Exhaust aftertreatment system diagnostic and conditioning

Abstract

A diagnostic engine calibration module is provided that is structured to diagnose a vehicle system by causing the vehicle system to operate outside of one or more calibration parameters. The diagnostic engine calibration module includes a diesel particulate filter (DPF) pressure module structured to determine a pressure differential across a DPF of an engine of the vehicle system and compare the determined pressure differential against a plurality of predetermined fault thresholds to diagnose the DPF, the plurality of predetermined fault thresholds including a predetermined minimum pressure threshold and a predetermined maximum pressure threshold.

What is claimed: 
     
         1 . An apparatus, comprising:
 a diagnostic engine calibration module structured to diagnose a vehicle system by causing the vehicle system to operate outside of one or more calibration parameters, wherein the diagnostic engine calibration module includes:
 a diesel particulate filter (DPF) pressure module structured to determine a pressure differential across a DPF of an engine of the vehicle system and compare the determined pressure differential against a plurality of predetermined fault thresholds to diagnose the DPF, the plurality of predetermined fault thresholds including a predetermined minimum pressure threshold and a predetermined maximum pressure threshold. 
   
     
     
         2 . The apparatus of  claim 1 , wherein the diagnostic engine calibration module is structured to only operate the vehicle system when the engine is immobilized. 
     
     
         3 . The apparatus of  claim 1 , wherein the diagnostic engine calibration module is structured to operate the vehicle system when the engine is turned on. 
     
     
         4 . The apparatus of  claim 1 , wherein the diagnostic engine calibration module includes a DPF ash restriction module structured to determine an amount of ash that remains on the diesel particulate filter and trigger a fault if the amount of ash meets or exceeds an upper threshold. 
     
     
         5 . The apparatus of  claim 4 , wherein the DPF ash restriction module is triggered when the determined pressure differential is below the predetermined minimum pressure threshold. 
     
     
         6 . The apparatus of  claim 1 , wherein the DPF pressure module is further structured to determine an initial pressure differential across the diesel particulate filter of the engine of the vehicle system before the engine is initially turned on and compare the initial pressure differential against zero. 
     
     
         7 . The apparatus of  claim 1 , wherein the diagnostic engine calibration module is uploaded to an electronic control unit of a vehicle when the vehicle is immobilized and removed from the electronic control unit prior to mobilization of the vehicle. 
     
     
         8 . The apparatus of  claim 1 , wherein the diagnostic engine calibration module includes a diesel oxidation catalyst (DOC)/DPF module structured to compare DOC and DPF temperature sensor readings to each other after the engine has run at an idle speed for a predetermined amount of time after running the engine at a relatively higher speed for another predetermined amount of time. 
     
     
         9 . A controller for a vehicle, the controller comprising:
 a diagnostic engine calibration module structured to diagnose a vehicle system by causing the vehicle system to operate outside of one or more calibration parameters, wherein the diagnostic engine calibration module includes:
 a diesel oxidation catalyst (DOC) performance module structured to activate a hydrocarbon (HC) dosing event, monitor a NO to NO 2  conversion rate within an aftertreatment system of the vehicle system as a function of HC dosing, and compare the NO to NO 2  conversion rate against a plurality of predetermined standards to diagnose a DOC of the aftertreatment system. 
   
     
     
         10 . The controller of  claim 9 , wherein the diagnostic engine calibration module is structured to only operate the vehicle system when an engine of the vehicle system is immobilized. 
     
     
         11 . The controller of  claim 9 , wherein the diagnostic engine calibration module is structured to only operate the vehicle system when an engine of the vehicle system is turned on. 
     
     
         12 . The controller of  claim 9 , wherein the DOC performance module is further structured to recondition the DOC of the aftertreatment system if the NO to NO 2  conversion rate does not fall within the plurality of predetermined standards by increasing a temperature of exhaust gas from an engine of the vehicle system and a NOx value from exhaust gas from the engine by adjusting an exhaust gas recirculation (EGR) fraction and a timing of the fuel injectors. 
     
     
         13 . The controller of  claim 9 , wherein the diagnostic engine calibration module includes a DOC/diesel particulate filter (DPF) module structured to compare DOC and DPF temperature sensor readings to each other after an engine of the vehicle system has run at an idle speed for a predetermined amount of time after running the engine at a relatively higher speed for another predetermined amount of time. 
     
     
         14 . An internal combustion engine system, comprising:
 a controller comprising memory that stores a diagnostic engine calibration program, the diagnostic engine calibration program structured to diagnose the internal combustion engine system without user intervention;   wherein the diagnostic engine calibration program includes a diesel particulate filter (DPF) pressure module structured to determine a pressure differential across a diesel particulate filter of an engine of the internal combustion engine system and compare the determined pressure differential against a plurality of predetermined fault thresholds, the plurality of predetermined fault thresholds including a predetermined minimum pressure threshold and a predetermined maximum pressure threshold, and   wherein the diagnostic engine calibration module is configured as an intrusive diagnostic process that causes the internal combustion engine system to operate outside of one or more calibration parameters.   
     
     
         15 . The system of  claim 14 , wherein the diagnostic engine calibration program is structured to operate when the engine is turned on. 
     
     
         16 . The system of  claim 14 , wherein the diagnostic engine calibration program includes a DPF ash restriction module structured to determine an amount of ash that remains on the diesel particulate filter and trigger a fault if the amount of ash meets an upper threshold. 
     
     
         17 . The system of  claim 16 , wherein the DPF ash restriction module is utilized by the diagnostic engine calibration program when the determined pressure differential is below the predetermined minimum pressure threshold. 
     
     
         18 . The system of  claim 14 , wherein the DPF pressure module is further structured to determine an initial pressure differential across the diesel particulate filter of the engine of the vehicle system before the engine is initially turned on and compare the initial pressure differential against a threshold. 
     
     
         19 . The system of  claim 14 , wherein the diagnostic engine calibration program is uploaded to the controller when the engine is immobilized and removed from the controller prior to mobilization of the engine. 
     
     
         20 . The system of  claim 14 , wherein the diagnostic engine calibration module includes a diesel oxidation catalyst (DOC)/DPF module structured to compare DOC and DPF temperature sensor readings to each other after the engine has run at an idle speed for a predetermined amount of time after running the engine at a relatively higher speed for another predetermined amount of time.