Method for diagnosing a digital flow-control valve of a high-pressure fuel injection pump

Abstract

Disclosed is a method for the diagnosis of a digital valve in a fuel injection system. In the diagnosis, a diagnosis current is applied to the digital valve with an intensity and for a hold time that are predetermined by experiment on digital valves identified as being fault-free, this intensity and this time being recognized as being sufficient for an inflection on a curve of the closing current to be detected in the hold time. Measurements are taken at more than 3 kHz of the diagnosis current added to the induced current in the hold time. When an inflection on the current curve is detected in this hold time, it is concluded that the valve is working correctly. When no inflection on the curve is detected in this hold time, it is concluded that the valve is faulty.

Claims

1. A method for the functional diagnosis of a digital flow-control valve (13) for a high-pressure fuel injection pump (4) forming part of a system (1) for injecting fuel into an internal combustion engine (12) of a motor vehicle, the digital control valve (13) controlling a flow rate of fuel in the pump by being electrically driven between an open position, with the digital valve (13) then taking an open position, in which a high-pressure portion of the injection system (1) is not supplied with fuel, and a closed position in which the high-pressure portion of the injection system (1) is supplied with the digital valve (13) taking a closed position, a nominal closing control electric current being applied to the digital valve (13) causing the digital valve to move toward the closed position and then canceled so that the digital valve opens under the action of a return spring, the movement of the digital valve (13) toward the closed position creating an induced current in the digital valve (13), wherein, in the diagnosis: a closing diagnosis control current is applied to the digital valve (13), which closing diagnosis control current is different from the nominal control current with an intensity and for a hold time (Dmain) that are predetermined beforehand by experiment on digital valves identified as being fault-free, this intensity and this time being recognized as being sufficient for an inflection (23) on a curve of the closing current added to the induced current to be detected in the hold time (Dmain) predetermined for these fault-free digital valves, measurements are taken at a high frequency higher than 3 kHz of the diagnosis current added to the induced current flowing through a digital valve (13) to be diagnosed in the predetermined hold time (Dmain) with an at least partial plot of the current curve and, when an inflection (23) on the current curve is detected in this predetermined hold time (Dmain), a determination is made that the digital valve (13) is operating normally while, when no inflection (23) on the current curve is detected in this predetermined hold time (Dmain), a determination is made that the digital valve (13) is faulty.

2. The method as claimed in claim 1, wherein the diagnosis current is maintained after an end of the predetermined hold time (Dmain) for a predetermined additional time (Dsup), and when no inflection (23) on the current curve is detected in the predetermined hold time (Dmain) and the predetermined additional time (Dsup), a determination is made that the digital valve (13) has a first type of fault, a closing movement of the digital valve (13) not having taken place or not having been sufficient to position the digital valve (13) in the closed position, whereas, when no inflection (23) on the current curve is detected in the predetermined hold time (Dmain) but one is detected in the predetermined additional time (Dsup), a determination is made that the digital valve (13) has a second type of fault, a closing movement of the digital valve (13) having taken place too late.

3. The method as claimed in claim 1, wherein a decrease in current intensity in the inflection (23) is measured and, when this decrease in intensity is smaller than a predetermined inflection decrease threshold, a determination is made that the digital valve (13) has a third type of fault.

4. The method as claimed in claim 1, wherein the predetermined intensity of the diagnosis current is higher than a first, low threshold (Sibas) predetermined by experiment that is sufficient to cause the digital valve (13) to move into the closed position and lower than a predetermined second, high threshold in order to ensure electrical protection of the valve (13) and the control thereof, the predetermined hold time (Dmain) of a diagnosis control current being longer than the hold time of a nominal control current in normal operation of the digital valve (13).

5. The method as claimed in claim 1, wherein the diagnosis current applied to the digital valve (13) when the digital valve is closed is in the form of a plurality of peak-and-hold electrical pulses for a determined number of segments according to pulse-width modulation.

6. The method as claimed in claim 5, wherein the determined number of segments is smaller than 40 and the peak-and-hold is for four milliseconds, the high-frequency measurement of the current taking place at 10 kHz.

7. The method as claimed in claim 1, which is initiated upon an external request (30) in aftersales or in a garage, upon a periodic routine request (31) or upon a request (32) initiated following a possible fault detected in the injection system (1).

8. The method as claimed in claim 1, wherein the method is implemented with the engine of the motor vehicle running or stopped, and when the method is implemented with the engine stopped, a battery voltage of the motor vehicle, called upon to supply the diagnosis current, in a range between +/−20% of a nominal voltage of the battery.

9. A method for deblocking a digital flow-control valve (13) for a high-pressure fuel injection pump (4) forming part of a system (1) for injecting fuel into an internal combustion engine (12) of a motor vehicle, wherein the deblocking method incorporates a method for the diagnosis of the digital valve (13) as claimed in claim 1 and, when a determination is made that the digital valve (13) has a fault in the diagnosis method, a step of deblocking the digital valve (13) is performed.

10. The deblocking method as claimed in claim 9, wherein the digital valve (13) is subjected to an unsticking control current applied in three consecutive phases having respective durations with, in a first phase, a current varying from a minimum value to a maximum value, in a second phase, a current varying between the maximum value and a freewheeling value and, in a third phase, a current varying between the freewheeling value and the minimum value.

11. A system (1) for injecting fuel into an internal combustion engine (12) of a motor vehicle comprising a high-pressure fuel injection pump (4) and a control unit (5, 6), the pump (4) comprising at least one piston (19) moving in a chamber and being equipped with a digital valve (13) for controlling a fuel flow rate and driven by the control unit (5, 6) via an electrical control element connected to the digital valve (13) by an electrical circuit and producing a nominal closing control electric current, the system implementing a method for the functional diagnosis of a digital flow-control valve (13) as claimed in claim 1, wherein the electrical control element comprises means for varying the intensity and the hold time (Dmain) of the nominal current for application of a diagnosis current, the control unit comprising means for measuring the diagnosis current at a high frequency higher than 3 kHz, means for detecting an inflection (23) on a diagnosis current curve and means for establishing a diagnosis of a fault or otherwise in the digital valve (13).

12. The method as claimed in claim 2, wherein a decrease in current intensity in the inflection (23) is measured and, when this decrease in intensity is smaller than a predetermined inflection decrease threshold, a determination is made that the digital valve (13) has a third type of fault.

13. The method as claimed in claim 2, wherein the predetermined intensity of the diagnosis current is higher than a first, low threshold (Sibas) predetermined by experiment that is sufficient to cause the digital valve (13) to move into the closed position and lower than a predetermined second, high threshold in order to ensure electrical protection of the valve (13) and the control thereof, the predetermined hold time (Dmain) of a diagnosis control current being longer than the hold time of a nominal control current in normal operation of the digital valve (13).

14. The method as claimed in claim 3, wherein the predetermined intensity of the diagnosis current is higher than a first, low threshold (Sibas) predetermined by experiment that is sufficient to cause the digital valve (13) to move into the closed position and lower than a predetermined second, high threshold in order to ensure electrical protection of the valve (13) and the control thereof, the predetermined hold time (Dmain) of a diagnosis control current being longer than the hold time of a nominal control current in normal operation of the digital valve (13).

15. The method as claimed in claim 2, wherein the diagnosis current applied to the digital valve (13) when the digital valve is closed is in the form of a plurality of peak-and-hold electrical pulses for a determined number of segments according to pulse-width modulation.

16. The method as claimed in claim 3, wherein the diagnosis current applied to the digital valve (13) when the digital valve is closed is in the form of a plurality of peak-and-hold electrical pulses for a determined number of segments according to pulse-width modulation.

17. The method as claimed in claim 4, wherein the diagnosis current applied to the digital valve (13) when the digital valve is closed is in the form of a plurality of peak-and-hold electrical pulses for a determined number of segments according to pulse-width modulation.

18. The method as claimed in claim 2, which is initiated upon an external request (30) in aftersales or in a garage, upon a periodic routine request (31) or upon a request (32) initiated following a possible fault detected in the injection system (1).

19. The method as claimed in claim 3, which is initiated upon an external request (30) in aftersales or in a garage, upon a periodic routine request (31) or upon a request (32) initiated following a possible fault detected in the injection system (1).

20. The method as claimed in claim 4, which is initiated upon an external request (30) in aftersales or in a garage, upon a periodic routine request (31) or upon a request (32) initiated following a possible fault detected in the injection system (1).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other features, aims and advantages of the present invention will become apparent from reading the detailed description that follows and from examining the appended drawings given by way of non-limiting example, and in which:

(2) FIG. 1 schematically shows a view of one embodiment of a high-pressure fuel supply system for an internal combustion engine, this system being equipped with a high-pressure fuel injection pump and a digital valve, the correct operation of which may be estimated according to a diagnostic method according to the present invention,

(3) FIG. 2 schematically shows a view in cross section of a high-pressure fuel injection pump provided with a digital valve on which the method for the diagnosis of a digital valve according to the present invention may be implemented,

(4) FIGS. 3 and 4 each show a respective curve of current intensity measured by oscilloscope with time for a correctly operating digital valve and a blocked incorrectly operating digital valve, respectively, an inflection being visible for the curve of the correctly operating digital valve and not being visible for the curve of the blocked digital valve, the curves being established in accordance with a diagnostic method according to the present invention,

(5) FIG. 5 shows two readback curves with time of an intensity of the current that has passed through the digital valve, the current having a control current component and an induced current component, one readback curve corresponding to a correctly operating digital valve in exhibiting an inflection and the other corresponding to an incorrectly operating digital valve,

(6) FIG. 6 shows a flow diagram for one preferred embodiment of the diagnosis method according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(7) In what follows, reference will be made to all of the figures taken in combination, pointing out some of these figures in particular.

(8) Referring more particularly to FIGS. 1 and 2, a high-pressure fuel injection system 1 for an internal combustion engine comprises a booster pump 2 which takes fuel at low pressure from a low-pressure fuel tank 3, a high-pressure fuel injection pump 4 being fed by the booster pump 2. This high-pressure pump 4 comprises an actuator for a digital valve, which actuator is not shown in FIG. 1 but is shown in FIG. 2 which will be discussed in detail later.

(9) The injection system 1 also comprises a controller for the high-pressure fuel injection pump 4 and, more particularly, for the digital valve actuator and means for activating the high-pressure injection pump 4 by time-based control or angular control using the high-pressure fuel injection pump 4 controller 5 and an engine control unit 6, time-based control being mainly used just after the starting of the motor vehicle. The controller 5 may also be integrated into the engine control unit 6 and not be embodied as shown in FIG. 1.

(10) The injection system 1 also comprises a high-pressure fuel tank or common rail 7 fed by the high-pressure fuel injection pump 4, the common rail 7 being provided with means 8 for measuring pressure. Injectors 9 are fed with fuel by the common rail 7 and controlled by the engine control unit to inject fuel into the cylinders 11 of the internal combustion engine 12.

(11) The high-pressure fuel injection pump 4 may be able to be driven in a known way by a drive means, not shown in FIG. 1, using the internal combustion engine 12, for example using a mechanical transmission linking mechanism of chain, gear, belt or similar type.

(12) FIG. 2 shows a high-pressure fuel injection pump 4 for the injection system shown in FIG. 1. This pump 4 comprises a pump housing 14. The housing 14 of the pump 4 houses within it a piston 19 returned by a spring 20, the piston 19 being driven by a cam drive mechanism 21.

(13) The pump housing 14 at its upper end has a displacement unit 15 housing a digital valve 13 or DIV valve. The unit 15 comprises a supply and return pipe 18 from and to the booster pump and an outlet pipe 17 leading toward the common rail, this outlet pipe comprising a non-return valve 16.

(14) When the digital valve 13 is in the open position, the piston 19 draws fuel from the supply pipe 18 into a cylinder while the non-return valve 16 of the outlet pipe 17 is closed.

(15) At the end of the filling phase, the digital valve 13 is still in the open position, the piston 19 drives the fuel in the supply pipe 18 toward the booster pump, namely the low-pressure portion of the injection system, while the non-return outlet valve 16 of the outlet pipe 17 remains closed. That allows excess fuel to be carried back into the low-pressure portion of the injection system.

(16) Next, the digital valve 13 is electrically controlled so as to close, the supply pipe 18 then being closed, the piston 19 drives the fuel in the outlet pipe 17 toward the common rail, namely toward the high-pressure portion of the injection system, the non-return valve 16 of the outlet pipe 17 then being open.

(17) Referring more particularly to FIGS. 1 to 5, the present invention relates to a method for the functional diagnosis of a digital flow-control valve 13 for a high-pressure fuel injection pump forming part of a system 1 for injecting fuel into an internal combustion engine of a motor vehicle.

(18) As previously mentioned, the digital control valve controls a flow rate of fuel in the pump by being electrically driven between, on the one hand, an open position, with the digital valve 13 then taking an open position and, on the other hand, a closed position.

(19) When the digital valve 13 is in the open position, a high-pressure portion of the injection system 1 is not supplied with fuel. In the closed position which corresponds to a position in which the digital valve 13 is closed, the high-pressure portion of the injection system 1 is supplied.

(20) A nominal closing control electric current is applied to the digital valve 13 causing it to move toward its closed position and then canceled so that it opens under the action of a return spring. The return to open does not happen automatically as soon as the closing control current ends because the return spring must overcome the pressure of the piston 19.

(21) The movement of the digital valve 13 toward its closed position under application of the closing control current creates an induced current in the digital valve 13 that is representative of the closing movement of the digital valve 13.

(22) This is the normal operation of a digital valve 13 subjected to a nominal control current for a nominal time. The operating conditions change, however, when a method for the diagnosis of the digital valve 13 according to the present invention is implemented.

(23) When such a method is implemented on a digital valve 13 to be diagnosed, a closing diagnosis control current is applied to the digital valve 13. This diagnosis control current differs from the nominal control current in its intensity, which is predetermined, but above all in its predetermined hold time Dmain.

(24) Specifically, routine experiments are performed on digital valves identified as fault-free in which control currents are applied at various intensities and for various hold times. A current intensity high enough to effect closure but low enough not to electrically damage the digital valve 13 and its control system should be chosen. Additionally, a hold time Dmain long enough to effect, for all the fault-free digital valves, valve closure, and even to detect delayed closing, should be chosen.

(25) Since a closing movement of the valve produces an induced current, this movement results in an inflection 23 on a curve of the closing current added to the induced current in the hold time Dmain predetermined for these fault-free digital valves. Those skilled in the art have the skills to choose a predetermined current intensity and a hold time Dmain for the current that are sufficient to effect closure of a fault-free digital valve 13. The current hold time Dmain may be selected so as to be higher than a nominal hold time Dmain resulting in the closure of the digital valve 13, this nominal hold time being decreased as substantially as possible in order to save on electrical power consumption.

(26) From this starting point, measurements are taken at a high frequency higher than 3 kHz of the diagnosis current added to the induced current flowing through a digital valve 13 to be diagnosed in the predetermined hold time Dmain. An at least partial plot of the current curve is then made. What is meant by at least partial plot is that it is not necessary to plot the entire current curve but only a portion of the curve for which the closing movement of the digital valve 13 is taking place and which is likely to exhibit an inflection 23.

(27) When an inflection 23 on the current curve is detected in this predetermined hold time Dmain, it is concluded that the digital valve 13 is operating normally, this digital valve 13 being in good working order. This is the case in FIG. 3 where an inflection 23 is visible on the current curve I with time t.

(28) When no inflection 23 on the current curve is detected in this predetermined hold time Dmain, it is concluded that the digital valve 13 is faulty. This is the case in FIG. 4 for which no inflection 23 on the current curve I with time t is visible.

(29) FIG. 5, while referring to FIG. 2, shows two control current readback curves of a digital valve 13 via a specific acquisition mode. On the abscissa, the time t is graduated every 0.5 milliseconds, a total hold time being approximately for 4 milliseconds. On the ordinate, a dimensionless quantity V is indicated, measured by an acquisition stage of the computer. A correspondence may be established between the graduations of the quantity V and a current intensity, one graduation of the scale on the ordinate corresponding to 2 amps and the total scale on the ordinate corresponding to 12 amps maximum.

(30) A current curve of a fault-free digital valve 13, or DIVok, which exhibits an inflection region 23, and a curve of a faulty digital valve 13, or DIVnok, which does not exhibit an inflection region 23, are shown. A plurality of inflection regions 23 may be present on the same curve. For example, the current curve of a fault-free digital valve 13 DIVok may exhibit four inflection regions of consecutive decreasing amplitude as the curve progresses, but only the first inflection region 23 is taken into account, the other inflection regions being echoes.

(31) In this FIG. 5, the predetermined hold time Dmain is shown, the arrow to the left representing its end. This predetermined hold time Dmain may be extended by an additional predetermined time Dsup in order to see whether an inflection region appears after the end of the predetermined hold time Dmain, which does not occur in FIG. 5. The end of the predetermined additional time Dsup is not shown in FIG. 5 because it is calibratable. In the non-limiting example shown in FIG. 5, the predetermined hold time Dmain is 2.5 milliseconds and the additional predetermined time Dsup may be 1.50 milliseconds to reach a total current hold and plot time for the curve of 4 milliseconds.

(32) Thus, the diagnosis current may be maintained after an end of the predetermined hold time Dmain for a predetermined additional time Dsup. When no inflection 23 on the current curve is detected in the predetermined hold time Dmain and the predetermined additional time Dsup, it is concluded that the digital valve 13 has a first type of fault. In this case, a closing movement of the digital valve 13 has not taken place or has not been sufficient to position the digital valve 13 in the closed position.

(33) When no inflection 23 on the current curve is detected in the predetermined hold time Dmain but one is detected in the predetermined additional time Dsup, it is concluded that the digital valve 13 has a second type of fault. In this case, a closing movement of the digital valve 13 has taken place too late or too slowly. This is not shown in FIG. 5.

(34) This may be due to a hard point and is not conceivable in nominal operation because the control current is time-limited and the nominal control hold time is shorter than the predetermined hold time. The nominal control current may thus be canceled before the digital valve is closed.

(35) The predetermined additional time Dsup may be equal to at least 10% of the predetermined hold time Dmain. In the example of FIG. 5, the predetermined additional time Dsup is equal to 60% of the predetermined hold time Dmain.

(36) The predetermined hold time Dmain of a diagnosis control current may be longer than the hold time of a nominal control current in normal operation of the digital valve 13, in order to read back the inflection 23 during the closure of the digital valve 13, the nominal control current potentially being stopped before the appearance of this inflection.

(37) When a decrease in current intensity in the inflection 23 is measured and, when this decrease in intensity is smaller than a predetermined inflection decrease threshold, for example less than 7%, advantageously less than 5%, it is concluded that the digital valve 13 has a third type of fault. This third fault is due to an electrical problem caused by high electrical resistance.

(38) Still referring mainly to FIG. 5, the predetermined intensity of the diagnosis current should be higher than a first, low threshold Sibas predetermined by experiment as sufficient to cause the digital valve 13 to move into the closed position. This is shown in FIG. 5 for a current intensity of between 1 and 8 amps which is a current region Cnok not suitable for the implementation of the method because it is too low, being lower than the predetermined first, low threshold Sibas which may be 8 amps.

(39) In addition, the predetermined intensity of the diagnosis current may be lower than a predetermined second, high threshold in order to ensure electrical protection of the valve and the control thereof. This threshold may be 16 amps.

(40) As can be seen more particularly in FIGS. 3 and 4, the diagnosis current applied to the digital valve 13 when it is closed may be in the form of a plurality of peak-and-hold electrical pulses for a determined number of segments according to pulse-width modulation.

(41) The determined number of segments may be smaller than 40 and the peak-and-hold may be for four milliseconds, the high-frequency measurement of the current possibly taking place at 10 kHz, which is the case in FIGS. 3 and 4. The 90% pulse-width modulation may be performed over a predetermined hold time of 4 milliseconds.

(42) Referring more particularly to FIG. 6 which shows a flow diagram of one preferred embodiment of the diagnosis method according to the present invention with mention of steps which are not essential for the implementation of the method, the diagnosis method may be initiated under various conditions. For example, the method may be initiated upon an external request 30 in aftersales or in a garage, for example following a malfunction of the injection system in order to check beforehand whether or not the digital valve is faulty.

(43) It may also be initiated upon a periodic routine request 31, initiated by a control unit for checking purposes or upon an internal request 32 initiated by a control unit, in particular following a possible fault detected in the injection system 1, an anomaly in the injection system 1 having been detected.

(44) In step 33, the conditions for the implementation of the diagnosis method according to the invention may be checked. These conditions for implementation may be with the internal combustion engine of the vehicle stopped, a battery voltage of the motor vehicle, called upon to supply the diagnosis current, in a range between +/−20% of a nominal voltage of the battery, in order to have a current intensity that is neither too low nor too high.

(45) In step 34, the digital valve may be driven so as to close under a diagnosis control current with a predetermined current intensity and predetermined current hold time.

(46) In step 35, the measurements taken at a high frequency higher than 3 kHz of the diagnosis current added to the induced current flowing through a digital valve to be diagnosed in the predetermined hold time with an at least partial plot of the current curve may be analyzed in order to detect or otherwise an inflection on the current curve.

(47) In step 36, the diagnosis is established: it is concluded that a digital valve is operating correctly or is faulty depending on whether or not a current inflection is detected in the predetermined hold time. If the digital valve is operating correctly, the information is sent in step 37 to an onboard control unit or to an external control unit. If the digital valve is faulty, the information is passed in step 38 to an onboard control unit or to an external control unit. A method for deblocking the faulty digital valve may then be implemented.

(48) With reference to all of the figures, a method for deblocking a digital flow-control valve 13 for a high-pressure fuel injection pump forming part of a system 1 for injecting fuel into an internal combustion engine of a motor vehicle may incorporate the method for the diagnosis of a digital valve 13 as described above. When it is concluded that the digital valve 13 has a fault in the diagnosis method, a step of deblocking the digital valve 13 is performed.

(49) There may be several deblocking procedures, also called unsticking procedures. One possible deblocking procedure is to subject the digital valve 13 to an unsticking control current applied in three consecutive phases having respective durations. In a first phase, the current varies from a minimum value to a maximum value. In a second phase, the current varies between the maximum value and a freewheeling value. Lastly, in a third phase, the current varies between the freewheeling value and the minimum value.

(50) In the first phase, the current intensity may form a peak oscillating between the maximum intensity value and a value that is lower but close to the maximum intensity value.

(51) The deblocking current comprising the three phases may be applied to the digital valve several times in succession.

(52) Still referring to all of the figures, the invention lastly relates to a system 1 for injecting fuel into an internal combustion engine 12 of a motor vehicle comprising a high-pressure fuel injection pump 4 and a control unit 5, 6. The pump 4 comprises at least one piston 19 moving in a chamber and is equipped with a digital valve 13 for controlling a fuel flow rate and driven by the control unit 5, 6 via an electrical control element connected to the digital valve 13 by an electrical circuit and producing a nominal closing control electric current.

(53) The injection system 1 implements a method for the functional diagnosis of a digital flow-control valve 13 or a method for deblocking a digital valve 13 as described above.

(54) To that end, the electrical control element comprises means for varying the intensity and the hold time Dmain of the nominal current for application of a diagnosis current. The control unit 5, 6 comprises means for measuring the diagnosis current at a high frequency higher than 3 kHz, means for detecting an inflection 23 on a diagnosis current curve and means for establishing a diagnosis of a fault or otherwise in the digital valve 13.

(55) The control unit may comprise means for transmitting the results of the diagnosis to an external unit and means for implementing a deblocking current for the digital valve 13.