Avoiding breakdowns due to particulate filter clogging in diesel machinery

The particulate filter retains solid particles from the exhaust system that, when it reaches temperatures of more than 400 ºC, enters what is called the regeneration process. Through pyrolysis, it removes these particles. However, if the ideal conditions for regeneration are not reached, the particulate filter can become clogged. The elimination, therefore, of the faults of the particulate filter is a headache for many machinery renters.

The particulate filter has a sensor that automatically detects when the accumulation of particles is necessary to carry out the regeneration. This regeneration is a process by which the particulate filter is heated above 400 ºC and, by the temperature itself, by pyrolysis, burns the particles. The clogging of the particulate filter occurs when it cannot enter into regeneration and make the pyrolysis of the accumulated particles. Therefore, to prevent clogging it is essential to know how it works and, in this way, facilitate that it can be heated enough to eliminate the carbon.

The Client

Our customer is a machine rental with more than 300 machines in its fleet, such as loaders, excavators, generators, tractors, and all types of diesel machinery. Since its machinery fleet is continuously renewed, the number of machines with particulate filters is increasing, and, therefore, the problems associated with it also increase.

The problem of eliminating faults in the particulate filter

The problem with this type of machine is usually that they require regeneration every certain number of working hours. Consequently, the machine warns the operator, who, in many cases, ignores the warnings launched by the machine, since this requires a slowdown of the task he is executing. The consequence of not proceeding with the regeneration when the machine requires it repeatedly, is the clogging of the particulate filter, whose cleaning or replacement can cost up to 3,000 Euros. Cost, which normally the client is not willing to assume. In the case of our client, it was a major headache that kept the machines stopped for long periods of time and generated high costs that the client was not willing to assume.

The solution for the elimination of faults in the particulate filter

The solution implemented has been the Fleet Digitalization, through which, our customer can know at all times the level of clogging of the particulate filter of all their machines. Also, other important parameters that ensure the constant monitoring of the machine, receiving the corresponding notifications by mail, SMS, WhatsApp, Telegram, etc. If necessary, you can even slow down or stop the machine to avoid such an expensive breakdown that, in most cases, your customer is not willing to take over. You can check the Success Story video here.