slip fit pipe connections etc. This way, the process of replacing the old muffler with the new DPF system, is MUCH easier and faster.

Of cause, designs can also be made as standard systems with a number of different inlet- and outlet configuration possibilities, to fit different application, with minimum need of installation modifications.

 

2) Preliminary Design in 3D CAD

dpfcadBased on scan, EAT principle, manufacturing facilities etc., a preliminary design is made in 3D to visualize the general design concept. A 3D pdf model is forwarded to decision makers for approval.

To speed up the design process, libraries with standard components is used in the 3D modeling process. This ensures a design, build from easy obtainable components, made with standard manufacturing methods, available anywhere.

 

3) Analysis of flow/ back pressure/ pressure drop/ Mixing of Urea or HC

With our advanced computational flow simulation software, we can simulate the flow of gas through the exhaust cleaning system. There's a couble og reasons why we want to do this: one is that we want to minimize the pressure drop over the unit. High pressure drop indicates excessive backpressure in normal operation, without a clogged filter. Another reason is that we want to distribute HC eveanly acroase the DOC front surface area/ or urea if we're dealing with an SCR system.

The two pics below shows a DPF design before, and after a CFD analysis:

Design of inlet can before and after CFD analysis - note that second design makers a much better distribution of HC

img3img7

 

4) Finite Element Analysis

dpf feaThe design undergoes thorough analysis to ensure optimal efficiency and durability.

Computational simulations of real life use is imposed on the 3D model. These simulations reviels weaknesses in the structural design, unwanted modal freequencies, functionality inefficiences etc. And all this while the design is still on the drawing board!

All designs is subjected to/ tested for:

  • Forces from accelerations, transversal, longitudinal, normal to vehicle operating direction.
  • High exhaust backpressure to simulate the event of a clogged filter.
  • High temperature/ thermal expansion to simulate the event of a stochastic regeneration of excessively accumulated soot.
  • Exhaust gas flow through the system to visualize flow trajectories, flow velocities, pressure drop, backflow, turbulence etc.
  • Injection of HC/ Urea to visualize the distribution of the reactant, and how this is introduced onto the catalytic converter DOC/ SCR CAT
  • Vibrations in engine operating frequency bands to analyze for unwanted modal frequencies

5) 2D Drawings/ Detailing/ Documentation

  • DPF illustration
    Detailing/ documentation acc. to standards
  • Schematics, diagrams and illustrations for approvals
  • Manufacturing drawings
  • Installation instructions
  • Assembly instructions
  • Maintenance instructions etc.

 

Kontakt os

Vi hjælper dig gerne, hvis du har nogen spørgsmål.
Du er velkommen til at kontakte os her eller via nedestående informationer:

Tlf. 51 80 58 80
Mail info@libak.dk