Pressure regulating mass flow system for multipoint gaseous fuel injection
11092091 · 2021-08-17
Assignee
Inventors
- Timothy J. Farrow (Fort Collins, CO, US)
- Michael Ryan Buehner (Fort Collins, CO)
- Gregory James Hampson (Boulder, CO, US)
- John Karspeck (Loveland, CO, US)
Cpc classification
Y02T10/30
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F02D41/3845
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D2200/0602
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/0027
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D19/0605
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D19/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/3854
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M21/0245
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/402
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D19/027
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M21/0239
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02D19/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D19/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/38
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M21/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Embodiments of a gaseous or dual fuel electronic pressure regulation system (EPRS) for a multipoint fuel injection engine are described herein. Additionally, embodiments of a method for controlling the EPRS are provided. In particular, the EPRS employs an electronic pressure regulator (EPR) capable of accurately determining and controlling the mass flow of gaseous fuel into a fuel rail so as to avoid pressure droop and over- and under-pressurization of the gas admission valves (GAVs). By using the EPRS described above, mass flow is able to be distributed to the downstream manifold or engine cylinders very accurately, and the GAVs are able to be driven simultaneously in a pressure/pulse duration that is optimal for accurate and repeatable operation.
Claims
1. A method of regulating flow of a gaseous fuel in a multipoint fuel injection system in which a fuel rail provides the gaseous fuel to a plurality of gas admission valves, the method comprising the steps of: determining a first mass flow of the gaseous fuel entering the fuel rail using an electronic pressure regulator; determining a second mass flow of the gaseous fuel exiting the fuel rail; calculating a rate of pressure change in the fuel rail as a function of a difference between the second mass flow and the first mass flow; and adjusting at least one of a first effective area of an electronic pressure regulator or a second effective area of the plurality of gas admission valves in response to the calculated rate of pressure change.
2. The method of claim 1, further comprising a step of creating a negative rate of pressure change when a pressure in the fuel rail trends toward a predetermined upper limit.
3. The method of claim 2, wherein the step of creating a negative rate of pressure change further comprises executing a temporary reduction in the first mass flow such that the second mass flow is greater than the first mass flow.
4. The method of claim 1, further comprising a step of creating a positive rate of pressure change when a pressure in the fuel rail trends toward a predetermined lower limit.
5. The method of claim 4, wherein the step of creating a positive rate of pressure change further comprises executing a temporary increase in the first mass flow such that the first mass flow is greater than the second mass flow.
6. The method of claim 1, wherein the step of calculating a rate of pressure change comprises numerically differentiating a pressure set point.
7. The method of claim 1, wherein the step of calculating a rate of pressure change comprises filtering a pressure set point and extracting a velocity term.
8. The method of claim 1, further comprising the step of calibrating the plurality of gas admission valves during a time in which the rate of pressure change is zero.
9. The method of claim 8, wherein the step of calibrating the plurality of gas admission valves further comprises calibrating based on the first mass flow determined by the electronic pressure regulator.
10. The method of claim 1, further comprising the step of changing the first effective area of the electronic pressure regulator so as to create a pressure change and wherein the adjusting step comprises adjusting the second effective area of the plurality of gas admission valves in response to the calculated rate of pressure change.
11. The method of claim 10, further comprising the step of coordinating the step of changing the first effective area of the electronic pressure regulator and the step of adjusting the second effective area of the plurality of gas admission valves so as to maintain a desired second mass flow through the plurality of gas admission valves.
12. The method of claim 11, further comprising the step of providing first finite bandwidth limitations for the first effective area of the electronic pressure regulator and second finite bandwidth limitations for the second effective area of the plurality of gas admission valves; wherein the step of changing the first effective area of the electronic pressure regulator does not exceed the first finite bandwidth limitations; wherein the step of adjusting the second effective area of the plurality of gas admission valves does not exceed the second finite bandwidth limitations; and wherein the rate of pressure change is saturated during the steps of adjusting the first effective area and the second effective area.
13. The method of claim 1, wherein the adjusting step further comprises adjusting at least one of the first effective area of the electronic pressure regulator or the second effective area of the plurality of gas admission valves so that the rate of pressure change transitions to zero.
14. The method of claim 13, wherein, after the rate of pressure change has transitioned to zero, the first mass flow and the second mass flow both equal a third mass flow that is different from either of the first mass flow and the second mass flow.
15. A gaseous fuel regulation system, comprising: a fuel rail; an electronic pressure regulator (EPR) upstream of and in fluid communication with the fuel rail, the EPR configured to meter a first mass flow of a gaseous fuel flowing through the EPR; a plurality of gas admission valves, each gas admission valve being downstream of and in fluid communication with the fuel rail; and a controller, the controller being configured to receive a mass flow delivery command and to set a first effective area of the EPR and a second effective area of the plurality of gas admission valves based at least in part on the mass flow delivery command and on the first mass flow.
16. The gaseous fuel regulation system of claim 15, wherein a pressure of the fuel rail is communicated to the controller, wherein the controller is configured to calculate a rate of change of the pressure, and wherein the controller is configured to set the first and second effective areas based also on the rate of change of the pressure.
17. The gaseous fuel regulation system of claim 16, further comprising a first order filter configured to filter a pressure set point and extract a velocity term in order to calculate the rate of change of the pressure.
18. The gaseous fuel regulation system of claim 16, wherein the controller is configured to calculate the rate of change of the pressure by extracting a velocity term from a dynamic model or a dynamic system.
19. The gaseous fuel regulation system of claim 16, wherein, when the rate of change of the pressure is positive, the controller is configured to decrease the first effective area.
20. The gaseous fuel regulation system of claim 19, wherein, when the rate of change of the pressure is negative, the controller is configured to increase the first effective area.
21. The gaseous fuel regulation system of claim 20, wherein, for a given mass flow command, the controller is configured to increase or decrease the first effective area without adjusting the second effective area.
22. The gaseous fuel regulation system of claim 15, wherein the controller is configured to set the first effective area and the second effective area asynchronously.
23. A gaseous fuel regulation system, comprising: a fuel rail; an electronic pressure regulator (EPR) upstream of and in fluid communication with the fuel rail, the EPR configured to meter a first mass flow of a gaseous fuel flowing through the EPR; a plurality of gas admission valves, each gas admission valve being downstream of and in fluid communication with the fuel rail; and a controller, the controller being configured to receive a mass flow delivery command and to set a first effective area of the EPR and a second effective area of the plurality of gas admission valves based at least in part on the mass flow delivery command and on the first mass flow; wherein the plurality of gas admission valves each have upper and lower operability pressure limits and wherein the controller is configured to maintain a pressure in the fuel rail within the upper and lower operability limits of the gas admission valves.
24. A dual fuel system, comprising: a first fuel rail carrying a liquid fuel; a second fuel rail carrying a gaseous fuel; and a plurality of engine cylinders; wherein the liquid fuel and the gaseous fuel are combusted in the plurality of engine cylinders; and wherein flow of the gaseous fuel to the plurality of engine cylinders is controlled by the gaseous fuel regulation system of claim 15.
25. The dual fuel system of claim 24, wherein the liquid fuel comprises diesel fuel.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10) While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
(11) Embodiments of a gaseous or dual fuel electronic pressure regulation system (EPRS) for a multipoint fuel injection (MPFI) engine are described herein. Additionally, embodiments of a method for controlling the EPRS are provided. In particular, the EPRS employs an electronic pressure regulator (EPR) capable of accurately determining and controlling the mass flow of gaseous fuel into a fuel rail so as to avoid pressure droop and over- and under-pressurization of the gas admission valves (GAVs). In particular, using the disclosed EPRS provides another degree of freedom for controlling mass flow in a multipoint system. Conventional fuel control systems (such as those discussed above and shown in
(12)
(13) Having generally described the components of the system, a simplified schematic representing the control method is provided in
(14) Advantageously, the EPR 12 is able to accurately control the mass flow of the gaseous fuel. Further, because of the ability of the EPR 12 to control mass flow, the ECU 20, as shown in
{dot over (m)}.sub.R≤(AC.sub.d).sub.Rf(P.sub.1,P.sub.2, gas properties) (1)
{dot over (m)}.sub.V=(AC.sub.d).sub.Vf(P.sub.2,P.sub.3, gas properties) (2)
{dot over (P)}.sub.2=f(Δ{dot over (m)}.sub.r, rail geometry, gas properties) (3)
wherein {dot over (m)}.sub.R, (AC.sub.d).sub.R, P.sub.1, P.sub.2, {dot over (m)}.sub.V, {dot over (m)}.sub.R, (AC.sub.d).sub.V, and P.sub.3, are given above. Gas properties are the traditional macroscopic properties (pressure, volume (V), number of particles, temperature (T)) along with the thermodynamic properties of the gaseous fuel. Rail geometry is the physical dimensions of the fuel rail. {dot over (P)}.sub.2 is the rate of change of pressure P.sub.2, and Δ{dot over (m)}.sub.r is the mass flow rate imbalance in the fuel rail 14 that is a result of {dot over (m)}.sub.R being either greater or less than {dot over (m)}.sub.V.
(15) In this model, the mass flows {dot over (m)}.sub.R and {dot over (m)}.sub.V for the EPR 12 and the GAVs 16, respectively, may be determined by several methods including the standard orifice flow equation, flow characterization of the valve, or using information stored in one of various databases (e.g., the NIST REFPROP database). For equations 1 and 2 above, an example of the standard orifice flow equation implementation of the ƒ(•) function given by:
(16)
(17) This function may be implemented directly, approximated, or accomplished via a lookup table. In the above equation, γ is the adiabatic index.
(18) In equation 3, the ƒ(•) function may be formulated in various ways. If ideal gas assumptions hold and the temperature and fuel composition is constant, {dot over (P)}.sub.2 may be expressed as a mass imbalance multiplied by a constant (e.g., R.sub.S*T/V). However, this could also be modeled using thermodynamic properties and real gas properties. If rail dynamics are substantial, they could also be included in this model. If spatial dynamics are included, the modeled P.sub.2 could be at any point in the rail.
(19) The control objective is to independently control both the mass flow through the GAVs 16 (through varying the pulse duration) and the pressure P.sub.2 in the volume V of the fuel rail 14 independently. A general form of equations for AC.sub.d that accomplish this control objective are given by:
(20)
(21) For this model, the flow is assumed to change instantaneously with changes in effective area (AC.sub.d), and there are no spatial dynamics with filling the volume V of the fuel rail 14. As discussed further below, these assumptions can be changed depending on the specific configuration of the EPRS 10.
(22) If the desired pressure P.sub.2 is actively changing, equations 4 and 5 utilize the reference mass imbalance Δ{dot over (m)}.sub.r.sup.ref, which is obtained by inverting equation 3 for a given set of gas properties. This requires a reference rate of pressure change {dot over (P)}.sub.2.sup.ref, which is able to be obtained by either numerically differentiating the set point P.sub.2.sup.set or by filtering the set point and extracting the velocity term.
(23) Exemplary embodiments of a hypothetical response of the EPRS 10 according to the first order filter 30 of
(24) Advantageously, the concepts underlying the control scheme are extendable to actuators with finite bandwidth by ensuring that AC.sub.d values for the EPR 12 and the GAVs 16 are synchronized with the volume reference trajectory. Finite bandwidth limitations refer to two conditions. First, the EPR 12 and GAVs 16 take a non-zero amount of time to change effective areas. For example, the actuator of the EPR 12 accelerates to move and decelerates to stop, i.e., the change in effective area (AC.sub.d).sub.R is not instantaneous. Similarly, the GAVs 16 change effective area (AC.sub.d).sub.V by changing pulse duration on a pulse-by-pulse basis. Thus, the change in pulse duration of the GAVs 16 is able to be coordinated with the change in effective area (AC.sub.d).sub.R of the EPR 12 over the timing of changing effective area (AC.sub.d).sub.R. Second, the EPR 12 and GAVs 16 have absolute operational limits for effective area AC.sub.d. For example, the EPR 12 is limited in movement between a fully open condition and a fully closed condition. The GAVs 16 have a maximum pulse duration and a minimum pulse duration needed to maintain delivery of fuel to the system. For this second condition, observing the finite bandwidth limitations is achieved by saturating the reference P.sub.2 velocity, e.g., saturating {dot over (P)}.sub.2.sup.ref (output signal 40) as shown in
(25) While the previous example did not consider any spatial dynamics in filling the volume V of the fuel rail 14, in embodiments the EPR 12 is configured to start changing the volume pressure P.sub.2 before the GAVs 16 (or throttle) begin changing their effective area AC.sub.d. In this way, the EPR 12 leads the GAVs 16, which is something that conventional mechanical regulators, as described above, are unable to perform. Further, the EPRS 10 as described herein provides for asynchronous control of the EPR 12 and the GAVs 16. That is, the effective areas (AC.sub.d).sub.R and (AC.sub.d)v are able to be changed independently at different times, or to put it differently, the effective areas (AC.sub.d).sub.R and (AC.sub.d)v do not have to be changed at the same time.
(26) Returning to
(27) According to the EPRS 10, the ECU 20 receives a mass flow delivery command based upon engine requirements (e.g., speed, load, environment, etc.). The ECU 10, using the above-described algorithm, meets the exit mass flow command by changing the duration of the GAVs 16 utilizing the knowledge of the constant pressure P.sub.2 of the fuel rail 14. Accordingly, the algorithm provides the ability to prescribe the pressure P.sub.2 in the fuel rail 14 during the execution of a new mass flow set point by managing the pressure P.sub.2 in the fuel rail 14 to a pressure set point that is used to accurately calculate the duration of the GAVs 16. Further, any mismatch in the actual mass flow to the target mass flow will manifest as a change in the pressure P.sub.2 of the fuel rail 14. In this way, stabilization of the pressure P.sub.2 serves as an indication that the mass flow {dot over (m)}.sub.V exiting the GAVs 16 matches the mass flow {dot over (m)}.sub.R entering the fuel rail 14 through the EPR 12. In this way, an EPR 12 is able to be used from a prognostics standpoint to determine when the GAVs 16 need to be serviced.
(28) Further, because the inlet mass flow controller in the EPR 12 is very accurate, the calibration constants of the GAVs 16 are able to be updated and saved at times of steady pressure (i.e., at times when the rate of pressure change is at or near zero) using the mass flow from the EPR 12, thereby enabling automatic recalibration during the life of the GAVs 16. Additionally, the present system and method help to prevent over-pressurization of the GAVs 16 during large transient events by using the EPR 12 to manage pressure. As an example of such a large transient event, during a full load rejection condition, the manifold absolute pressure could drop significantly, which would create a large differential pressure across the GAVs 16. As another example, a large pressure differential could be created during a shutdown event in which the shutoff valve is located well upstream of the fuel rail. In such situations, the close coupling of the EPR 12 to the GAVs 16 allows for a faster reduction in the pressure P.sub.2 of the fuel rail 14 during such events.
(29) Additional protection is provided to the GAVs 16 because the algorithm knows the upper and lower operability pressure limits (i.e., finite bandwidth limitations) of the GAVs 16 and is able to manage the pressure P.sub.2 of the fuel rail 14 to stay within those operability limits by commanding temporary deviations in the inlet mass flow {dot over (m)}.sub.R. Similar protection is provided for the EPR 12 such that the EPR 12 operates within its finite bandwidth limitations to maintain accuracy of the EPR 12 and avoid damage. Thus, if the pressure P.sub.2 is trending high, the inlet mass flow controller executes a temporary mass flow rate reduction/imbalance, such that the outflow exceeds the inflow and the pressure differential is negative. Conversely, if the pressure P.sub.2 is trending low, the inlet mass flow device will temporarily increase mass flow to increase the pressure P.sub.2. Further, ideally, the pressure P.sub.2 in the fuel rail 14 is maintained as low as possible (with margin) to maintain the duration of the GAVs 16 as long as possible. Without the level of monitoring and control provided by the disclosed EPRS 10, the pressure P.sub.2 typically would not be set so low because of the possibility of droop taking it under the operable pressure
(30) All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
(31) The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
(32) Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.