Method for controlling a turbocharger system with a pressurized gas tank connected to an exhaust manifold of a combustion engine

Abstract

A method for controlling a turbocharger system fluidly connected to an exhaust manifold of a combustion engine and an exhaust after treatment system. The turbocharger system comprises a turbocharger turbine operable by exhaust gases from the exhaust manifold, and a tank with pressurized gas, the tank being fluidly connectable to the turbocharger turbine. The method comprises the steps of: determining a NOx parameter being indicative of, or correlated to, NOx emissions from the exhaust after treatment system; and injecting pressurized gas from the tank to drive the turbocharger turbine based on the determined NOx parameter, wherein a determined NOx parameter above a pre-defined first threshold determines that pressurized gas from the tank is injected.

Claims

1. A method for controlling a turbocharger system fluidly connected to an exhaust manifold of a combustion engine and an exhaust after treatment system, said turbocharger system comprising a turbocharger turbine operable by exhaust gases from said exhaust manifold, and a tank with pressurized gas, said tank being fluidly connectable to said turbocharger turbine, wherein said combustion engine is operable in a plurality of engine operational modes, including a low NOx mode in which the combustion engine is operated in order to reduce the NOx emissions, wherein injection of pressurized gas from said tank when the combustion engine is in said low NOx mode enables compensation for an impaired engine performance parameter in the form of impaired torque response, said method comprising the steps of: determining a NOx parameter being indicative of, or correlated to, NOx emissions from said exhaust after treatment system; injecting pressurized gas from said tank to drive said turbocharger turbine with the pressurized gas based on the determined NOx parameter, wherein a determined NOx parameter above a pre-defined first threshold determines that the pressurized gas from said tank is injected, wherein the NOx parameter is the NOx concentration in the exhaust after treatment system, the method comprising the step of measuring NOx emissions using a NOx measuring device arranged in said exhaust after treatment system, or the NOx parameter is correlated to the temperature in the exhaust after treatment system, the method comprising the step of measuring the temperature using a temperature measuring device arranged in said exhaust after treatment system.

2. A method according to claim 1, further comprising deactivating injection functionality of pressurized gas from said tank based on the determined NOx parameter, wherein a determined NOx parameter below said pre-defined first threshold determines that injection functionality of pressurized gas from said tank is deactivated.

3. A method according to claim 1, further comprising operating said combustion engine in a low NOx mode based on the determined NOx parameter, wherein a determined NOx parameter above a pre-defined second threshold determines that the combustion engine is operated in said low NOx mode and/or comprising the step of operating said combustion engine in a high responsive fuel economy mode, based on the determined NOx parameter, wherein a determined NOx parameter below a pre-defined third threshold determines that the combustion engine is operated in said high responsive fuel economy mode.

4. A method according to claim 1, wherein, in which the NOx parameter is the NOx concentration in the exhaust after treatment system, said pre-defined first threshold is a point in the range of 0.15 g NOx/kWh to 1.5 g NOx/kWh or wherein, in which the NOx parameter is the correlated to the temperature in the exhaust after treatment system, said pre-defined first threshold is 1/200.degree. C.

5. A method according to claim 1, further comprising modelling the NOx emissions, or determining the theoretical NOx emissions, based on said NOx parameter.

6. A method according to claim 1, wherein said step of injecting pressurized gas from said tank to drive said turbocharger turbine is independent of an engine speed increasing action of the combustion engine.

7. A control unit configured to perform the steps of the method according to claim 1.

8. A computer program comprising program code means for performing the steps of claim 1, when said program is run on a computer.

9. A computer readable medium carrying a computer program comprising program code means for performing the steps of claim 1, when said program product is run on a computer.

10. A turbocharger system for use together with a combustion engine having an exhaust manifold, and an exhaust after treatment system fluidly connected to said exhaust manifold, said turbocharger system comprising: a turbocharger turbine operable by exhaust gases from said exhaust manifold, a tank comprising pressurized gas, said tank being fluidly connectable to said turbocharger turbine, and a control unit, wherein said combustion engine is operable in a plurality of engine operational modes, including a low NOx mode in which the combustion engine is operated in order to reduce the NOx emissions, wherein injection of pressurized gas from said tank when the combustion engine is in said low NOx mode enables compensation for an impaired engine performance parameter in the form of impaired torque response, wherein the control unit is configured to determine a NOx parameter being indicative of, or correlated to, NOx emissions out from said exhaust after treatment system; initiate injection of pressurized gas from said tank to drive said turbocharger turbine with the pressurized gas based on the determined NOx parameter, wherein a determined NOx parameter above a pre-defined first threshold determines that the pressurized gas from said tank is injected, wherein the NOx parameter is the NOx concentration in the exhaust after treatment system, the control unit being configured to measure NOx emissions using a NOx measuring device arranged in said exhaust after treatment system, or the NOx parameter is correlated to the temperature in the exhaust after treatment system, the control unit being configured to measure the temperature using a temperature measuring device arranged in said exhaust after treatment system.

11. A turbocharger system according to claim 10, wherein said control unit is configured to deactivate injection functionality of pressurized gas from said tank based on the determined NOx parameter, wherein a determined NOx parameter below said first pre-defined threshold determines that the injection functionality of pressurized gas from said tank is deactivated.

12. A turbocharger system according to claim 10, wherein said control unit is configured to: operate said combustion engine in a low NOx mode based on the determined NOx parameter, wherein a determined NOx parameter above a pre-defined second threshold determines that the combustion engine is operated in said low NOx mode, and/or operate said combustion engine in a high responsive fuel economy mode, based on the determined NOx parameter, wherein a determined NOx parameter below a pre-defined third threshold determines that the combustion engine is operated in said high responsive fuel economy mode.

13. A turbocharger system according to claim 10, wherein, in which the NOx parameter is the NOx concentration in the exhaust after treatment system, said pre-defined first threshold is a point in the range of 0.15 g NOx/kWh to 1.5 g NOx/kWh or wherein, in which the NOx parameter is correlated to the temperature in the exhaust after treatment system, said pre-defined first threshold is 1/200.degree. C.

14. A turbocharger system according to claim 10, further comprising a valve for controlling the release of pressurized gas from said tank to the turbocharger turbine, wherein said control unit is configured to control the operation of the valve to release pressurized gas needed for at least partly drive said turbocharger turbine.

15. A vehicle comprising a turbocharger system according to claim 10 or a control unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of exemplary embodiments of the present invention, wherein:

(2) FIG. 1 is a side view of a vehicle comprising a combustion engine, a turbocharger system and an exhaust after treatment system in accordance with one example embodiment of the present invention;

(3) FIG. 2 shows a schematic overview of the combustion engine and the turbocharger system of FIG. 1, in accordance with one example embodiment of the present invention;

(4) FIG. 3 is a flow chart describing the steps of a method for controlling a turbocharger system in accordance with some example embodiments of the invention.

(5) FIG. 4 is a schematic view showing the pre-defined first threshold, the pre-defined second threshold, and the pre-defined third threshold, and how they are set in relation to each other in accordance with some example embodiments of the invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION

(6) The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which an exemplary embodiment of the invention is shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein; rather, the embodiment is provided for thoroughness and completeness. Like reference character refer to like elements throughout the description.

(7) With particular reference to FIG. 1, there is provided a vehicle 800 with a combustion engine 100, such as an internal combustion engine 100, and a turbocharger system 10 comprising a turbocharger 20, a tank with pressurized air 40 and a control unit 50, such as e.g. an ECU 50, according to the present invention (further described below with reference to FIG. 2). The combustion engine 100 is fluidly connected to the turbocharger system 20 and an exhaust after treatment system 900. The vehicle 800 depicted in FIG. 1 is a truck 800 for which the inventive concept which will be described in detail below, is particularly suitable for.

(8) FIG. 2 shows a schematic overview of at least parts of a combustion engine 100 and a turbocharger system 10. In the non-limiting example of FIG. 2, the combustion engine 100 comprises an engine block 101 in a four-cylinder, four-stroke, diesel engine with a gear box 110 and a clutch 112 that is connected to an engine crankshaft 120. The combustion engine 100 of FIG. 2 comprises an inlet manifold 104 fluidly connected to an intake port (not shown) of the combustion engine 100, for supplying fuel and/or air and/or a fuel-air mixture to the combustion engine 100. Correspondingly, the combustion engine 100 comprises an exhaust manifold 102 fluidly connected to an exhaust after treatment system 900 of the combustion engine 100.

(9) In the example of FIG. 2, the combustion engine 100 is overloaded by means of the turbocharger system 10. More specifically, the turbocharger system 10 comprises a turbocharger 20 having a turbocharger turbine 22 and a turbocharger compressor 24 of known type coupled to the turbocharger turbine 22 by a turbine shaft 23. The turbocharger turbine 22 is operable by exhaust gases from the exhaust manifold 102, and thus drives the turbocharger compressor 24 via the turbine shaft 23. The turbocharger compressor 24 is fluidly connected to the inlet manifold 104 via an inlet manifold pipe 106, and is configured for compressing intake air to the combustion engine 100. Optionally, an intercooler (not shown) may be arranged in fluid contact between the turbocharger compressor 24 and the inlet manifold 104. Correspondingly, the turbocharger turbine 22 is fluidly connected to the exhaust manifold 102 via an exhaust manifold pipe 108, and is configured for driving the turbocharger compressor 24 via the turbine shaft 23. In other words, the exhaust manifold pipe 108 is fluidly connected between the exhaust manifold 102 of the combustion engine 100 and the turbocharger turbine 22. The turbocharger turbine 22 is fluidly connected in between the exhaust manifold 102 of the combustion engine 100 and the exhaust after treatment system 900.

(10) As shown in FIG. 2, the turbocharger system 10 further comprises a tank 40 with pressurized gas, a compressor 42 for supplying pressurized gas to the tank 40, and a valve 44 for controlling the release of pressurized gas from the tank 40. The turbocharger system 10 in FIG. 2 further comprises a control unit 50 connected to the valve 44 and the compressor 42. In FIG. 2, the valve 44 may control the release of pressurized gas from the tank 40 to various locations before, to, and after the combustion engine 100, typically via a valve pipe 46 fluidly connected to the valve 44 and the respective various locations. In FIG. 2, the valve pipe 46 is arranged to provide the pressurized gas from the tank 40 to the exhaust manifold 102, but as indicated with dashed valve pipes 46′, the pressurized gas from the tank 40 may alternatively be injected to the exhaust manifold pipe 108, the turbocharger turbine 22 casing, the inlet manifold 104, the turbocharger compressor 24 casing, or the inlet manifold pipe 106.

(11) The operation of the turbocharger system 10, and the function of the control unit 50 will now be described in more detail. The control unit 50 is configured to determine a NOx parameter being indicative of, or correlated to, NOx emissions out from the exhaust after treatment system 900, and

(12) initiate injection of pressurized gas from the tank 40 to drive the turbocharger turbine 22 based on the determined NOx parameter, wherein a determined NOx parameter above a pre-defined first threshold determines that pressurized gas from the tank 40 is injected. Hence, the turbocharger turbine 22 may be at least partly driven by the pressurized gas from the tank 40, and at least partly be driven by exhaust gases from the exhaust manifold 102.

(13) Hereby, the injection of pressurized gas from the tank 40 may be determined in response to the determined NOx parameter, and thus the NOx emissions of the exhaust after treatment system 900. Hence, the combustion engine 100 may be operated in an engine operational mode in order to respond to the determined NOx parameter and the NOx emissions, and the injection of pressurized gas from the tank 40 may be adapted to such engine operational mode. Hereby, the pressurized gas from the tank 40 may be used to compensate a relative poor engine performance parameter resulting from the chosen engine operational mode and/or the pressurized gas in the tank 40 may be saved as the chosen engine operational mode is in no need for an increased spin-up of the turbocharger turbine 22 by the pressurized gas from the tank 40.

(14) Hence, the control unit 50 may be configured to deactivate injection functionality of pressurized gas from the tank 40 based on the determined NOx parameter, wherein a determined NOx parameter below the pre-defined first threshold determines that injection functionality of pressurized gas from the tank is deactivated. Thus, the use of pressurized gas can be reduced in response to the determined NOx parameter or NOx emissions.

(15) According to one embodiment, the control unit 50 is configured to operate the combustion engine 100 in a low NOx mode based on the determined NOx parameter, wherein a determined NOx parameter above a pre-defined second threshold determines that the combustion engine 100 is operated in the low NOx mode and/or

(16) the control unit 50 may be configured to operate the combustion engine 100 in a high responsive fuel economy mode, based on the determined NOx parameter, wherein a determined NOx parameter below a pre-defined third threshold determines that the combustion engine 100 is operated in the high responsive fuel economy mode.

(17) As mentioned previously, the pressurized gas from the tank 40 may be used to compensate for a poor engine performance, such as e.g. a poor torque response, in the low NOx mode. Alternatively, the injection of pressurized gas from the tank 40 may be terminated, or simply not initiated, or the injection functionally may be deactivated, in the high responsive fuel economy mode, in order to reduce the use of pressurized gas.

(18) The control unit 50 may e.g. be configured to release pressurized gas from the tank 40 for a pre-set time period of at least 1 second, or between 1 second and 5 seconds. For example, the size of the tank, and the release of pressurized gas via the valve 44, may be sized and dimensioned such that the tank 40 is fully depleted or emptied after e.g. 5 seconds. Thus, the turbocharger system 10, and the turbocharger turbine 22, may be operated by pressurized gas from the tank 40 e.g. for at least 5 seconds. When the tank has been at least partly depleted or emptied, it may be recharged using e.g. the compressor 42. According to one embodiment, the control unit 50 is configured to initiate recharging of the tank 40 with pressurized gas using the compressor 42.

(19) As shown in FIG. 2, the exhaust after treatment system 900 comprises a measuring device 902 configured to measure a parameter, such as the NOx parameter, in the exhaust after treatment system 900. The NOx parameter may e.g. be the NOx concentration in the exhaust after treatment system 900 or the inverse temperature in the exhaust after treatment system 900. Hence, the measuring device may be a NOx measuring device 902 or a temperature measuring device 902. In case of the latter, the temperature in the exhaust after treatment system 900 may be used to model the NOx emissions, e.g. by taking the inverse measured temperature.

(20) Turning to FIG. 4 showing a schematic drawing of the pre-defined first, second and third thresholds 401-403 along an axis Y which corresponds to the NOx parameter. As seen in FIG. 4, the pre-defined second threshold 402 may be located in between the pre-defined first threshold 401 and the pre-defined third threshold 403. As also shown in FIG. 4 by the range indicating arrows, the pre-defined second threshold 402 may be equal to, or smaller than, the pre-defined first threshold 401. Correspondingly, the pre-defined third threshold 403 may be equal to, or smaller than, the pre-defined second threshold 402 and/or the pre-defined first threshold 401, also indicated by range indicating arrows. According to one embodiment, the pre-defined first threshold 401 is within 10% of the pre-defined second threshold 402 and/or the pre-defined third threshold 403. For example, the NOx parameter may be the measured NOx emissions (or the NOx parameter can be used to model the NOx emissions) and the pre-defined first threshold 401 may be 0.15 g NOx/kWh or 1.5 g NOx/kWh, or a point between 0.15 g NOx/kWh and 1.5 g NOx/kWh, such as e.g. at 0.69 g NOx/kWh, or at 0.46 g NOx/kWh. Alternatively, the NOx parameter may be correlated to the temperature (e.g. the inverse temperature) in the exhaust after treatment system 900, and the pre-defined first threshold 401 may be between 0 and 1/200° C. such as e.g. 1/200° C. The control unit 50 may comprise or hold information related to the pre-defined first threshold 401, the pre-defined second threshold 402 and/or the pre-defined third threshold 403.

(21) Moreover, the injection of pressurized gas from the tank 40 may be independent of an engine speed increasing action of the combustion engine 100. For example, if the combustion engine 100 and the turbocharger system 10 are comprised in a vehicle 800, the injection of pressurized gas from the tank 40 may be independent of the vehicle's accelerator pedal.

(22) It should be noted that the vehicle 800 in FIG. 1, may comprise the combustion engine 100, the turbocharger system 10 and the exhaust after treatment system 900. Thus, the vehicle 800 may comprise the control unit 50 being configured according to any embodiment described with reference to FIG. 2.

(23) The present invention also relates to a method for controlling a turbocharger system, as e.g. the turbocharger system 10 shown in FIG. 2, fluidly connected to an exhaust manifold of a combustion engine and an exhaust after treatment system (also shown in FIG. 2). Thus, the present invention will hereafter be described with reference to the above described combustion engine 100, turbocharger system 10 and exhaust after treatment system 900 in a non-limiting way, with reference to the flow-chart in FIG. 3 (hence, the reference numerals of FIG. 1 and FIG. 2 are used below when describing the steps of the method in the flow-chart in FIG. 3).

(24) In a first step 601, a NOx parameter being indicative of, or correlated to, NOx emissions out from the exhaust after treatment system is determined. The NOx parameter may e.g. be the NOx concentration in the exhaust after treatment system 900 or be correlated to the temperature in the exhaust after treatment system 900, measure by the measuring device 902. Thus, in an optional second step 602 the NOx emissions are measured using a NOx measuring device arranged in the exhaust after treatment system 900 or the temperature of the exhaust gases is measured using a temperature measuring device arranged in the exhaust after treatment system 900. It should be noted that the method may comprises an optional second sub-step 602′ of modelling the NOx emissions, or determining the theoretical NOx emissions, based on a NOx parameter, such as e.g. the inverse temperature in the exhaust after treatment system 900.

(25) In an optional third step 603, e.g. carried out subsequently to said first step 601, said optional second step 602 or said optional second sub-step 602′, the combustion engine 100 is operated in a low NOx mode based on the determined NOx parameter from the first step 601. A determined NOx parameter above a pre-defined second threshold 402 determines that the combustion engine 100 is operated in the low NOx mode.

(26) In an optional fourth step 604, injection functionality of pressurized gas from the tank 40 is deactivated based on the determined NOx parameter, wherein a determined NOx parameter below the pre-defined first threshold 401 determines that injection functionality of pressurized gas from the tank 40 is deactivated. Thus, pressurized gas from the tank need not to be injected to at least partly drive the turbocharger turbine 22, when the determined NOx parameter is below the pre-defined first threshold 401, as the engine operational mode can be chosen such that the pressurized gas from the tank 40 is not needed.

(27) In an optional fifth step 605, e.g. carried out subsequently to said optional fourth step 604, the combustion engine 100 is operated in a high responsive fuel economy mode, based on the determined NOx parameter from the first step 601. A determined NOx parameter below a pre-defined third threshold determines that the combustion engine 100 is operated in the high responsive fuel economy mode. Hence, the combustion engine 100 may be operated in an engine operational mode which does not focus on reducing the NOx emissions, but instead provide improved engine performance parameters such as e.g. fuel economy and/or torque response. The optional fifth step 605 may for example be carried out as an alternative to the optional third step 603, as shown in FIG. 3, but may as well be carried out prior to, or subsequent to, the optional third step 603.

(28) As mentioned previously, according to one embodiment the turbocharger system 10 comprises a valve 44 for controlling the release of pressurized gas from the tank 40. Thus, in an optional sixth step 606, the valve 44 is operated to release pressurized gas from the tank 40. As previously described, the valve 44 may be connected to a valve pipe 46 which in turn is connected to supply the pressurized gas to the exhaust manifold 102, the exhaust manifold pipe 108, the turbocharger turbine 22 casing, the inlet manifold 104, the turbocharger compressor 24 casing, and/or the inlet manifold pipe 106. The valve 44 may be operated in such a way that the pressurized gas is released from the tank 40 during at least 1 second, such as e.g. between 1 second and 5 seconds.

(29) In a seventh step 607, pressurized gas from the tank 40, e.g. via the valve 44, is injected to drive the turbocharger turbine 22, based on the determined NOx parameter, wherein a determined NOx parameter above the pre-defined first threshold 401 determines that pressurized gas from the tank 40 is injected.

(30) For example, in the low NOx mode, the pressurized gas from the tank 40 may be used to at least partly drive the turbocharger turbine 22, in order to compensate for e.g. a relatively poor torque response which the low NOx mode otherwise would result in.

(31) Preferably, steps 601 to 607 may be repeated.

(32) The control unit 50 may for example be manifested as a general-purpose processor, an application specific processor, a circuit containing processing components, a group of distributed processing components, a group of distributed computers configured for processing, a field programmable gate array (FPGA), etc. The control unit 50 may further include a microprocessor, microcontroller, programmable digital signal processor or another programmable device. The control unit 50 may also, or instead, include an application specific integrated circuit, a programmable gate array or programmable array logic, a programmable logic device, or a digital signal processor. Where the control unit 50 includes a programmable device such as the microprocessor, microcontroller or programmable digital signal processor mentioned above, the processor may further include computer executable code that controls operation of the programmable device.

(33) The processor (of the control unit 50) may be or include any number of hardware components for conducting data or signal processing or for executing computer code stored in memory. The memory may be one or more devices for storing data and/or computer code for completing or facilitating the various methods described in the present description. The memory may include volatile memory or non-volatile memory. The memory may include database components, object code components, script components, or any other type of information structure for supporting the various activities of the present description. According to an exemplary embodiment, any distributed or local memory device may be utilized with the systems and methods of this description. According to an exemplary embodiment the memory is communicably connected to the processor (e.g., via a circuit or any other wired, wireless, or network connection) and includes computer code for executing one or more processes described herein.

(34) The control unit 50 is connected to the various described features of the combustion engine 100 and the turbocharger system 10, and is configured to control system parameters. Moreover, the control unit 50 may be embodied by one or more control units, where each control unit may be either a general purpose control unit or a dedicated control unit for performing a specific function.

(35) The present disclosure contemplates methods, devices and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor.

(36) By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a machine, the machine properly views the connection as a machine-readable medium. Thus, any such connection is properly termed a machine-readable medium. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data that cause a general-purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.

(37) Although the figures may show a specific order of method steps, the order of the steps may differ from what is depicted. In addition, two or more steps may be performed concurrently or with partial concurrence. Such variation will depend on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps and decision steps. Additionally, even though the disclosure has been described with reference to specific exemplifying embodiments thereof, many different alterations, modifications and the like will become apparent for those skilled in the art.

(38) It should be understood that the control unit 50 may comprise a digital signal processor arranged and configured for digital communication with an off-site server or cloud based server. Thus data may be sent to and from the control unit 50.

(39) It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims. Thus, variations to the disclosed embodiments can be understood and effected by the skilled addressee in practicing the claimed disclosure, from a study of the drawings, the disclosure, and the appended claims. Furthermore, in the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality.