SYSTEM AND METHOD FOR EXHAUST-GAS AFTERTREATMENT OF AN INTERNAL COMBUSTION ENGINE

Abstract

The invention relates to an exhaust gas aftertreatment system for a spark ignition internal combustion engine based on the Otto principle. The internal combustion engine is connected on the outlet side to an exhaust gas system, wherein an electrically heatable three-way catalytic converter, a four-way catalytic converter downstream from the electrically heatable three-way catalytic converter, and a further three-way catalytic converter downstream from the four-way catalytic converter are situated in the exhaust gas system in the flow direction of an exhaust gas through the exhaust gas system. Before the internal combustion engine is started, the electrically heatable three-way catalytic converter and preferably also the four-way catalytic converter are heated to allow efficient exhaust gas aftertreatment of the untreated emissions of the internal combustion engine upon starting the internal combustion engine. The exhaust gas aftertreatment system is also configured to allow efficient conversion of the pollutants also during a regeneration of the four-way catalytic converter, and thus, to ensure particularly low emissions in all operating states of the motor vehicle.

Claims

1. An exhaust gas aftertreatment system for a spark ignition internal combustion engine, comprising: an exhaust gas system that is connected to an outlet of the internal combustion engine, an electrically heatable three-way catalytic converter close to the engine, downstream from the outlet, a four-way catalytic converter downstream from the electrically heatable three-way catalytic converter, a second three-way catalytic converter downstream from the four-way catalytic converter, and a secondary air system in the exhaust gas system via which secondary air is blown or may be blown into the exhaust gas system of the internal combustion engine, upstream from the electrically heatable three-way catalytic converter.

2. The exhaust gas aftertreatment system according to claim 1, further comprising a burner is provided in the exhaust gas system, downstream from the electrically heatable three-way catalytic converter and upstream from the four-way catalytic converter, via which the four-way catalytic converter is heatable.

3. The exhaust gas aftertreatment system according to claim 1, further comprising an HC adsorber in the exhaust gas system, downstream from the electrically heatable three-way catalytic converter and upstream from the four-way catalytic converter.

4. The exhaust gas aftertreatment system according to claim 1, wherein the secondary air system includes a secondary air pump and a secondary air valve, the secondary air valve being situated on the outlet side on a cylinder head of the internal combustion engine.

5. The exhaust gas aftertreatment system according to claim 4, further comprising a burner in the exhaust gas system, downstream from the electrically heatable three-way catalytic converter and upstream from the four-way catalytic converter, via which the four-way catalytic converter is heatable, wherein the secondary air pump is connected to the burner via a second secondary air line and a second secondary air valve.

6. The exhaust gas aftertreatment system according to claim 4, further comprising: a burner in the exhaust gas system, downstream from the electrically heatable three-way catalytic converter and upstream from the four-way catalytic converter, via which the four-way catalytic converter is heatable, and a second secondary air pump via which the burner is suppliable with fresh air.

7. The exhaust gas aftertreatment system according to claim 2, further comprising: a first temperature sensor downstream from an opening of the burner into an exhaust duct of the exhaust gas system and upstream from the four-way catalytic converter, and a second temperature sensor downstream from the four-way catalytic converter.

8. The exhaust gas aftertreatment system according to claim 1, further comprising lambda sensors are situated in the exhaust duct, in each case upstream and downstream from the electrically heatable three-way catalytic converter and upstream and downstream from the four-way catalytic converter, the lambda sensors being designed as hydrolock-resistant, electrically heatable lambda sensors.

9. A method for exhaust gas aftertreatment of an internal combustion engine, having an exhaust gas aftertreatment system with an exhaust gas system connected to an outlet of the internal combustion engine, an electrically heatable three-way catalytic converter close to the engine, downstream from the outlet, a four-way catalytic converter downstream from the electrically heatable three-way catalytic converter, a further three-way catalytic converter downstream from the four-way catalytic converter, and a burner downstream from the electrically heatable three-way catalytic converter and upstream from the four-way catalytic converter via which the four-way catalytic converter is heatable, the method comprising: prior to or upon starting the internal combustion engine, starting the heating of the electrically heatable three-way catalytic converter by a trigger signal of a signal generator, and activating the burner to heat up the electrically heatable three-way catalytic converter and the four-way catalytic converter to a light-off temperature as quickly as possible.

10. The method for exhaust gas aftertreatment of an internal combustion engine according to claim 9, wherein the signal generator is a door contact switch, a sensor for seat occupancy, a receiver for a keyless locking system, a seat belt sensor, or a control unit of a hybrid vehicle.

Description

[0020] The invention is explained below in exemplary embodiments, with reference to the associated drawings. Identical components or components having the same function are denoted by the same reference numerals. In the figures:

[0021] FIG. 1 shows a first exemplary embodiment of an exhaust gas aftertreatment system according to the invention for a spark ignition internal combustion engine;

[0022] FIG. 2 shows a preferred exemplary embodiment of an exhaust gas aftertreatment system according to the invention for a spark ignition internal combustion engine;

[0023] FIG. 3 shows another exemplary embodiment of an exhaust gas aftertreatment system according to the invention for a spark ignition internal combustion engine;

[0024] FIG. 4 shows another exemplary embodiment of an exhaust gas aftertreatment system according to the invention for a spark ignition internal combustion engine, wherein the burner and the outlet are supplied with fresh air via a shared secondary air pump;

[0025] FIG. 5 shows another exemplary embodiment of a preferred exhaust gas aftertreatment system according to the invention, wherein the burner and the outlet are supplied with fresh air via a shared secondary air pump having two secondary air valves; and

[0026] FIG. 6 shows a flow chart for heating up the exhaust gas aftertreatment system prior to and during a cold start of the internal combustion engine.

[0027] FIG. 1 illustrates a first exemplary embodiment of an exhaust gas aftertreatment system according to the invention for an internal combustion engine 10. The internal combustion engine 10 is designed as a spark ignition internal combustion engine 10, preferably as an internal combustion engine 10, based on the Otto principle, that is spark-ignited by means of spark plugs 16. An exhaust gas system 20 is connected to an outlet 12 of the internal combustion engine 10. In the exhaust gas system 20, a turbine 22 of an exhaust gas turbocharger 18 is situated downstream from the outlet 12 of the internal combustion engine 10, and an electrically heatable three-way catalytic converter 24 close to the engine is situated downstream from the turbine 22, in the flow direction of an exhaust gas through the exhaust gas system 20. The electrically heatable three-way catalytic converter 24 has an electric heating element, preferably an electric heating disk 66, that is preferably situated on the electrically heatable three-way catalytic converter 24 on the inlet side. A four-way catalytic converter 28, i.e., a particulate filter having a three-way catalytically active coating, is situated downstream from the electrically heatable three-way catalytic converter 24, and a further three-way catalytic converter 32 is situated farther downstream. Provided in the exhaust gas system 20 is a secondary air system 62 with a secondary air pump 34, via which fresh air may be introduced into an exhaust duct 60 of the exhaust gas system 20 at a first inlet point upstream from the electrically heatable three-way catalytic converter 24 via a first secondary air valve 38, and at a second inlet point downstream from the electrically heatable three-way catalytic converter 24 and upstream from the four-way catalytic converter 28 via a second secondary air valve 64. The two secondary air valves 38, 64 are connected to the secondary air pump 34 via two secondary air lines 36, 42, respectively. Situated upstream from the electrically heatable three-way catalytic converter 24 is a first lambda sensor 44, preferably a wideband lambda sensor, with which the combustion air ratio of the internal combustion engine 10 may be adjusted. Situated in the exhaust duct 60, downstream from the electrically heatable three-way catalytic converter 24 and upstream from the second secondary air valve 64, is a second lambda sensor 46, in particular a jump lambda sensor, for correcting the deviations of the lambda control via the wideband lambda sensor 44 and ensuring proper functioning of the electrically heatable three-way catalytic converter 24. Situated downstream from the second inlet point and upstream from the four-way catalytic converter 28 is a third lambda sensor 48, in particular a further wideband lambda sensor, for determining the exhaust gas-air ratio that flows across the four-way catalytic converter 28, in particular when fresh air is blown into the exhaust duct 60 through the second secondary air valve 64. Situated downstream from the four-way catalytic converter 28 is a fourth lambda sensor 50, in particular a further jump lambda sensor, for checking the functioning of the four-way catalytic converter 28. Situated in the exhaust duct 60, downstream from the second secondary air valve 64 and upstream from the four-way catalytic converter 28, is a first temperature sensor 54 with which an inlet temperature of the exhaust gas before it enters the four-way catalytic converter 28 may be determined. Provided downstream from the four-way catalytic converter 28 and upstream from the further three-way catalytic converter 32 is a further temperature sensor 56 with which an exhaust gas temperature downstream from the four-way catalytic converter 28 may be determined. The exhaust gas aftertreatment system also has a control unit 58, in particular a control unit 58 of the internal combustion engine 10, via which the signals of the lambda sensors 44, 46, 48, 50 and of the temperature sensors 54, 56 may be processed, and the combustion air ratio of the internal combustion engine 10, in particular the fuel quantity, and the secondary air quantities supplied to the exhaust duct 60 via the secondary air valves 38, 64, may be regulated.

[0028] FIG. 2 illustrates one preferred exemplary embodiment of an exhaust gas aftertreatment system according to the invention for a spark ignition internal combustion engine 10. In the exhaust gas system 20 of the internal combustion engine 10, an electrically heatable three-way catalytic converter 24 close to the engine, an HC adsorber 26 downstream from the electrically heatable three-way catalytic converter 24, a four-way catalytic converter 28 farther downstream, and a further three-way catalytic converter 32 downstream from the four-way catalytic converter 28 are situated in the flow direction of an exhaust gas of the internal combustion engine 10 through the exhaust gas system 20. The electrically heatable three-way catalytic converter 24 may be heated by a heating disk 66. The four-way catalytic converter 28 is heatable by a burner 30 that opens into the exhaust duct 60 of the exhaust gas system 20 at an opening 52 downstream from the HC adsorber 26 and upstream from the four-way catalytic converter 28. The exhaust gas aftertreatment system also includes a secondary air system 62 having a first secondary air pump 34 that is connected to a cylinder head 14 of the internal combustion engine 10 via a first secondary air line 36. Fresh air in the area of the outlet 12 directly downstream from the exhaust valves of the internal combustion engine 10 may be introduced into the hot exhaust gas via the first secondary air line 36 to facilitate an exothermic reaction of the unburned fuel components. In the exhaust gas system 20, an exhaust gas turbocharger 18 together with a turbine 22 may preferably be situated upstream from the electrically heatable three-way catalytic converter 24. Situated directly upstream from the electrically heatable three-way catalytic converter 24 is a first lambda sensor 44, preferably a wideband lambda sensor, with which the combustion air ratio that flows across the electrically heatable three-way catalytic converter 24 may be determined. Situated directly downstream from the electrically heatable three-way catalytic converter 24 is a further lambda sensor 46, in particular a jump lambda sensor, with which the functioning of the electrically heatable three-way catalytic converter 24 may be monitored and a rich or lean breakthrough through the electrically heatable three-way catalytic converter 24 may be detected.

[0029] In addition, the secondary air system 62 has a second secondary air pump 40 that is connected to a secondary air valve 64 on the burner 30 via a second secondary air line 42. A third lambda sensor 48 and a first temperature sensor 54 are provided directly upstream from the four-way catalytic converter 28, via which the exhaust gas-air ratio flowing across the four-way catalytic converter 28 may be determined and the burner 30 may be correspondingly controlled. A fourth lambda sensor 50 and a second temperature sensor 56 are provided downstream from the four-way catalytic converter 28.

[0030] FIG. 3 illustrates another exemplary embodiment of an exhaust gas aftertreatment system according to the invention for an internal combustion engine 10. The design is essentially the same as in FIG. 1; only the differences from the first exemplary embodiment are discussed below. The secondary air pump 34 is connected to the cylinder head 14 of the internal combustion engine 10 via a secondary air line 36; situated on the cylinder head is a secondary air valve 38 via which the secondary air on the outlet side directly downstream from the exhaust valves of the internal combustion engine 10 may be blown into the cylinder head. Also situated downstream from the electrically heatable three-way catalytic converter 24 and upstream from the four-way catalytic converter 28 is an HC adsorber, via which unburned hydrocarbons may be temporarily stored when the exhaust gas is cold, and may be delivered back to the exhaust gas when the exhaust gas is hot. Also provided is a second secondary air pump 40 that is connected to a second secondary air valve 64 via a second secondary air line 42, the second secondary air valve 64 being connected to an inlet point via which fresh air may be blown into the exhaust duct 60 downstream from the HC adsorber 26 and upstream from the four-way catalytic converter 28.

[0031] FIG. 4 shows another exemplary embodiment of an exhaust gas aftertreatment system according to the invention for an internal combustion engine 10. The design is essentially the same as in FIG. 2; only the differences from the exemplary embodiment illustrated in FIG. 2 are discussed below. In comparison to the exemplary embodiment in FIG. 2, in the present exemplary embodiment the HC adsorber downstream from the electrically heatable three-way catalytic converter 24 and upstream from the four-way catalytic converter 28 is absent. This is possible due to the fact that the electrically heatable catalytic converter 24 may be heated even before the internal combustion engine 10 is started, and the four-way catalytic converter 28 is heated by the burner 30 to a light-off temperature very quickly after the internal combustion engine is started. The HC slip may thus be kept low. In addition, a shared secondary air pump 34 for blowing secondary air into the cylinder head 14 and for supplying fresh air to the burner 30 is provided in this exemplary embodiment. For this purpose, the secondary air pump 34 is connected to the first secondary air valve 38 on the cylinder head 14 of the internal combustion engine 10 via a first secondary air line 36, and is connected to a second secondary air valve 64 on the burner 30 via a second secondary air line 42. Due to the secondary air pump 34, a volumetric flow may pass through the electrically heatable catalytic converter 24 even before the internal combustion engine 10 is started, thus facilitating heating up the electrically heatable catalytic converter 24.

[0032] FIG. 5 illustrates another preferred exemplary embodiment of an exhaust gas aftertreatment system according to the invention for an internal combustion engine 10. The design is essentially the same as in FIG. 2; in the present exemplary embodiment only one secondary air pump 34 is provided, which is connected to the cylinder head 14 of the internal combustion engine 10 via a first secondary air line 36 and a first secondary air valve 38. The secondary air may thus be introduced into the outlet 12 of the internal combustion engine 10, directly downstream from the exhaust valve. The secondary air pump 34 is connected to the burner 30 via a second secondary air line 42 and a second secondary air valve 64, so that the burner 30 may likewise be supplied with fresh air by the secondary air pump 34 and the combustion air ratio of the burner 30 may be adjusted. The control of the air quantity preferably takes place via the regulation of the secondary air pump 34. In addition, the oxygen required for regenerating the soot that is retained in the four-way catalytic converter 28 may be provided by the secondary air line 42 and the burner 30, so that controlled soot burnoff on the four-way catalytic converter 28 is possible without the risk of thermal damage to the four-way catalytic converter 28.

[0033] FIG. 6 illustrates a method according to the invention for exhaust gas aftertreatment of an internal combustion engine 10. The electrical heating of the heating disk 66 of the electrically heatable three-way catalytic converter 24 may be started in a prestart phase <100> in a first method step <110>. Alternatively, this may take place only upon starting the internal combustion engine 10. The preheat phase <100>, as described above, is initiated by a trigger signal of a signal generator, for example a door contact switch or a control unit of a hybrid drive. At the same time, the secondary air pump 34 may blow fresh air into the exhaust gas system 20, upstream from the electrically heatable three-way catalytic converter 24, in order to provide flow through the exhaust gas system 20 and allow convective heat transfer from the heating disk 66 to the remaining portion of the electrically heatable catalytic converter 24 when the internal combustion engine 10 is not running. Alternatively, preheating of the electrically heatable three-way catalytic converter 24 is also possible without introducing secondary air. At the same time, the lambda sensors 44, 46, 48, 50 may be heated to an operating temperature in a method step <120>. Optionally, in a method step <130>, hot gas may be introduced into the exhaust gas system 20 upstream from the four-way catalytic converter 28 by means of the burner 30 in order to likewise heat up the four-way catalytic converter before the internal combustion engine 10 is started. Blowing in of the secondary air may be ended when the internal combustion engine 10 is started. Alternatively, the electrically heatable three-way catalytic converter 24, in particular for a hybrid vehicle, may be periodically heated so that the electrically heatable three-way catalytic converter 24 is always operationally ready, even in an electric driving situation. Thus, when there is a load requirement on the internal combustion engine 10, the gaseous pollutant components may be effectively converted immediately after the engine is started.

[0034] The internal combustion engine 10 is started in a start phase <200>. The electrically heatable three-way catalytic converter 24 is actuated and the heating disk 66 is further heated in a method step <210> until a threshold temperature is reached that is preferably above the light-off temperature of the electrically heatable three-way catalytic converter 24. In a parallel method step <220>, the combustion air ratio is regulated to a stoichiometric combustion air ratio =1 by the lambda sensors, also during the cold start, to keep the untreated emissions as low as possible, also during the cold start. At the same time, the electrically heatable three-way catalytic converter 24 is further heated by engine-related measures, for example by adjusting the ignition angle in the retarded direction, in a method step <230>. Likewise at the same time, in a method step <240> the four-way catalytic converter 28 is heated by the burner 30 until the four-way catalytic converter has also reached a threshold temperature. The burner 30 is preferably activated upon starting the internal combustion engine 10. When the exhaust gas is cold, the unburned hydrocarbons are stored in the HC adsorber 26 in a further parallel method step <250>. When the HC adsorber 26 has reached a threshold temperature, in a method step <260> the unburned hydrocarbons stored in the HC adsorber 26 are discharged, and the HC adsorber 26 is regenerated. A change is made to normal operation <300> when the start phase <200> has concluded and the catalytic converters 24, 28, 32 have reached their operating temperature. In normal operation <300>, the internal combustion engine 10 is operated essentially with a stoichiometric combustion air ratio =1 in a method step <310> to ensure optimal conversion of the harmful exhaust gas components.

LIST OF REFERENCE NUMERALS

[0035] 10 internal combustion engine [0036] 12 outlet [0037] 14 cylinder head [0038] 16 spark plug [0039] 18 turbocharger [0040] 20 exhaust gas system [0041] 22 turbine [0042] 24 electrically heatable three-way catalytic converter [0043] 26 HC adsorber [0044] 28 four-way catalytic converter [0045] 30 burner [0046] 32 three-way catalytic converter [0047] 34 (first) secondary air pump [0048] 36 secondary air line [0049] 38 secondary air valve [0050] 40 (second) secondary air pump [0051] 42 (second) secondary air line [0052] 44 first lambda sensor [0053] 46 second lambda sensor [0054] 48 third lambda sensor [0055] 50 fourth lambda sensor [0056] 52 opening [0057] 54 (first) temperature sensor [0058] 56 (second) temperature sensor [0059] 58 control unit [0060] 60 exhaust duct [0061] 62 secondary air system [0062] 64 (second) secondary air valve [0063] 66 heating disk