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This paper describes the joint development by Tenneco and Pi Shurlok of a complete diesel engine aftertreatment system for controlling particulate matter emissions. The system consists of a DOC, DPF, sensors, controller and an exhaust fuel injection system to allow active DPF regeneration. The mechanical components were designed for flow uniformity, low backpressure and component durability. The overall package is intended as a complete PM control system solution for OEMs, which does not require any significant additions to the OEM's engine control strategies and minimizes integration complexity. Thus, to make it easier to adapt to different engine platforms, ranging from small off-road vehicle engines to large locomotive engines, model-based control algorithms were developed in preference to map-based controls.

Road inputs are one of the most significant components of operational loading of motor vehicles and their exhaust systems. Even if road profiles remain the same, the response spectrums measured on exhaust system components vary for different vehicle and exhaust system combinations. Existing exhaust system product development and design approval procedures require multi-channel data acquisition on vehicles under specified driving conditions and at proving grounds to cover all representative customer usage events. After analysis and reduction, damage relevant sections of this data package will be used for test lab simulation purposes. This vehicle instrumentation and data acquisition process is very time consuming and cost intensive. The method presented here is based on the calculation of the dynamic characteristics of each road segment, or road events using road measured acceleration time histories, and lab measured transfer functions of vehicle body and suspension.

In order to scientifically approach the design of mounting systems for substrates in emissions control systems, it is essential to characterize the behavior of the involved materials, particularly the support mat. Manufacturing processes and various in-field conditions impact the long term performance of the support mat, and life-long emissions performance is critically dependent on its ability to retain the substrate throughout the intended life. Therefore, to ensure product robustness, the behavior during operation of all available support mats must be appropriately characterized to determine the technical layout in specific applications. This paper addresses three common characterization tests, developed internally and externally. Additionally, equipment improvements to minimize artifacts in test results as well as the development of a new mat test for manufacturing methods are addressed.