NOx emission-control system using a virtual sensor

[0001] This invention relates generally to emission-control systems, and more particularly to methods and systems for controlling NO_x emissions using virtual sensors.

[0002] Growing government standards associated with combustion engine emissions have increased the burden on manufacturers to reduce the amount of nitrogen oxides (NO_x) and particulates that may be exhausted from their developed engines. Along with this burden is the manufacturer's commitment to their customers to produce fuel efficient engines. However, the sometimes inverse relationship between fuel economy and reduced emissions tends to make the task of reducing NO_x while meeting customer needs a daunting one.

[0003] One known type of NO_x reduction technique is Selective Catalytic Reduction (SCR). This technique of reducing NO_x in a combustion engine generally includes the use of selective reagents, such as ammonia, aqueous urea, and other types of ammonia containing compounds. In a conventional open loop control urea based SCR system, a urea pump may inject a urea solution into the exhaust stream of a combustion engine through an atomizer. An SCR controller may control the rate of urea that is being applied to the atomizer. Within the exhaust stream, the urea solution may decompose into ammonia and carbon dioxide above certain temperatures, such as 160 degrees C. When the exhaust gas mixture is passed over a SCR catalyst, the NO_x molecules react with the ammonia molecules over the catalyst sites and are reduced to molecular nitrogen.

[0004] The performance of a SCR catalyst to reduce NO_x may depend upon may factors, such as catalyst formulation, the size of the catalyst, exhaust gas temperature, and urea dosing rate. With regard to the dosing rate, the NO_x reduction efficiency tends to increase linearly until the dosing rate reaches a certain limit. Above the limit, the efficiency of the NO_x reduction may start to increase in a slower rate. One reason for the decline in the NO_x reduction efficiency is that the ammonia may be supplied at a faster rate that the NO_x reduction process can consume. The excess ammonia, known as ammonia slip, may be expelled from the SCR catalyst which may constitute a source of unregulated emissions. A known technique for abating the ammonia slip is to add an oxidation catalyst behind the SCR catalyst. The oxidation catalyst may convert the ammonia back to NO_x thus increasing oxide emissions. Accordingly, optimum NO_x reduction can be achieved by maximizing the urea dosing rate while avoiding ammonia slip.

[0005] A known technique for controlling the urea dosing rate is through an open-loop control process. With the open-loop control process, a predetermined aqueous urea injection rate at a given engine operating load is used for NOx reduction. Due to varying ambient conditions (e.g., humidity, temperature, and pressure), however, the NO_x expelled from an engine may vary. Accordingly, an SCR system employing an open-loop control process must allow for a sufficient margin in the urea dosing rate to ensure that NO_x emissions standards are met while avoiding ammonia slip. Instituting these margins, however, may lead to under-dosing of the urea solution and loss of NOx reduction performance.

[0006] To compensate for the possible loss of performance, SCR systems have implemented closed-loop control processes. In these types of SCR systems, a NO_x sensing device, such as a NO_x sensor, is placed in the exhaust stream after the SCR catalyst. The sensing device may measure the level of NO_x and provide signals to a SCR controller to adjust the urea dosing rate. Although NO_x reduction efficiency may be maximized using a closed-loop control process, the costs and maintenance associated with NO_x sensing devices make implementing these processes in a SCR system unattractive to engine manufacturers.

[0007] To minimize the costs associated with physical sensors, some conventional engine-control systems may implement virtual sensors. U.S. Pat. No. 6,236,908 issued to Cheng et al. shows a vehicle sensor system that stores one or more virtual sensors in the form of neural networks in an Engine Control Module (ECM) of an engine. In the sensor system taught by Cheng et al., the ECM receives values associated with various engine parameters from a plurality of physical sensors and applies various combination of the values to the neural network. Based on these input values, the network then produces values for one or more output parameters. The output values may reflect virtual data that replaces data that would have been received from physical sensors. For example, the neural network may receive various combinations of values from selected physical sensors, such as engine speed, manifold absolute pressure, exhaust gas recirculation, and air/flow ratio values. Based on the input values, the neural network may determine values of other engine operating parameters, including residual mass fraction, emissions, exhaust gas temperatures, and exhaust gas oxygen content. These virtual values may be used by the ECM to control various functions associated with the engine, including spark timing, fuel injection timing, and emissions.

[0008] Although Cheng et al. suggests the ability to control emissions through the use of virtual sensors, the control is based on parameters and/or engine functions not directly related to emission characteristics. For example, Cheng et al. teaches generally reducing NO_x emissions by lowering peak temperatures during combustion in the engine. The peak temperatures are lowered by controlling various engine functions, such as throttle position to allow more gases to be trapped in a combustion chamber. The engine functions are controlled based on, among other things, a residual mass fraction value determined by a virtual sensor configured on selected input values including engine speed, manifold pressure, exhaust gas recirculation values, and air flow values. Accordingly, the attenuated relationship between emission control functions and selected input and output parameters associated with the virtual sensors taught by Cheng et al. decreases the efficiency and accuracy of the ECM in controlling emissions.

[0009] In an embodiment of the present invention, a process for controlling emissions of an engine is provided. The process may include determining predicted NO_x values based on a model reflecting a predetermined relationship between control parameters and NO_x emissions, wherein the control parameters include ambient humidity, manifold pressure, manifold temperature, fuel rate, and engine speed associated with the engine. Further, the process may include adjusting the model based on a determination of whether the predicted NO_x values meet a predetermined criteria associated with actual NO_x values. The adjusted model may be stored in a memory associated with the engine whereby NO_x emissions exhausted from the engine may be reduced based on virtual NO_x emission values determined from the adjusted model.

[0015] Reference will now be made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0016] FIG. 1 illustrates an exemplary system 100 in which features and principles consistent with one embodiment of the present invention may be implemented. In one embodiment of the invention, system 100 may be associated with any type of machine engine, such as internal combustion type engines, that operate in various types of host systems. For example, system 100 may be affiliated with an engine associated with a marine vehicle, land vehicle, and/or an aircraft. Further, system 100 may be associated with an engine operating in a non-vehicle based system, such as machines operating within a manufacturing plant or generator sets. Moreover, while system 100 is shown for illustrative purposes in a urea-based SCR system, system 100 has potential use in other emission-control applications. Accordingly, one skilled in the art would recognize that system 100 may be associated with any type of host system that includes various types of engines that may operate in different environments with different emission-control systems and standards.

[0017] As shown in FIG. 1, system 100 may include a urea tank 110, urea pump 120, disbursement system or atomizer 130, SCR controller 135, exhaust system 140, and SCR catalyst 150. Urea tank 110 may be a reservoir used to hold gaseous, solid-based solutions, or aqueous solutions, such as urea, used as reagents in SCR systems. Urea pump 120 may be a device that is hardware or software controlled that extracts the urea solution from tank 110 into atomizer 130. Atomizer 130 may be a hardware or software controlled device that atomizes the urea solution and places the atomized solution 145 in exhaust system 140 based on control signals from SCR controller 135. In one embodiment of the present invention, an SCR catalyst 150 may be used to allow the NO_x molecules within the exhaust gas mixture to react with ammonia molecules to produce molecular nitrogen. Alternatively, the exhaust system 140 may operate without an SCR catalyst 150.

[0018] Further, system 100 may include a physical NO_x sensor 160 that is configured to measure and/or analyze NO_x emissions exhausted from exhaust system 140 after the SCR catalyst 150. In one embodiment of the invention, sensor 160 may provide actual NO_x emission values to SCR controller 135 based on operations of a target engine associated with system 100. Although FIG. 1 shows system 100 including physical NO_x sensor 160, certain embodiments of the invention allow system 100 to operate with out the use of sensor 160.

[0019] SCR controller 135 maybe a processing system that monitors and controls operations of a system 100. Controller 135 may be configured to collect information from various sensors operating within system 100 and the host system and to provide control signals that affect the operations of system 100 and/or the host system. In one embodiment of the present invention, SCR controller may be part of an Engine Control Module (ECM) that monitors and controls the operation of an engine associated with system 100. For example, SCR controller may be a module programmed or hardwired within an ECM that performs functions dedicated to certain embodiments related to the present invention. In this example, SCR controller 135 may be software that is stored as instructions and data within a memory device of an ECM and is executed by a processor operating within the ECM. Alternatively, SCR controller 135 may be a module that is separate from other components of a host system.

[0020] FIG. 1 shows SCR controller 135 configured as a separate module dedicated to SCR control functions consistent with certain features related to one embodiment of the present invention. Controller 135 may include a processor 136, memory 137, and an interface 138. Processor 136 may be a processing device, such as a microcontroller, that may exchange data with memory 137 and interface 138 to perform certain processes consistent with features related to the present invention. Although a single processor is shown in FIG. 1, one skilled in the art would recognize that SCR controller 135 may include a plurality of processors that operate collectively to perform functions consistent with certain embodiments of the present invention.

[0021] Memory 137 may be any type of storage device that is configured to store information used by processor 136. For example, memory 137 may include magnetic, semiconductor, tape, and/or optical type storage devices that may be volatile or non-volatile in nature. Moreover, memory 137 may include one or more storage devices configured in various architectures, such as redundant configurations for fault tolerant operations. One skilled in the art would recognize that the type, configuration, and architecture of memory 137 may vary without departing from the spirit and scope of the present invention. In one embodiment of the present invention, memory 137 may store data reflecting a NO_x virtual sensor 139.

[0022] Interface 138 may be an input/output interface device that receives data from processor 136 and from entities external to SCR controller 135. Further, interface 138 may also provide data to processor 136 and the external entities. Interface 138 may be a module that is based on hardware, software, or a combination thereof. In one embodiment of the present invention, interface 138 may receive signals from one or more physical sensors 160 that may be positioned in various locations within system 100 and/or the host system. Further, interface 138 may provide control signals from processor 136 to various components within system 100 and/or the host system, such as, for example, fuel injection components operating in an engine. One skilled in the art would recognize that the configuration of interface 138 may vary without departing from the scope of the present invention. For example, interface 138 may include separate communication ports dedicated for receiving and sending data, respectively. Alternatively, interface 138 may be integrated within processor 136 to provide and/or send data to and/or from one or more processing elements operating within processor 136.

[0023] In one embodiment of the invention, system 100 may be configured to maximize the efficiency of a NO_x reduction process performed in exhaust system 140 using a NO_x virtual sensor 139 maintained by SCR controller 135. The NO_x virtual sensor 139 may be a software-based construct that determines the levels of NO_x expelled from exhaust system 140 based on changes in ambient conditions and host system operating parameters. Based on the determined levels of NO_x emissions, SCR controller 135 may provide control signals to an ECM (not shown) to adjust the operations of the engine to reduce NO_x emissions. Alternatively, SCR controller 135 may adjust an emission control system, such as adjusting the urea dosing rate of system 100, based on the measured control parameters and predicted NO_x values. The development of the NO_x virtual sensor 139 may be based on various design and/or historical operating data associated with the type of host system associated with system 100.

[0024] In one embodiment of the present invention, a NO_x virtual sensor 139 may be created by a test system that is configured to test various types of engines either during development or post operations (e.g., running an engine in a controlled environment after operations in real world conditions). The test system may include hardware and/or software that is used to manipulate test engines by applying various control variables to the test engines and collecting information associated with one or more response and control parameters. For example, the test system may include one or more processors, memory devices, interface devices, and any other component that may be used to perform processes consistent with certain features related to the present invention.

[0025] FIG. 2 shows a flowchart of an exemplary virtual sensor creation process consistent with certain features related to one embodiment of the present invention. Initially, to create a NO_x virtual sensor 139, the test system may determine one or more control parameters associated with the type of target engine utilizing the NO_x virtual sensor 139 (Step 210). The control parameters may be parameters that control the operations of various response characteristics of the engine. Further, the control parameters may be parameters that are associated with conditions corresponding to the operations of the engine For example, an engine's operating characteristics may vary based on fuel injection timing, compression ratios, turbocharger efficiency, after cooler characteristics, temperature values, pressure values, ambient conditions (e.g., humidity), fuel rates, and engine speeds.

[0026] Accordingly, the test system may determine one or more control parameters based on one or more response parameters, such as NO_x emissions. In one embodiment of the present invention, the test system may determine that an engine's NO_x emissions may vary based on selected control parameters, such as humidity and ambient temperature and pressures associated with the target engine. Accordingly, the relationship between NO_x emissions and these control parameters may be determined by the test system in order to create a virtual sensor that may accurately predict NO_x emissions. For example, the test system may create a model that may predict the emission behavior of a diesel engine by monitoring and/or modeling the operating characteristics of a plurality of test diesel engines of similar types.

[0027] In one embodiment of the present invention, the test system may determine the control parameters that may provide an accurate relationship between NO_x emissions and various operating parameters associated with a target engine type. These control parameters may then be used for creating the NO_x virtual sensor 139. For example, based on previous modeling and monitoring processes, the test system may determine that humidity may cause a significant change in NO_x emissions for an engine. Other control parameters may be determined to have a significant impact on NO_x emissions as well, such as intake manifold temperature, intake manifold pressure, fuel rate, and engine speed. Accordingly, in one embodiment of the present invention, the control parameters determined by the test system in Step 210 may include, but not be limited to, ambient humidity (H), intake manifold pressure (Pint), intake manifold temperature (Tint), fuel rate (Mf), and engine speed (N). One skilled in the art may recognize that other operating parameters may have an impact on NO_x emissions and these other parameters may also be used by the test system to create a virtual sensor.

[0028] Once determined, the test system may expose one or more test engines to test operations and collect values for each of the control parameters associated with each test engine during the test operations (Step 220). Further, the test system may collect corresponding actual NO_x emission values from each of the test engine's exhaust systems (Step 230). The collected NO_x emission values may be stored in a memory device associated with the test system. Each of the test engines may have similar characteristics, such as, for example, diesel engines with similar design specifications. The test system may vary the values of the control parameters in different combinations to collect a plurality of NO_x emission values. Based on the collected NO_x emission and control parameter values, the test system may create a model that reflects a relationship between the NO_x emissions and the control parameters associated with the type of engines being tested (Step 240).

[0029] In one embodiment of the present invention, the model may be a mathematical construct that reflects a relationship between the NO_x emissions and the control parameters determined in Step 210. Accordingly, the NO_x emissions for each type of engine may be represented as a function based on the determined control parameters. For example, in one embodiment of the present invention, the mathematical model may be reflected as a function:
NO_x=f(H, P_int, T_int, M_f, N),

• • [0030] where H may be the ambient humidity measured from a humidity sensor placed in an air induction system before a compressor inlet, P_int may be the intake manifold pressure, T_int may be the intake manifold temperature, M_f may be the fuel rate, and N may be the engine speed, all associated with the target engine that is associated with the model. Accordingly, the model created by the testing system may be used to predict the level of NO_x emissions from a target engine based on the values of the control parameters H, P_int, T_int, M_f, and N. Thus, the generated model may act as a NO_x virtual sensor that operates similar to a physical NO_x sensor by providing values associated with NO_x emissions associated with the target engine exhaust. Accordingly, the terms “model” and “NO_x virtual sensor” described below may be used interchangeably.

[0031] In one embodiment of the present invention, the model (virtual sensor 139) may be associated with a neural network that accepts the determined control parameters as inputs and produces a predicted NO_x value as an output. The neural network may be configured in a number of different well known neural network configurations, such as a back propagation or a feed forward network. FIG. 3 shows a block diagram of an exemplary neural network that may represent the virtual sensor 139.

[0032] As shown, the neural network may include an input layer 310, a hidden layer 320, and an output layer 330. The input layer 310 may receive the control parameters (H, P_int, T_int, M_f, and N, for example) at respective input nodes. These parameter values may each be provided to a node in the hidden layer 320 over links 315 that have a weight associated with each respective input and hidden layer node. The weights associated with links 315 may have values that are zero or negligible. Each node in the hidden layer 320 may perform a function on the incoming signals that may be a composite of the weights associated with links 315 and a transfer function. Each node in the hidden layer 320 may apply the same transfer function to the signals received from the nodes in the input layer 310. For example, in one type of neural network, each parameter value is multiplied by the weight associated with its respective link, and then each node sums the values of each parameter (multiplied by its weight). This number is then used as the input to a two dimensional map, typically a sigmoid, etc. Each node in the hidden layer 320 may, in turn, provide an output signal over a link 325 to the output node in the output layer 330 which may produce a predicted value corresponding to the response parameter, in this case a NO_x emission value. The links 325 extending from each node in the hidden layer 320 may also have an associated weight. As with the weights associated with links 315, the weights associated with links 315 may have values that are zero or negligible.

[0033] The operations of neural networks are well known and methods and systems consistent with certain features related to embodiments of the present invention may incorporate various types of neural networks to produce data reflecting a predicted NO_x emission value based on the control parameters provided at the input layer 310. For example, although FIG. 3 shows the hidden layer 320 with one level of nodes and a single output node in output layer 330, one skilled in the art would recognize that more than one level of nodes may be included within hidden layer 320 and more than one node may be included in output layer 330 associated with different response parameters. For example, a second output node (not shown) could be included to output values associated with fuel rate, exhaust manifold temperature, turbo speed, torque, etc.

[0034] Referring back to FIG. 2, to ensure that the model created by the test system may accurately predict NO_x emission values for a target engine, in embodiments of the invention, the test system may test the model (Step 250). In one embodiment of the present invention, the test system may apply test values for each control parameter to the model to determine a predicted set of NO_x emission values. Further, the target system may be exposed to test operations that produce the same values for each control parameter as those applied to the model. The test system may then collect actual NO_x emission values from a physical NO_x emission sensor associated with the target system. In one embodiment of the invention, the physical NO_x emission sensor may be included in the exhaust system associated with the target engine as a permanent component or may be temporarily attached to the exhaust system for testing purposes.

[0035] The test system may then compare the actual and predicted NO_x values to determine whether the model meets a predetermined criteria (Step 260). For example, the predetermined criteria may be associated with a threshold value that reflects a maximum acceptable difference between the actual and predicted NO_x values. One skilled in the art would recognize that a number of different conditions, thresholds, etc. may be applied as the predetermined criteria without departing from the scope of the present invention.

[0036] If the model does not meet the predetermined criteria (Step 260; NO), the model may be adjusted (Step 270) and re-tested until the predetermined criteria is met (Step 260; YES). Once the model produces accurate predicted NO_x emission values based on the determined control parameters, the test system may store the model in memory 137 of SCR controller 135 of system 100 (Step 280) prior to exposing the target engine to operations in real world environments.

[0037] In one embodiment of the present invention, when the model is configured as a neural network and the model does not meet the predetermined criteria, the test system may adjust the weights associated with the links corresponding to the nodes in the network's hidden layer to compensate for previous inaccurate predictions of NO_x emission values. For example, if the neural network includes more than one level of nodes in the hidden layer 320, the weights associated with each link interconnecting the hidden layer nodes may be adjusted to train the network to produce more accurate NO_x emission values. The weight adjustments may be performed by any number of known algorithms executed by the test system that are used for training neural networks, such as algorithms associated with radial basis function approximations. One skilled in the art would recognize that certain embodiments of the present invention may employ different algorithms that affect the learning process of the neural network.

[0038] As previously described, once a trained model is stored in SCR controller 135, the target engine may be commissioned for operation. That is, the target engine may be provided in a host system (e.g., tractor, highway-based vehicle, stationary plant equipment, etc.) and exposed to real world operations. During these operations, the ambient and engine operating conditions may be monitored and measured by physical sensors, an ECM, and/or SCR controller 135. The measured values associated with the engine's operations may be provided to SCR controller 135 as control parameters for the model stored in memory 137. For instance, during operation, values reflecting humidity H, intake manifold pressure P_int, intake manifold temperature T_int, engine speed N, and fuel rate M_fassociated with the target engine may be provided to SCR controller 135 through interface 138. These values may be used by SCR controller 135 to determine NO_x emission values using the model stored in memory 137. Based on the determined NO_x values, SCR controller 135 may provide control signals that are used by system 100 for minimizing, or otherwise affecting NO_x emissions exhausted from exhaust system 140. In one exemplary embodiment, based on the predicted NO_x emission values, SCR controller 135 may provide control signals that adjust the dosing rate of the urea solution provided to exhaust system 100 in order to enhance or minimize NO_x emissions. Accordingly, system 100, and the target engine, may perform emission enhancing or minimization processes during operations without the use of costly physical NO_x sensors or analyzers.

[0039] Because the performance of a target engine may vary based on the engine's application, it may be desirable to fine tune the model based on desired or actual engine operations. In one embodiment of the present invention, system 100 may incorporate NO_x sensors to accomplish this fine tuning. To reduce costs, it may be desirable to use a sensor having a relatively short expected life. For example, a physical NO_x sensor that is more susceptible to failure than more expensive fault tolerant NO_x sensors may be placed at the output of the exhaust system 140 and used by system 100 to fine tune the operation of the model stored in SCR controller 135 during real world operations.

[0040] FIG. 4 shows a flowchart of an exemplary training process that may be implemented by methods and systems consistent with certain features related to embodiments of the present invention. As shown, a target engine that includes system 100 and a model stored in memory 137 may be exposed to operations, such as field operations that take place in a work environment (Step 410). During these operations, SCR controller 135 may collect actual NO_x emission values from an accurate physical sensor 160 placed after the SCR catalyst 150 (Step 420). Further, SCR controller 135 may collect the corresponding values of the control parameters (e.g., H, Pint, Tint, Mf, and N) that are known to affect the NO_x emission values. The control parameters may be collected from physical sensors and/or from an ECM operating in the target engine. The actual NO_x values and corresponding control parameter values may be used to train the model (Step 430) stored in memory 137 during the operations in a manner similar to that described above with respect to Steps 250-270 in FIG. 2. That is, SCR controller 135 may apply the control parameter values to the model stored in memory 137 to produce predicted NO_x emission values. The predicted NO_x values may then be compared to the collected actual NO_x values, and based on the comparison, the model may be adjusted (e.g., the weights of the neural network may be adjusted until the predicted NO_x values meet predetermined criteria). In one embodiment of the present invention, during training, the SCR controller 135 may create or update a map reflecting the relationship between the NO_x values and the control parameters values. The map may be used by an ECM to control the operation of the target engine to minimize NO_x emissions during real world operations. Alternatively, the map may be used by SCR controller 135 to adjust the urea dosing rate in system 100.

[0041] In one embodiment of the invention, the model stored in the SCR controller 135 may be continuously trained using the physical NO_x sensor values until the sensor 160 fails (Step 440; YES). System 100 may detect a failure of the physical NO_x sensor 160 using a number of different fault detection techniques known to those skilled in the art. For example, system 100 may be configured to receive a fault detection signal from a device that houses the physical NO_x sensor 160 when the sensor 160 fails to produce sensor signals. Alternatively, SCR controller 135 may be configured to determine when the physical NO_x sensor 160 has stopped providing a sensor signal, such as in well known watchdog type processes. One skilled in the art would recognize that the manner by which system 100 detects a failure of the physical NO_x sensor is not limited to the above examples and various fault detection techniques may be implemented without departing from the scope of the present invention.

[0042] Once the system detects that the physical NO_x sensor 160 has failed, SCR controller 135 may be configured to set the model based on the trained values incorporated into the model prior to the failure of the physical NO_x sensor 160. In the exemplary embodiment of FIG. 4, the controller 135 sets the model at the last trained value (Step 450). Setting the model may be associated with terminating training and fixing the model weights associated with the neural network. Also, the last trained value is not intended to be limited to a single data value or point, but may also reflect a multitude of operating points. Further, SCR controller 135 may update the map created during training. In one embodiment of the present invention, SCR controller 135 may place the model and/or map in another memory device that has greater fault tolerant capabilities than memory 137. For example, to set the model, processor 136 may copy the model and/or the updated map to a non-volatile memory device that may be configured to withstand multiple types of failures. System 100 may then operate the target engine and system 100 in subsequent operations using the virtual sensor 139 stored in SCR controller 135 (Step 460). Accordingly, system 100 may enhance or minimize NO_x emissions of the target system during the subsequent operations based on predicted NO_x emission values produced by the trained model stored in SCR controller 135. For example, system 100 may be configured to adjust the dosing rate of a urea-solution deposited into exhaust system 140 based on predicted NO_x emission values. Alternatively, SCR controller 135 and/or an ECM may use the predicted NO_x emission values to produce control signals that adjust one or more operating parameters associated with the target engine, such as fuel injection timing, valve positions, injection rates, etc. The control signals may affect the operation of engine components, emissions control components, or both.

[0043] Methods and systems consistent with certain features related to the present invention allow a target engine to minimize NO_x emissions based on a virtual NO_x sensor that may be trained based on the specific application of the target system. Moreover, by properly modeling the virtual NO_x sensor using a selected set of control parameters, the virtual sensor can provide reliable and accurate information that obviates the need for physical sensors that are expensive, prone to errors, and require significant maintenance.

[0044] In one embodiment of the present invention, the exemplary virtual sensor creation process may be performed by SCR controller 135 or an ECM associated with system 100, instead of a test system. For example, SCR controller 135 or an ECM may be configured to perform model testing processes based on the on-site connection of a physical NO_x sensor 160 placed in the exhaust output of system 140. That is, a physical sensor 160 may be brought to the target engine on-site and connected to exhaust system 140. In this embodiment of the invention, interface 138 may receive a connection signal from a device that may receive the physical NO_x sensor 160. Accordingly, when SCR controller 135 detects the connection signal, processor 136 may begin the virtual sensor creation process for generating a NO_x virtual sensor 139. When the creation process is completed, and the NO_x virtual sensor 139 is set, processor 136 may store the virtual sensor 139 in memory 137 for use during operations. The physical NO_x sensor 160 may then be removed and used to retrain another target engine or may be provided at a later time to tweak the performance of system 100. Therefore, for example, when a target engine is exposed to a different work application, such as a different work site, a physical NO_x sensor 160 may be brought to the new work site to retrain the model stored in memory 137.

[0045] In another embodiment of the present invention, a target engine may be identified with a particular desired work application, and the model may be re-trained to ensure accurate NO_x emission predictions during actual work operations associated with the desired application. A desired work application of a model may be associated with work environments, such as farming environments, construction site environments, mining environments, etc. Further, a model may be re-trained based on the type of target engine. The type of a target engine may be associated with performance specifications corresponding to the engine, such as threshold values, maximum operating limits, physical characteristics of the engine, etc. Accordingly, a test system may be configured with a storage device that maintains historical operation data for various work applications associated with various types of engines. For example, a test system may include various files associated with various target engines having particular performance specifications. The files may include historical operation data reflecting collected real world NO_x emissions data based on corresponding measured values of control parameters associated with operations of a plurality of engines. Corresponding control parameters may be applied to the model stored in the SCR controller 135 of the target engine to re-train the model. In one embodiment of the invention, the test system may use a physical NO_x emission sensor 160 to validate the accuracy of the re-trained model in a manner similar to the process performed in FIG. 2. Alternatively, the test system may use the historical feedback data as actual NO_x emission values to fine tune the predicted NO_x emission value produced by the model. Therefore, an engine manufacture, for example, may create a generic model for various types of engines and subsequently fine tune the model based on a desired application or engine type for individual target engines.

[0046] In another embodiment of the present invention, a test system may determine a set of control parameters used to create a NO_x virtual sensor 139 based on the type of target engine. For example, based on historical operating data, a test system may determine that a first type of engine with a first set of design specifications (e.g., operational thresholds, limits, etc.) may have different control parameters that impact NO_x emissions as compared with a second type of engine. Accordingly, the test system may include additional or fewer control parameters used for a first type of engine to generate a NO_x virtual sensor as compared with a second type of engine.

[0047] In yet another embodiment of the present invention, SCR controller 135 may maintain a log file of historical operating conditions based on operations of the target engine with which system 100 is associated. The log file may be maintained in memory 137 or in another local or remote memory device and may include a map of the relationship between selected control parameters and predicted and/or actual NO_x emission values. The log file may be downloaded to a remote memory device by a test system if the target engine is brought to a test site, or alternatively, may be downloaded to a portable system that is brought to the work site where the target engine is located. The downloaded log file may be provided to a test system and used to provide historical operating condition data that is used to create and/or train NO_x virtual sensors used in other target engines.

[0048] In another embodiment of the invention, memory 137 may include a plurality of processors that individually and/or collectively may perform one or more processes consistent with certain features related to the present invention. For example, SCR controller 135 may be configured to execute program code stored in memory 137 that represents the NO_x virtual sensor 139. Further, memory 137 may include program code that performs processes, when executed by processor 136, for training the virtual sensor 139. Accordingly, one skilled in the art would recognize that SCR controller 135 may be configured to perform one or more software based processes that reflect the features and principles related to certain embodiments of the present invention.

[0049] As described, the SCR controller 135 may take action if a predicted NO_x is above a predetermined threshold value (e.g., does not meet a predetermined criteria). The action taken by SCR controller 135 may be on an engine, emissions control devises, or both. For example, the control parameters may be adjusted directly, or indirectly, to reduce actual NO_x emissions produced by system 100. Further, SCR controller 135 may consider engine performance when making changes that adjust the values of the control parameters determined by a test system, for example. For example, fuel injection timing may be changed in conjunction with fuel rate to maintain selected levels of power while affecting NO_x emissions.

[0050] The features, embodiments, and principles of the present invention may be implemented in various environments. Such environments and related applications may be specially constructed for performing the various processes and operations of the invention. The processes disclosed herein are not inherently related to any particular system, and may be implemented by a suitable combination of electrical-based components. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.