XIOS - the modular control system for exhaust aftertreatment

August 2017

In order to manage diverse control tasks of industrial combustion engines, HEINZMANN has developed the modular XIOS Hardware Platform. Among the various successfully implemented projects is an SCR control system, which lets customers comply with the increasingly strict exhaust limit values for nitrogen oxide in diesel and gas engines.

XIOS 425pxThe selective catalytic reduction (SCR) of nitrogen oxides in the exhaust gas by means of urea injection in the form of AdBlue is the present state of the art. The XIOS controller ensures optimum dosing of the urea solution at all operating points. For this purpose, the CAN bus is able to record great number of process values. For example, the data of up to four NOx sensors, four exhaust gas temperature sensors and other engine data such as boost and exhaust gas pressure, temperature, oil pressure, speed, etc. Following the analysis, up to two AdBlue pumps and AdBlue nozzles can then be actuated at the same time if needed. Comprehensive monitoring functions in the control system monitor the engine and catalyst systems to prevent damage. The integrated data logger records all system-relevant measured values in parallel. A tank management system also records the tank fill level and the AdBlue temperature to ensure reliable exhaust gas cleaning throughout the engine operating time.

The solution was developed specifically for use in special-purpose and rail vehicles, ships and stationary industrial engines. During implementation, particular focus was placed on both minimising initial investments as well as lowering ongoing operating costs.

Illustration of theSCR-Systems based on XIOS:

SCR system based on XIOS control unit

The scalable, basic XIOS model offers various inputs and outputs alongside its high-performance computing core, and it can be expanded by up to 11 pluggable I/O modules. The bandwidth of the various I/O modules therefore covers everything from inputs for temperature sensors to 4Q actuation of the actuators. If this is not enough for extensive tasks, multiple controllers can be combined in the master-slave mode. This way, the available number of inputs/outputs can be expanded flexibly. As alternatives to HEINZMANN’s numerous software applications, users can develop their own application. Based on CoDeSys or MATLAB/Simulink functions and configurations for control and monitoring tasks can be created as needed and according to specific requirements. As communication interfaces, the controller offers 2 x Ethernet, 2 x CAN, RS232 and RS458. >> Technical specifications of XIOS controller

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