Spark plug heat up method via transient control of the spark discharge current

Abstract

A spark plug heat up method via transient control of the spark discharge current. The high temperature plasma channel is used to heat up the central electrode, and the temperature and energy of the plasma channel are realized via transient control of the discharge current. The heating up process takes place before firing the engine, using discharge current to actively heat up the spark plug from inside. By monitoring the discharge current amplitude and discharge duration, the temperature change of the central electrode and the ceramic insulator can be carefully measured and controlled within a proper window. This method can be used to measure the heating range of the spark plug, and to prevent or remove the carbon deposit on the central electrode and the ceramic insulator generated under various engine operation conditions, such as engine cold start, full load operation, and heavy EGR condition, as well as realize self-cleaning.

Claims

1. A spark plug heat up method via transient control of a spark discharge current, wherein a high-temperature plasma channel (103) is used to heat up a central electrode (101), and the temperature and energy of the plasma channel (103) are monitored via transient control of the discharge current; wherein by monitoring a discharge current amplitude and a discharge duration, the temperature change of the central electrode (101) and a ceramic insulator (102) are carefully measured and controlled; wherein the method comprising: measure a heat rating of a spark plug (100) by actively heating up the spark plug (100) via transient control of the continuous discharge current; and precisely control a discharge energy, the discharge duration, and the temperature of the surfaces of the central electrode (101) and the ceramic insulator (102) within a proper window to clean up a carbon deposit on the spark plug as well as realize self-cleaning.

2. The method of claim 1, wherein a heating up process takes place before the engine operation, using the discharge current to heat up the spark plug (100) from inside to control the temperature of the spark plug (100) within a preferable temperature window, and to prevent or remove the carbon deposit on the spark plug (100), the central electrode (101) and the ceramic insulator (102) generated by engine cold start.

3. The method of claim 1, wherein a stable discharge process is achieved by real-time controlling the discharge current amplitude and discharge duration of a spark event; a discharge current profile is precisely real-time controlled; the discharge current and the discharge energy during a heating up process of the spark plug (100) are controlled by a real-time current feedback; and to clean the carbon deposit by heating up the central electrode (101) of the spark plug (100) during the engine operation.

4. The method of claim 1, wherein a controllable heating up process to the central electrode (101) of the spark plug (100) is achieved by using discharge current to heat up the spark plug (100) from inside; by precise control of the discharge current and the same discharge energy, the temperature change of the central electrode (101) and the ceramic insulator (102) are carefully measured and controlled, thus to measure the heating range of the spark plug (100) and to prevent or remove the carbon deposit of the spark plug (100) mainly accumulated on the surfaces of the central electrode (101) and the ceramic insulator (102) without any modification on the spark plug (100).

5. The method of claim 1, wherein the accurate control of the discharge energy is based on the control of the discharge current amplitude and the discharge duration of a spark event.

6. The method of claim 5, wherein the continuous control of the discharge current amplitude is based on a discharge current feedback control method, using a real-time controller (10) to control a charging and discharge duration of an ignition coil (90), and the discharge duration and the discharge current amplitude of the spark event.

7. The method of claim 6, wherein the real-time controller (10) was used to control a discharge process based on the discharge current feedback control method via procedures as described below: 1) an ignition command is generated by the real-time controller (10) to close a first switch (60), in order to charge the ignition coil (90), at the end of the charging process, the first switch (60) is open to cut off a primary current, in order to generate a breakdown event at the spark gap; 2) after a discharge channel is established, a second switch (70) is closed to adjust the discharge current to a setting value via a second capacitor (40); 3) because of the voltage potential difference between the second capacitor (40) and a first capacitor (50), the first capacitor (50) is charged up by the second capacitor (40) when a second switch (70) is closed; the upstream voltage of the spark plug (100) is adjusted to control the discharge current amplitude dynamically; when the second switch (70) is open, the first capacitor (50) is used as a voltage buffer to continue supply current to the spark gap on the spark plug (100); the voltage potential of the first capacitor (50), i.e. the upstream voltage of the spark plug (100), is controlled by the operation frequency and duty cycle of the second switch (70); and the discharge current amplitude is adjusted by the voltage potential of the first capacitor (50); 4) when the second switch (70) is closed, the second capacitor (40) will discharge to the first capacitor (50) as well as the spark gap; and when the second switch (70) is open, only the first capacitor (50) will discharge to the spark gap, in order to stabilize the discharge current across the spark gap.

8. The method of claim 7, wherein the second capacitor (40) act as an energy storage device to deliver energy to the first capacitor (50) and the spark gap, and the second capacitor (40) has a relative larger capacitance compared with the first capacitor (50); the capacitance of the second capacitor (40) is around 1˜2 μF which is used to stabilize voltage at the secondary side of a rectifier (20) and guarantee a stable upstream voltage for a downstream discharge circuit; and the capacitance of the first capacitor (50) is around 100 nF which is used to stabilize the discharge current across the spark gap.

9. The method of claim 7, wherein a direct current measurement module (110) measures the strength of the discharge current which as a real-time feedback signal for the real-time controller (10); and the control strategies are applied for the transient control of the discharge current includes but not limited to, a Proportional-Integral-Derivative (PID) control, a data-driven nonlinear model predictive control, a data-driven adaptive model guided control, a data-driven nonlinear model guided optimization, and an adaptive model feedforward control which speeds up the system's transient response.

10. The method of claim 7, wherein a third switch (80) is installed between the first capacitor (50) and the ground; when the third switch (80) closes, the first capacitor (50) is charged, hence the voltage difference across the first capacitor (50) is reduced; and the voltage across the first capacitor (50) is actively raised by closing the second switch (70); hence the voltage across the first capacitor (50) is flexibly altered by actuating either the second switch (70) or the third switch (80); thus the upstream voltage of the spark plug (100) is modified, and the discharge current is adjusted as the strength of the upstream voltage is shifted.

11. The method of claim 7, wherein to further enhance the accuracy of the measured feedback discharge current and suppress the influence of the electric noise originated from the spark discharge released from the spark plug (100), a Hall Effect sensor was selected to provides discharge current measurement; the Hall Effect sensor is isolated from the ground which separates a measurement circuit with a target circuit; and instrumentation amplifiers are used as a signal conditioner to improve the signal to noise ratio of the feedback current measurement.

12. The method of claim 6, wherein the power of the discharged spark is applied as a feedback for the control of a discharge current profile; by using a measured high voltage feedback signal and the discharge current, the power of the discharged spark is estimated in real-time; a voltage and current measurement are physically acquired at the same point which is the terminal of the spark plug (100); and the real-time estimate of the power of the discharged spark is used as a performance factor to control the heating of the central electrode (101) of the spark plug (100).

13. The method of claim 5, wherein the control of the discharge current amplitude and the discharge duration of the spark event are realized through a nonlinear feedback control; a cost function is designed using selected system performance parameters; and the detailed design steps for a controller are elaborated below: 1) identify a desired reference trajectory for a feedback control, the trajectory is designed based on but not limited to the following parameters: a desired spark discharge current profile, the discharge current amplitude of the discharge current, the change rate of the discharge current, and the discharge duration of the spark event; 2) measure the discharge current in real time; 3) use a designed model to predict the discharge current; 4) determine the transient and steady state requirement for a control system includes: a desired response rise time, a system overshoot allowance, and bounds for a steady state error; 5) use a nonlinear controller to derive the control parameters based on the nonlinear cost function; 6) to improve the transient performance of the system, an adaptive feedforward model can be used to derive a control correction based on the desired reference trajectory, the model parameters are optimized in real-time using a related measurement acquired in 1), hence the accuracy of a model prediction is improved, an ideal control input to the system is derived using an optimized model, and a final control input applied to the system is the combination of the ideal control input and the control input derived by the nonlinear feedback controller; 7) the system would generate different discharge current profiles based on the control input values, the discharge current feedback measurement are sent to both the feedforward model and a data-driven nonlinear model embedded in the nonlinear controller, both models are optimized using the real-time measurement, the data-driven nonlinear model predicts the system output, and both the model prediction and the real-time feedback measurement are applied to the cost function.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A better understanding of the present invention will be had upon reference to the following detailed description when read in conjunction with the accompanying drawing schematic:

(2) FIG. 1 is the schematic of the electric circuit of the system for transient control of discharge current.

(3) FIG. 2 is the block diagram of the working principle of non-liner control method.

(4) FIG. 3 is the structure of a typical spark plug used in the present invention.

(5) FIG. 4 is a demonstration of possible discharge current profile realized by the proposed discharge current control method.

(6) FIG. 5 is a schematic of transient control procedure of discharge current.

DESCRIPTION OF THE EMBODIMENTS

Embodiment 1

(7) The present invention involves a spark plug heat up method via transient control of the spark discharge current. With reference to FIG. 3, the high temperature plasma channel 103 is used to heat up the central electrode 101, and the temperature and energy of the plasma channel 103 are monitored by transient control of discharge current amplitude and discharge duration. By monitoring the discharge current amplitude and discharge duration, the temperature change of the central electrode 101 and the surrounding ceramic insulator 102 can be carefully measured and controlled. This method can be used to measure the heat rating of the spark plug 100. By actively heating up the spark plug 100 via transient control of discharge current, the temperature of the surfaces of the central electrode 101 and the surrounding ceramic insulator 102 can be precisely controlled within a proper window, avoiding carbon deposit as well as realize self-cleaning.

(8) The heating up process can start before firing the engine, using discharge current to heat up the spark plug 100 from inside, as well as cleaning the carbon deposit on the surfaces of ceramic insulator 102 and central electrode 101.

(9) The real-time control over the discharge current and discharge energy to spark plug 100 is realized by an electric circuit with reference to FIG. 1. The ignition system consists of spark initiation circuit, power supply system for the discharge event, and a real-time control circuit. The spark initiation circuit consist of ignition coil 90 and the first switch 60. The function of this circuit is to generate enough high voltage on the spark gap to establish the plasma channel. The power supply system consists of an insulated high voltage transformer 30, a rectifier bridge 20, a second capacitor 40, a first capacitor 50, and a second switch 70. Rectifier bridge 20 can convert the AC output of the insulated high voltage transformer 30 into DC voltage, and then charge up the second capacitor 40. When the second switch 70 is closed, the second capacitor 40 can discharge to the spark gap to boost up the discharge current. The control circuit based on real-time controller 10 is used to control the discharge timing of the ignition coil, the discharge duration, as well as discharge current amplitude.

(10) A detailed operation procedure is explained below based on a discharge current feedback close loop control method.

(11) 1. An ignition command is generated by real-time controller 10 to close the first switch 60, in order to charge the ignition coil 90. At the end of the charging process, the first switch 60 is open to cut off the primary current, in order to generate a breakdown event at the spark gap.

(12) 2. After the discharge channel is established, the second switch 70 is closed to adjust discharge current to the setting value via the second capacitor 40.

(13) 3. Because of the voltage potential difference between the second capacitor 40 and the first capacitor 50, the first capacitor 50 is charged up by the second capacitor 40 when the second switch 70 is closed. The upstream voltage of the spark plug 100 can be adjusted to control the discharge current amplitude dynamically. When the second switch 70 is open, the first capacitor 50 is used as a voltage buffer to continue supply current to the spark gap on the spark plug 100. The voltage potential of the first capacitor 50, i.e. upstream voltage of the spark plug 100, is controlled by the operation frequency and duty cycle of the second switch 70. The discharge current amplitude is adjusted by the voltage potential of the first capacitor 50.

(14) 4. When the second switch 70 is closed, the second capacitor 40 will discharge to the first capacitor 50 as well as the spark gap; when the second switch 70 is open, only the first capacitor 50 will discharge to the spark gap.

(15) 5. During operation, direct current measurement module 110 report the discharge current amplitude data to real-time controller 10 as a feedback signal. The real-time controller 10 uses the second switch 70 to adjust the voltage potential flow through spark plug 100 by adjusting the operation frequency and duty cycle of the second switch 70, and the discharge current profile and discharge duration is properly controlled.

(16) The second capacitor 40 acts as the energy storage device to deliver energy to the first capacitor 50 and spark gap, and has a relative larger capacitance compared with first capacitor 50. The capacitance of the second capacitor 40 is around 1˜2 μF. The main function of the second capacitor 40 is to stabilize voltage at the secondary side of the bridge rectifier 20, and guarantee a stable upstream voltage for the downstream discharge circuit. The capacitance of the first capacitor 50 is around 100 nF, and its main function is to stabilize the discharge current across the spark gap. If the capacitance of the first capacitor 50 is too small, the discharge current cannot be stabilized because of the limited energy storage capacity of the first capacitor 50. If the capacitance of the first capacitor 50 is too large, a transient voltage adjustment across the spark gap is not possible, leading to failure for transient control of discharge current.

(17) The control strategies that can be applied includes but not limited to, the Proportional-Integral-Derivative (PID) control (as shown in FIG. 2), data-driven nonlinear model predictive control (nonlinear model predictive control using models such as neural network models, Wiener model, and Sandwich model), data-driven adaptive model guided control, data-driven nonlinear model guided optimization, and the adaptive model feedforward control which speeds up the system's transient response. The spark plug heating system is controlled based on the proposed data-driven nonlinear model adaptive control method, the reference trajectory (the targeted spark amplitude) is sent to both the feedforward model and the cost function. After being optimized by the cost function, the reference trajectory is sent to the nonlinear controller. The final control input applied to the spark plug heating system is the combination of the ideal control input derived by the feedforward model and the control input derived by the nonlinear feedback controller. The measured feedback together with the final control input are sent to the data-driven nonlinear model, which both the model output and the measured feedback are used for the model optimization. As a result, the model is adaptively adjusted online, hence the nonlinear controller becomes an adaptive nonlinear controller.

Embodiment 2

(18) Embodiment 2 has similar operation principle as embodiment 1, with difference in discharge current control algorithm.

(19) The present invention involves a spark plug heat up method via transient control of the spark discharge current. With reference to FIG. 3, the high temperature of plasma channel 103 is used to heat up the central electrode 101, and the temperature and energy of the plasma channel 103 are monitored by transient control of discharge current amplitude and discharge duration. By monitoring the discharge current amplitude and discharge duration, the temperature change of the central electrode 101 and the surrounding ceramic insulator 102 can be carefully measured and controlled. This method can be used to measure the heat rating of the spark plug 100. By actively heating up the spark plug 100 via transient control of discharge current, the temperature of the surfaces of the central electrode 101 and the surrounding ceramic insulator 102 can be precisely controlled within a proper window, avoiding carbon deposit as well as realize self-cleaning.

(20) The heating up process can start before firing the engine, using discharge current to heat up the spark plug 100 from inside, as well as cleaning the carbon deposit on the surfaces of ceramic insulator 102 and central electrode 101.

(21) The real-time control over the discharge current and discharge energy to spark plug 100 is realized by an electric circuit with reference to FIG. 1. The ignition system consists of spark initiation circuit, power supply system for the discharge event, and a real-time control circuit. The spark initiation circuit consist of ignition coil 90 and the first switch 60. The function of this circuit is to generate enough high voltage on the spark gap to establish the plasma channel. The power supply system consists of an insulated high voltage transformer 30, a rectifier bridge 20, a second capacitor 40, a first capacitor 50, and a second switch 70. Rectifier bridge 20 can convert the AC output of the insulated high voltage transformer 30 into DC voltage, and then charge up the second capacitor 40. When the second switch 70 is closed, the second capacitor 40 can discharge to the spark gap to boost up the discharge current. The control circuit based on real-time controller 10 is used to control the discharge timing of the ignition coil, the discharge duration, as well as discharge current amplitude.

(22) A detailed operation procedure is explained below based on a discharge current feedback close loop control method.

(23) 1. An ignition command is generated by real-time controller 10 to close the first switch 60, in order to charge the ignition coil 90. At the end of the charging process, the first switch 60 is open to cut off the primary current, in order to generate a breakdown event at the spark gap.

(24) 2. After the discharge channel is established, the second switch 70 is closed to adjust discharge current to the setting value via the second capacitor 40.

(25) 3. Because of the voltage potential difference between the second capacitor 40 and the first capacitor 50, the first capacitor 50 is charged up by the second capacitor 40 when the second switch 70 is closed. The upstream voltage of the spark plug 100 can be adjusted to control the discharge current amplitude dynamically. When the second switch 70 is open, the first capacitor 50 is used as a voltage buffer to continue supply current to the spark gap on the spark plug 100. The voltage potential of the first capacitor 50, i.e. upstream voltage of the spark plug 100, is controlled by the operation frequency and duty cycle of the second switch 70. The discharge current amplitude is adjusted by the voltage potential of the first capacitor 50.

(26) 4. When the second switch 70 is closed, the second capacitor 40 will discharge to the first capacitor 50 as well as the spark gap; when the second switch 70 is open, only the first capacitor 50 will discharge to the spark gap.

(27) 5. During operation, direct current measurement module 110 report the discharge current amplitude data to real-time controller 10 as a feedback signal. The real-time controller 10 uses the second switch 70 to adjust the voltage potential flow through spark plug 100 by adjusting the operation frequency and duty cycle of the second switch 70, and the discharge current profile and discharge duration is properly controlled.

(28) 6. A third switch 80 is arranged between the first capacitor 50 and the common ground, as referenced with FIG. 1. When the third switch 80 is closed, the first capacitor 50 can discharge to the ground actively to reduce the voltage potential. With proper opening and closing sequence of the second switch 70 and the third switch 80, the voltage potential of the first capacitor 50 can be precisely controlled, in order to control the spark discharge current amplitude. With reference to FIG. 5, when discharge current amplitude is adjusted from low level to high level, the working frequency of the second switch 70 is increased, the third switch 80 is left open; when discharge current amplitude is adjusted from high to low level, the working frequency of the second switch 70 is decreased, and the third switch 80 is closed to actively discharge the first capacitor 50, in order to realize fast control over the discharge current.

(29) Moreover, in order to increase the accuracy of the feedback signal of the discharge current, the direct current measurement module utilize a none-contact hall effect sensor. The ground of the module is insulated from the circuit ground, with amplifier circuit to collect the discharge current signal, in order to increase the signal to noise ratio of the discharge current measurement signal.

Embodiment 3

(30) Embodiment 3 has similar operation principle as embodiment 1, with difference in discharge current control algorithm.

(31) The present invention involves a spark plug heat up method via transient control of the spark discharge current. With reference to FIG. 3, the high temperature plasma channel 103 is used to heat up the central electrode 101, and the temperature and energy of the plasma channel 103 are monitored by transient control of discharge current amplitude and discharge duration. By monitoring the discharge current amplitude and discharge duration, the temperature change of the central electrode 101 and the surrounding ceramic insulator 102 can be carefully measured and controlled. This method can be used to measure the heat rating of the spark plug 100. By actively heating up the spark plug 100 via transient control of discharge current, the temperature of the surfaces of the central electrode 101 and the surrounding ceramic insulator 102 can be precisely controlled within a proper window, avoiding carbon deposit as well as realize self-cleaning.

(32) The heating up process can start before firing the engine, using discharge current to heat up the spark plug 100 from inside, as well as cleaning the carbon deposit on the surfaces of ceramic insulator 102 and central electrode 101.

(33) Unlike the description in embodiment 1, which uses discharge current as a feedback control signal, embodiment 3 uses the output power as the feedback signal. The feedback discharge voltage signal can also be collected, and combined with the acquired discharge current signal to calculate the transient output power of the ignition system. The physical position where feedback voltage is measured can be the same position where the discharge current is measured, i.e. the connection joint where spark plug 100 is connected with the high voltage cable of the output of the ignition coil. This method can use total discharge power as a criterion to heat up the spark plug 100 and central electrode 101. This is useful for benchmarking the heat range of spark plugs, because the temperature difference of the electrodes among spark plug with different heat ranges will be significantly different under same heating power.

Embodiment 4

(34) Embodiment 4 has similar operation principle as embodiment 1, with difference in discharge current control algorithm.

(35) The present invention involves a spark plug heat up method via transient control of the spark discharge current. With reference to FIG. 3, the high temperature plasma channel 103 is used to heat up the central electrode 101, and the temperature and energy of the plasma channel 103 are monitored by transient control of discharge current amplitude and discharge duration. By monitoring the discharge current amplitude and discharge duration, the temperature change of the central electrode 101 and the surrounding ceramic insulator 102 can be carefully measured and controlled. This method can be used to measure the heat rating of the spark plug 100. By actively heating up the spark plug 100 via transient control of discharge current, the temperature of the surfaces of the central electrode 101 and the surrounding ceramic insulator 102 can be precisely controlled within a proper window, avoiding carbon deposit as well as realize self-cleaning.

(36) The heating up process can start before firing the engine, using discharge current to heat up the spark plug 100 from inside, as well as cleaning the carbon deposit on the surfaces of ceramic insulator 102 and central electrode 101.

(37) The described precise control over the discharge energy is based on the continuous control of discharge current. Nonlinear control methods are applied to precisely control the discharge energy of the discharged current using a real-time controller (as shown in FIG. 2).

(38) 1) Identify the desired reference trajectory for the feedback control. (i.e. the desired discharge current profile, the discharge current amplitude, the change rate of discharge current, and the discharge duration.)

(39) 2) Measure the spark discharge current in real time.

(40) 3) Use the designed model to predict the spark discharge current.

(41) Use the nonlinear controller to derive the control parameters (in this application, the duty cycle and the frequency for the control of second switch 70 based on the nonlinear cost function. To improve the transient performance of the system, an adaptive feedforward model can be used to derive a control correction based on the desired reference trajectory. The model parameters are optimized in real-time using the related measurement acquired in 1), hence the accuracy of the model prediction is improved. The ideal control input to the system can be derived using the optimized model. The final control input applied to the system is the combination of the ideal control input and the control input derived by the nonlinear feedback controller.

(42) The system would generate different discharge current profiles based on the control input values (the control applied to the second switch 70). The discharge current feedback measurement is sent to both the feedforward model and the data-driven nonlinear model embedded in the nonlinear controller. Both models are optimized using the real-time measurement. The data-driven nonlinear model predicts the system output. Both the model prediction and the real-time feedback measurement are applied to the cost function.

(43) The proposed control method has the robustness similar to adaptive control and the fast transient response of model based control. When the proposed control method is applied to heat up spark plug, and the overall system response time is around 2 microseconds.

(44) The system can be used to adjust the discharged current profile to realize the conventional or any desired discharge current profile, which is one notable feature of the proposed control system. As shown in FIG. 2, the discharge current amplitude can increase during the spark discharge period (1), the discharge current amplitude is kept at a constant level during the spark discharge period (2), the discharge current amplitude can gradually reduce during the spark discharge period (3), and the discharge current amplitude can be adjusted to any desired profile (4).

(45) The examples given above are only the technical explanation for the attached figures to this patent. Apparently, the descried examples are merely some achievable examples using the proposed system but not all its achievable applications. The terms such as “above, below, front, back, middle” used in the text are mere for the ease of explanation but not used to limit the freedom of application of the proposed system. The change of the relative direction of the terms in the texts would not affect the application of the proposed system and should still be considered as part of the proposed patent only with the exception of change in the detailed technical designs of the system. The structure, scale and the size of the figures in this text are merely used to help the explanation of the technical contents of the proposed system but are not used to limit the application of the proposed system. Hence, the change in design, the change in scale or size which would not affect the function of the propose system should still be considered as part of the proposed patent. Based on the examples given in this patent, the readers who have acquired the system without making any technical change should still be considered as belonging to the scope of protection of the present invention.