In accordance with the recently reinforced exhaust regulations and onboard diagnostics regulations, it is essential to adopt diesel particulate filter systems in diesel vehicles; a sensor that directly measures particulate matter (PM) in exhaust gas is installed to precisely monitor diesel particulate filter (DPF) failure. Because the reduction of particulate matter in the diesel particulate filter system is greatly influenced by the physical wall structure of the substrate, the presence or absence of damage to the substrate wall (cracks or local melting, etc.) determines the reliability of normal DPF operation. Therefore, an onboard diagnostics sensor for particle matter is being developed with a focus on monitoring damage to the DPF wall. In this study, as a sensor for determining damage to the substrate wall, an accumulation-type sensor whose resistance changes as soot particles are deposited between two electrodes was fabricated. The sensor characteristics were investigated by changing the gap between the sensor electrodes, sensor cap shape, and electrode bias voltage to improve resistive soot sensor sensitivity and response. From the signal characteristics of various sensor configurations, a combination sensor with improved signal stability and response time is manufactured, and they were compared with the characteristics of commercially available sensors in the engine-simulated NEDC mode in terms of the degree of DPF crack. As a result of transient mode, PM monitoring cycle was improved by 1.2~1.5 times during the same vehicle driving time compared to the existing commercial sensor.

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The urea-selective catalytic reduction (SCR) system, a nitrogen oxide reduction device for diesel vehicles, is a catalytic system that uses urea water solution (UWS) as a reducing agent. This system has a relatively wide range of operating temperatures. However, the freezing point of the reducing urea solution used in this system is −11 °C. When the ambient temperature dips below this freezing point in winter, the solution may freeze. Therefore, it is important to understand the melting characteristics of frozen UWS in relation to the operating conditions of the heating device to supply the minimum amount of aqueous solution required by the system in the initial stage of normal operation and startup of the urea–SCR system. In this study, we artificially froze a liquid solution by placing it along with a heating module in an acrylic chamber to simulate a urea solution tank. Two types of heating modules (P120 and P160) consisting of two heating elements and heat transfer bodies were used to melt the frozen solution. The melting characteristics of the frozen solution were observed, for example, changes in the temperature distribution around the heating module and the cross-sectional melting shape with the passage of time since the start of the power supply to the heating module. The shape of melting around the heating module differed depending on the level of UWS relative to the heater inside the urea tank. In case 1, it melted in a wide shape with an open top, and in case 2, it melted in a closed shape. This shape change was attributed to the formation of internal gaseous space due to volume reduction during melting and the heat transfer characteristics of the fluid and solid substances.