Gasoline engine knock control

Abstract

Various methods of control of combustion knock are disclosed in relation to a spark ignition, internal combustion engine having active tappets, whereby an inlet poppet valve can be moved independently of the usual operating cam. In one embodiment the invention provides for combustion knock to be controlled solely by variation of inlet air charge.

Claims

1. A method of combustion knock control in a spark ignition reciprocating piston internal combustion engine having a combustion chamber, an inlet valve at an inlet to said combustion chamber, and an active tappet for said inlet valve whereby valve operation may be adjusted on demand, the method comprising: selecting and using a first one of two modes of combustion knock control in dependence on a temperature of the spark ignition reciprocating piston internal combustion engine exceeding a predetermined threshold operating temperature; continuing to use the first one of the two modes of combustion knock control until the temperature of the spark ignition reciprocating piston internal combustion engine drops below the predetermined threshold operating temperature; and subsequently selecting and using a second one of the two modes of combustion knock control instead of the first one of the two modes of combustion knock control in dependence on the temperature of the spark ignition reciprocating piston internal combustion engine dropping below the predetermined threshold operating temperature, wherein: a timing of an ignition spark has a value at a time of the temperature of the spark ignition reciprocating piston internal combustion engine exceeding said predetermined threshold operating temperature; said first one of two modes of combustion knock control comprises maintaining the timing of the ignition spark fixed at the value until the temperature of the spark ignition reciprocating piston internal combustion drops below said threshold operating temperature, and controlling knock solely by varying an air charge of the combustion chamber by controlling the active tappet while maintaining the timing of the ignition spark fixed at the value; and said second one of the two modes of combustion knock control comprises varying the air charge of the combustion chamber by controlling the active tappet and varying the timing of the ignition spark.

2. The method according to claim 1, wherein said operation of said active tappet comprises commanding at least re-timing an opening of the inlet valve to increase overlap with operation of at least one exhaust valve of said combustion chamber so as to increase a duration over which the inlet valve and said at least one exhaust valve are open simultaneously or to reduce overlap with operation of the at least one exhaust valve of said combustion chamber so as to reduce the duration over which the inlet valve and said at least one exhaust valve are open simultaneously.

3. The method according to claim 1, wherein above said threshold operating temperature, combustion knock is treated by commanding said active tappet to reduce the air charge in said combustion chamber.

4. The method according to claim 1, wherein the inlet valve is a poppet valve, and wherein the spark ignition reciprocating piston internal combustion engine has an inlet manifold upstream of said inlet valve, and a throttle valve at an inlet to said inlet manifold.

5. An electronic control unit configured to control an internal combustion engine having a combustion chamber, an inlet valve at an inlet to said combustion chamber, and an active tappet for said inlet valve whereby valve operation may be adjusted on demand, the electric control unit comprising: a processor; and a memory associated with the processor, the memory containing parameters defining two modes of combustion knock control, wherein the processor is configured to control combustion knock by selecting and using a first one of two modes of combustion knock control in dependence on a temperature of the internal combustion engine exceeding a predetermined threshold operating temperature; continuing to use the first one of the two modes of combustion knock control until the temperature of the internal combustion engine drops below the predetermined threshold operating temperature; and subsequently selecting and using a second one of the two modes of combustion knock control instead of the first one of the two modes of combustion knock control in dependence on the temperature of the internal combustion engine dropping below the predetermined threshold operating temperature, wherein: a timing of an ignition spark has a value at a time of the temperature of the internal combustion engine exceeding said predetermined threshold operating temperature; said first one of two modes of combustion knock control comprises maintaining the timing of the ignition spark fixed at the value until the temperature of the internal combustion engine subsequently drops below said threshold operating temperature, and controlling knock solely by varying an air charge of the combustion chamber by controlling the active tappet while maintaining the timing of the ignition spark fixed at the value; and said second one of the two modes of combustion knock control comprises varying the air charge of the combustion chamber by controlling the active tappet and varying the timing of the ignition spark.

6. The electronic control unit of claim 5, wherein operation of said active tappet comprises commanding at least re-timing an opening of the inlet valve to increase overlap with operation of at least one exhaust valve of said combustion chamber so as to increase a duration over which the inlet valve and said at least one exhaust valve are open simultaneously or to reduce overlap with operation of the at least one exhaust valve of said combustion chamber so as to reduce the duration over which the inlet valve and said at least one exhaust valve are open simultaneously.

7. A system comprising: an internal combustion engine including a combustion chamber, an inlet valve at an inlet to said combustion chamber, and an active tappet for said inlet valve whereby valve operation may be adjusted on demand; and an electronic control unit configured to control combustion knock of the internal combustion engine by selecting and using a first one of two modes of combustion knock control in dependence on a temperature of the internal combustion engine exceeding a predetermined threshold operating temperature; continuing to use the first one of the two modes of combustion knock control until the temperature of the internal combustion engine drops below the predetermined threshold operating temperature; and subsequently selecting and using a second one of the two modes of combustion knock control instead of the first one of the two modes of combustion knock control in dependence on the temperature of the internal combustion engine dropping below the predetermined threshold operating temperature, wherein: a timing of an ignition spark has a value at a time of the temperature of the internal combustion engine exceeding said predetermined threshold operating temperature; said first one of two modes of combustion knock control comprises maintaining the timing of the ignition spark fixed at the value until the temperature of the internal combustion engine subsequently drops below said threshold operating temperature, and controlling knock solely by varying an air charge of the combustion chamber by controlling the active tappet while maintaining the timing of the ignition spark fixed at the value; and said second one of the two modes of combustion knock control comprises varying the air charge of the combustion chamber by controlling the active tappet and varying the timing of the ignition spark.

8. The system of claim 7, wherein the active tappet comprises an electro-hydraulic actuation device for continuously varying a valve lift of said inlet valve.

9. The system of claim 8, wherein the active tappet is between a cam and the inlet valve, and the active tappet is for continuously varying the valve lift of the inlet valve independently of the cam.

10. The system of claim 7, wherein operation of said active tappet comprises commanding at least re-timing an opening of the inlet valve to increase overlap with operation of at least one exhaust valve of said combustion chamber so as to increase a duration over which the inlet valve and said at least one exhaust valve are open simultaneously or to reduce overlap with operation of the at least one exhaust valve of said combustion chamber so as to reduce the duration over which the inlet valve and said at least one exhaust valve are open simultaneously.

11. A vehicle comprising the system of claim 7.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Other features of the invention will be apparent from the following description of an embodiment, described by way of example only with reference to the accompanying drawings in which:

(2) FIG. 1 illustrates exemplar noise profile of events within an engine combustion chamber;

(3) FIG. 2 illustrates a prior art ignition response to knock sensing;

(4) FIG. 3 illustrates the effect of ignition retardation upon combustion efficiency.

(5) FIG. 4 shows schematically the inlet arrangement of an internal combustion engine to which the invention may be applied.

DESCRIPTION OF EMBODIMENTS

(6) With reference to the drawings, FIG. 1 illustrates an exemplar noise profile from the combustion chamber of an internal combustion engine. A conventional knock sensor listens to such noise to determine breach of a threshold (F.sub.T), to distinguish a knock event (t.sub.5-t.sub.6) from background noise (t.sub.1-t.sub.2) and a normal combustion event (t.sub.3-t.sub.4). Upon such detection an electronic signal is passed to the ignition control module of the ECU, and the vehicle ignition is conventionally retarded until the knock sensor ceases to detect knock. Thereafter ignition may again be advanced. The shape of the traces in FIG. 1 is representative of typical combustion events, and is not an illustration of a real combustion sequence.

(7) FIG. 2 illustrates a typical prior art control strategy where successive combustion events are indicated by 9 blocks between t.sub.1 and t.sub.10. At t.sub.1 knock is sensed, and ignition is retarded by a small amount for the next combustion event. In the illustration knock is sensed for three successive combustion events, each being followed by a further retardation. In the fourth block knock is not sensed, and ignition is again advanced for the next two blocks. In block 6 knock is again sensed, followed by a retardation in block 7, an advance in block 8, and a further retardation due to knock sensing in block 9.

(8) The amount of retardation and advance applied in each block is determined by the skilled technician according to the capabilities of the engine and of the control system. Although in this example the step change is the same for both retardation and advance, it need not be. By this means knock can be controlled throughout the operating envelope of the engine.

(9) FIG. 3 illustrates how combustion efficiency () varies with retardation of ignition from the optimum point (0). A small degree of retardation (10), depending upon operating circumstances, may have a relatively small effect upon efficiency, whereas a large retardation (20) has a comparatively large effect.

(10) FIG. 4 shows an internal combustion engine 10 having a cylinder 11 within which a piston 12 reciprocates. A combustion chamber 13 is defined above the piston, and contains a poppet valve 14 which is opened to admit air from an inlet port 15. The inlet port is fed from an inlet manifold 16, at the mouth of which is provided a throttle valve 17.

(11) The poppet valve 14 is closed by a spring (not shown), and is opened by action of a rotatable cam 18 which is conventionally provided by a lobe of a camshaft (not shown) between the cam 18 and the valve 14 is provided a tappet 19.

(12) The generally arrangement of FIG. 4 is very common, and for ease of illustration certain other components, such as a corresponding poppet exhaust valve, are not illustrated.

(13) The tappet of FIG. 4 is active, and adjustable in length by relative inward and outward movement of the components thereof, so that the lift of the valve may be varied between minimum and maximum. The kind of active tappet is not important save that it should permit fast variation of valve lift on an event basis. Thus it is envisaged that valve lift may be varied at each successive opening thereof, if required. FIG. 4 illustrates by way of example a schematic electro-hydraulic tappet 19 having a hydraulic chamber 20 supplied with oil at a steady rate and a solenoid operated bleed valve 21 to allow a varying volume of oil to escape, as indicated by arrow 22. Operation of the valve 21 is by electronic signal from an ECU 23.

(14) One example of an active tappet is disclosed in EP-A-2511504, and relies upon such an electro-hydraulic device having a hydraulic chamber of variable volume.

(15) In use the admission of air into the engine is controlled via the throttle valve 17, which in turn is commanded by the ECU 23 according to conventional control parameters such as accelerator pedal position, altitude, air temperature and the like. It will be understood an alteration of the position of the throttle valve 17 changes the rate of air inflow, but does not immediately influence the amount of air admitted to the combustion chamber because of the air volume contained in the inlet manifold 16 and inlet tract 15. Accordingly immediate control of knock by variation of the position of the throttle valve is not possible.

(16) In the method of the invention, admission of air into the engine is varied by use of an active tappet, according to a knock sensor, to substantially reduce or eliminate knock. Variation of air admission may be used alone to counter knock, or may be used in conjunction with ignition retardation, as will become apparent from the following description. The invention has particular application to a multi-cylinder spark ignition engine.

(17) In a first embodiment combustion knock is controlled by commanding the or each active tappet to reduce the air charge in the cylinder(s) in which combustion knock is detected. The air charge may be reduced progressively on a cylinder by cylinder basis, for each successive combustion event, until knocking is no longer detected.

(18) Combustion knock may be treated in this manner solely by control of the active tappets, but in most cases will be used in conjunction with a retarding of the ignition spark so as to achieve best overall combustion efficiency with minimum fuel consumption. The use of the active tappets to individually control air charge may be used particularly in that area of the engine speed/load map where knocking is most prevalent, and where the engine may otherwise require to be knock limited.

(19) As demonstrated in FIG. 3, retarding of ignition can generally be used without a serious effect on overall combustion efficiency, but it will be understood that the allowable amount of retardation is governed by the particular engine and the condition thereof; the characteristic of FIG. 3 can be determined empirically by conventional methods.

(20) A suitable control cycle, for each cylinder, will allow the active tappets to increase the air charge on successive combustion cycles in a knock approaching manner so as to allow an engine to be operated as close to the knock limit as possible. The size and type of each progressive air charge reduction associated with treating combustion knock is selected to give an acceptable control response, and may be equal to, or different from any corresponding progressive increase in air charge.

(21) In an embodiment, the invention allows variation of air charge in conditions where the engine operating temperature is high, for example when the engine is operating in high ambient temperatures or when towing. In this circumstance, treatment of combustion knock by retarding the ignition can be counterproductive, because retarded ignition generally results in additional waste heat to be absorbed by the engine cooling system, which in turns leads to a hotter engine and a further demand for ignition retard.

(22) In such circumstances, a threshold engine temperature (set for example according to vehicle type and specification) may be selected, above which combustion knock is controlled solely by variation of air charge via the active tappets. Increased heat generation and thus heat input to the engine is thereby avoided, whilst providing an effective treatment of combustion knock.

(23) An embodiment concerns the variation of an ignition timing system in conjunction with active tappets to best optimise combustion under selected condition of engine speed and load. The use of active tappets provides for an additional control parameter (air charge volume) to ensure that optimum fuel economy can be substantially achieved at all desired parts on the engine load/speed map.

(24) An important aspect of the invention relates to the treatment of combustion knock where a lower octane fuel is provided to the combustion chamber. Such fuels (depending on engine type and state of time) tend to exacerbate combustion knock and conventionally require a large amount of ignition retardation in a spark ignition engine. In turn this produces additional waste heat, which in turn results in engine and exhaust temperatures which may be considered too high.

(25) In this aspect, variation of air charge using active tappets allows lower octane fuels, including very low octane fuels approaching 80 RON, to be safely used without risk of combustion knock. In the case of the lowest octane ratings, air charge reduction and ignition timing retardation may be used in conjunction to protect the engine from damage due to combustion knock.

(26) The ability to treat combustion knock by air charge variation, on a cylinder by cylinder basis and in a different amount for successive combustion events, allows the smoothness of engine operation to be improved. One embodiment of the invention treats the cylinder with a combustion knock which is more than any other cylinder, so as to promote equalisation of combustion events in different cylinders. The treated cylinder may vary continually so as to achieve smooth running for all conditions of engine speed and load, and a particular advantage of an active tappet is the ability to respond differently for successive combustion cycles.

(27) As noted above, the air charge is reduced when responding to combustion knock, either by directly influencing the volume of the incoming air charge, or by ensuring that a greater proportion of combustion gases remain in the combustion chamber after combustion.

(28) It will be understood that each engine equipped with active tappets will have different characteristics, which can be determined empirically by conventional methods. In addition, the installation of the engine will also affect the prevalence of combustion knock, in particular according to the amount of cooling provided by the engine cooling system.

(29) Accordingly, the values of air charge variation will vary from case to case, but can be selected to the intent that combustion knock be limited in all circumstances of use, and on a cylinder by cylinder basis within one combustion cycle.

(30) Although described in relation to a cam operated valve, it will be understood that an active tappet may be used independently of a cam to activate a valve, and may replace such a cam rather than modify the lift thereof.

(31) The embodiments described above are by way of example only, and not intended to restrict the invention.