Injector delivery measurement with leakage correction

Abstract

A method for operating a combustion engine is provided. A fuel injector is operated to perform a fuel injection, a sequence of pressure signals of the fuel rail pressure during the fuel injection is sampled and filtered and a total pressure difference between a first sample after a top dead center of the fuel pump and before the fuel injection has started and a chosen second sample after the injection and before a next pumping stroke is determined. A linear pressure slope at the second sample and a leakage pressure difference between the first sample and the second sample based on the linear pressure slope is calculated, leading to calculating an injection pressure difference as the difference between total pressure difference and the leakage pressure difference. With this, a value of a fuel quantity injected as a function of the injection pressure difference can be determined, while leakages are compensated.

Claims

1. A method of operating an internal combustion engine having a fuel rail in fluid communication with a fuel pump and a fuel injector, the method comprising: operating the fuel injector to perform a fuel injection; sampling a sequence of pressure signals representative of a fuel pressure within the fuel rail during the fuel injection in a crankshaft angular domain; filtering the sequence of pressure signals to reduce signal noise; acquiring a first sample of the filtered pressure signals after a top dead center of the fuel pump and before the fuel injection has started in an injection interval; acquiring a second sample of the filtered pressure signals after the injection and before a next pumping stroke; calculating a total pressure difference between the first sample and the second sample; determining a linear pressure slope at least at the second sample and calculating a leakage pressure difference between the first sample and the second sample based on the linear pressure slope; calculating an injection pressure difference as the difference between total pressure difference and the leakage pressure difference; calculating a value of a fuel quantity injected by the fuel injection as a function of the calculated value of the injection pressure difference; and sending a fuel injection command to the fuel injector based on the value of a fuel quantity calculated.

2. The method of claim 1, further comprising: acquiring a third sample of the filtered pressure signals after the injection and before a next pumping stroke, wherein the second sample and the third sample are spaced apart from each other; wherein determining the linear pressure slope includes calculating a pressure difference between the second sample and the third sample and dividing it by the crankshaft angle difference between the second sample and the third sample.

3. The method of claim 2, wherein the second sample and the third sample are spaced apart about at least 0.05.Math. of the crankshaft angle.

4. The method of claim 2, wherein the second sample and the third sample are spaced apart in a range between 0.1.Math. and 0.2.Math. of the crankshaft angle.

5. The method of claim 1, wherein calculating the leakage pressure difference includes multiplying the linear pressure slope at the second sample by the angle difference between the first sample and the second sample.

6. The method of claim 1, wherein filtering the sequence of pressure signals includes using a SINC filter.

7. The method of claim 6, wherein the SINC filter is tuned on a rail wave pressure dominant frequency.

8. A fuel injection system comprising: a fuel pump in fluid communication with a fuel injector through a fuel rail; and an electronic control unit configured to: operate the fuel injector to perform a fuel injection; sample a sequence of pressure signals representative of a fuel pressure within the fuel rail during the fuel injection in a crankshaft angular domain; filter the sequence of pressure signals so as to reduce signal noise; acquire a first sample after a top dead center of the fuel pump and before the fuel injection has started in an injection interval; acquire a second sample after the injection and before a next pumping stroke; calculate a total pressure difference between the first sample and the second sample; determine a linear pressure slope at least at the second sample and calculate a leakage pressure difference between the first sample and the second sample based on the linear pressure slope; calculate an injection pressure difference as the difference between the total pressure difference and the leakage pressure difference; calculate a value of a fuel quantity injected by the fuel injection as a function of the calculated value of the injection pressure difference; and send a fuel injection command to the fuel injector based on the value of a fuel quantity calculated.

9. The fuel injection system of claim 8, further comprising: choosing a third sample after the injection and before a next pumping stroke, wherein the second sample and the third sample are spaced apart from each other; wherein determining the linear pressure slope includes calculating a pressure difference between the second sample and the third sample and dividing it by the crankshaft angle difference between the second sample and the third sample.

10. The fuel injection system of claim 9, wherein the second sample and the third sample are spaced apart about at least 0.05.Math. of the crankshaft angle.

11. The fuel injection system of claim 10, wherein the second sample and the third sample are spaced apart in a range between 0.1.Math. and 0.2.Math. of the crankshaft angle.

12. The fuel injection system of claim 8, wherein calculating the leakage pressure difference includes multiplying the linear pressure slope at the second sample by the angle difference between the first sample and the second sample.

13. The fuel injection system of claim 8, wherein filtering the sequence of pressure signals includes using a SINC filter.

14. The fuel injection system of claim 13, wherein the SINC filter is tuned on a rail wave pressure dominant frequency.

15. An internal combustion engine comprising: an engine block having a cylinder with a piston disposed therein and a cylinder head cooperating with the piston to define a combustion chamber; a fuel pump configured to supply pressurized fuel to a fuel rail; a fuel injector in fluid communication with the fuel rail and configured to inject fuel into the combustion chamber; and an electronic control unit configured to: operate the fuel injector to perform a fuel injection; sample a sequence of pressure signals representative of a fuel pressure within the fuel rail during the fuel injection in a crankshaft angular domain; filter the sequence of pressure signals so as to reduce signal noise; in an injection interval determine a first sample after a top dead center of the fuel pump and before the fuel injection has started; acquire a second sample after the injection and before a next pumping stroke; calculate a total pressure difference between the first sample and the second sample; determine a linear pressure slope at least at the second sample and calculate a leakage pressure difference between the first sample and the second sample based on the linear pressure slope; calculate an injection pressure difference as the difference between the total pressure difference and the leakage pressure difference; calculate a value of a fuel quantity injected by the fuel injection as a function of the calculated value of the injection pressure difference; and send a fuel injection command to the fuel injector based on the value of a fuel quantity calculated.

Description

DESCRIPTION OF THE DRAWINGS

(1) The exemplary embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements.

(2) FIG. 1 schematically shows an automotive system in the form of internal combustion engine;

(3) FIG. 2 is a sectional view (A-A) of the system shown in FIG. 1;

(4) FIG. 3 shows a method in form a schematic flowchart;

(5) FIG. 4 shows pressure and fuel flow graphs without leakage; and

(6) FIG. 5 shows pressure and fuel flow graphs with leakage.

DETAILED DESCRIPTION

(7) The following detailed description is merely exemplary in nature and is not intended to limit the invention disclosed herein or the application and uses of the invention disclosed herein. Furthermore, there is no intention to be bound by any principle or theory, whether expressed or implied, presented in the preceding technical field, background, summary or the following detailed description, unless explicitly recited as claimed subject matter.

(8) Some embodiments may include an automotive system 100, as shown in FIGS. 1 and 2, that includes an internal combustion engine (ICE) 110 having an engine block 120 defining at least one cylinder 125 having a piston 140 coupled to rotate a crankshaft 145. A cylinder head 130 cooperates with the piston 140 to define a combustion chamber 150. A fuel and air mixture (not shown) is disposed in the combustion chamber 150 and ignited, resulting in hot expanding exhaust gasses causing reciprocal movement of the piston 140. The fuel is provided by at least one fuel injector 160 and the air through at least one intake port 210. The fuel is provided at high pressure to the fuel injector 160 from a fuel rail 170 in fluid communication with a high-pressure fuel pump 180 that increase the pressure of the fuel received from a fuel source 190. Each of the cylinders 125 has at least two valves 215, actuated by a camshaft 135 rotating in time with the crankshaft 145. The valves 215 selectively allow air into the combustion chamber 150 from the port 210 and alternately allow exhaust gases to exit through a port 220. In some examples, a cam phaser 155 may selectively vary the timing between the camshaft 135 and the crankshaft 145.

(9) The air may be distributed to the air intake port(s) 210 through an intake manifold 200. An air intake duct 205 may provide air from the ambient environment to the intake manifold 200. In other embodiments, a throttle body 330 may be provided to regulate the flow of air into the manifold 200. In still other embodiments, a forced air system such as a turbocharger 230, having a compressor 240 rotationally coupled to a turbine 250, may be provided. Rotation of the compressor 240 increases the pressure and temperature of the air in the duct 205 and manifold 200. An intercooler 260 disposed in the duct 205 may reduce the temperature of the air. The turbine 250 rotates by receiving exhaust gases from an exhaust manifold 225 that directs exhaust gases from the exhaust ports 220 and through a series of vanes prior to expansion through the turbine 250. The exhaust gases exit the turbine 250 and are directed into an aftertreatment system 270. This example shows a variable geometry turbine (VGT) with a VGT actuator 290 arranged to move the vanes to alter the flow of the exhaust gases through the turbine 250. In other embodiments, the turbocharger 230 may be fixed geometry and/or include a waste gate.

(10) The aftertreatment system 270 may include an exhaust pipe 275 having one or more exhaust aftertreatment devices 280. The aftertreatment devices may be any device configured to change the composition of the exhaust gases. Some examples of aftertreatment devices 280 include, but are not limited to, catalytic converters (two and three way), oxidation catalysts, lean NO.sub.x traps, hydrocarbon adsorbers, selective catalytic reduction (SCR) systems, and particulate filters, such as a Selective Catalytic Reduction on Filter (SCRF) 500. The SCRF 500 may be associated with a temperature sensor upstream of the SCRF 500 and temperature sensor downstream of the SCRF 560.

(11) Other embodiments may include a high-pressure exhaust gas recirculation (EGR) system 300 coupled between the exhaust manifold 225 and the intake manifold 200. The EGR system 300 may include an EGR cooler 310 to reduce the temperature of the exhaust gases in the EGR system 300. An EGR valve 320 regulates a flow of exhaust gases in the EGR system 300.

(12) The automotive system 100 may further include an electronic control unit (ECU) 450 in communication with one or more sensors and/or devices associated with the ICE 110. The ECU 450 may receive input signals from various sensors configured to generate the signals in proportion to various physical parameters associated with the ICE 110. The sensors include, but are not limited to, a mass airflow and temperature sensor 340, a manifold pressure and temperature sensor 350, a combustion pressure sensor 360, coolant and oil temperature and level sensors 380, a fuel rail pressure sensor 400, a cam position sensor 410, a crank position sensor 420, exhaust pressure sensors 430, an EGR temperature sensor 440, and an accelerator pedal position sensor 445. Furthermore, the ECU 450 may generate output signals to various control devices that are arranged to control the operation of the ICE 110, including, but not limited to, the fuel injectors 160, the throttle body 330, the EGR Valve 320, the VGT actuator 290, and the cam phaser 155. Note, dashed lines are used to indicate communication between the ECU 450 and the various sensors and devices, but some are omitted for clarity.

(13) Turning now to the ECU 450, this apparatus may include a digital central processing unit (CPU) in communication with a memory system, or data carrier 460, and an interface bus. The CPU is configured to execute instructions stored as a program in the memory system, and send and receive signals to/from the interface bus. The memory system may include various storage types including optical storage, magnetic storage, solid state storage, and other non-volatile memory. The interface bus may be configured to send, receive, and modulate analog and/or digital signals to/from the various sensors and control devices. The program may embody the methods disclosed herein, allowing the CPU to carry out the steps of such methods and control the ICE 110.

(14) The program stored in the memory system is transmitted from outside via a cable or in a wireless fashion. Outside the automotive system 100 it is normally visible as a computer program product, which is also called computer readable medium or machine readable medium in the art, and which should be understood to be a computer program code residing on a carrier, said carrier being transitory or non-transitory in nature with the consequence that the computer program product can be regarded to be transitory or non-transitory in nature.

(15) An example of a transitory computer program product is a signal, e.g. an electromagnetic signal such as an optical signal, which is a transitory carrier for the computer program code. Carrying such computer program code can be achieved by modulating the signal by a conventional modulation technique such as QPSK for digital data, such that binary data representing said computer program code is impressed on the transitory electromagnetic signal. Such signals are e.g. made use of when transmitting computer program code in a wireless fashion via a Wi-Fi connection to a laptop.

(16) In case of a non-transitory computer program product the computer program code is embodied in a tangible storage medium. The storage medium is then the non-transitory carrier mentioned above, such that the computer program code is permanently or non-permanently stored in a retrievable way in or on this storage medium. The storage medium can be of conventional type known in computer technology such as a flash memory, an Asic, a CD or the like.

(17) Besides other functions, the ECU 450 is configured to operate the fuel injectors 160 to inject fuel into the associated combustion chambers 150. Preferably, a fuel injector 160 may be realized in the form of an electromechanical valve having a nozzle in fluid communication with the associated combustion chamber 150, a needle and an electro-magnetic actuator, which moves the needle from a closed into an open position. The closed position may be maintained through a spring. Consequently, a cylinder 125 only receives fuel from the fuel rail 170 if the fuel injector 160 is in an open state, i.e. if the electro-magnetic actuator is energized. The quantity of the fuel depends on the duration of the open state. This fuel injection may be referred to as the injection pulse, which is controlled and monitored through the ECU 450

(18) During normal operation of the combustion engine 110, the ECU 450 operates the fuel injectors 160 to conduct the fuel injections as required for each engine cycle, which fuel injections may include a single injection pulse or a plurality of injection pulses for each combustion chamber 150. Operating the fuel injectors 160 includes energizing the respective electro-magnetic actuator at the right time and for a desired period. While the fuel quantity is an important parameter, also a correct injection timing is required. In particular, the correct timing of the injection pulses depends on an angular position of the engine crankshaft 145. A desired starting point for the injection (SOI) may be in a period when the crankshaft 145 passes through top dead center (TDC), i.e. just before TDC and just after TDC.

(19) The fuel quantity of an injection pulse itself depends on the pressure in the fuel rail, a flow resistance and other flow influencing parameters between the fuel rail 170 and the combustion chamber 150 through the injector 160, and the energizing time (ET) for the respective fuel injector 160. The flow resistance depends on the type of fuel injector 160 and its momentary state that is controlled by the ECU 450. The energizing time is directly influenced by the ECU 450 through timing the activation and deactivation of the respective fuel injector 160, e.g. by selectively energizing its electromagnetic actuator. Hence, the ECU 450 is able to provide a desired injection fuel quantity for each injection pulse and each combustion chamber 150 by adjusting the energizing time and controlling the fuel injectors 160 depending on the actual requirement for the engine 110. The required energizing time may be calculated under consideration of the momentary fuel rail pressure as well as the respective parameters of the fuel injectors 160.

(20) As explained above, the actual fuel quantity injected by the fuel injector 160 may not only differ from a desired quantity due to aging and/or production spread of the fuel injector 160, but also from a leakage effect. In order to always maintain the desired fuel quantities, the ECU 450 may be configured to perform a method for determining the correct timing and the correct fuel quantity, thereby adjusting the timing. For this purpose, the ECU 450 may be configured to execute a method as explained above.

(21) Instead of an ECU 450, the automotive system 100 may have a different type of processor to provide the electronic logic, e.g. an embedded controller, an onboard computer, or any processing module that might be deployed in the vehicle and operable to execute computer program code for carrying out the method described above.

(22) FIG. 3 shows a flowchart of a method of operating the internal combustion engine 110. Here, the fuel injector 160 is operated (block 600) for a certain period of time by energizing the fuel injector 160, such that a single or a plurality of fuel injections is accomplished. A sequence of pressure signals representative of a fuel pressure within the fuel rail 170 during the fuel injection is sampled in a crankshaft angular domain (block 605). The fuel rail pressure may be acquired by the fuel rail pressure sensor 400. To reduce signal noises and facilitating the analysis of the sampled pressure signals, the sequence of pressure signals is filtered (block 610). In the method, a first sample after a top dead center of the fuel pump and before the fuel injection has started is determined (block 615) and a second sample after the injection and before a next pumping stroke is chosen (block 620). The total pressure difference between the first sample and the second sample is calculated (block 625), a linear pressure slope at the second sample is determined (block 630) and a leakage pressure difference between the first sample and the second sample based on the linear pressure slope is calculated (block 635). The injection pressure difference is calculated as the difference between total pressure difference and the leakage pressure difference (block 640) and a value of a fuel quantity injected by the fuel injection as a function of the calculated value of the injection pressure difference (block 645). A fuel injection command may be sent to the fuel injectors based on the value of a fuel quantity calculated.

(23) FIG. 4 shows a sequence of pressure signals in a fuel rail 170 over the crankshaft angle in a certain crankshaft angle interval, which may exemplarily be 360, i.e. 2.Math., of a single fuel injector 160. In this illustration, zero leakage is assumed, in order to explain the basic strategy for calculating the fuel quantity. Just for illustration purposes, a raw pressure signal curve is shown as a dashed line, while a filtered pressure signal curve is shown as a solid curve. The calculation of the injected fuel quantity is conducted under using the filtered curve. FIG. 4 additionally shows the derivative of the fuel quantity Q over the crankshaft angle .

(24) The fuel quantity is a function depending on a pressure difference between a first sample during the injection (sample A) and a second sample after the injection (sample B): Q.sub.iniet=f(p.sub.inj). Since in this example leakage effects are non-existent, the total pressure difference between these samples are the determining factor for the injection. Therefore, the total pressure difference is equal to the injection pressure difference.

(25) In the pressure graph of FIG. 4, the injection pressure difference p.sub.inj is marked as a difference between p.sub.A, i.e. the pressure at a first sample, and p.sub.B, i.e. the pressure at a second instance. In a lower part of FIG. 4, the resulting fuel flow is shown. During the fuel injection, the pressure has a higher value (p.sub.A) than after the injection is accomplished (p.sub.B), wherein, due to the assumed lack of leakages, the pressure p.sub.B remains constant. The ECU 450 controls the respective fuel injector 160 and injects fuel into the associated combustion chamber, driven by the fuel rail pressure. As stated before, the fuel quantity can be calculated by consideration of the flow resistance and other flow determining parameters between the fuel rail 170 and the combustion chamber 150 over the respective fuel injector 160, the pressure on the fuel rail 170 as well as the energizing time (ET). Consequently, the fuel quantity injected into the respective combustion chamber 150 can be calculated by using just two pressure values over the injection process. The fuel quantity follows to Q.sub.inlet=f(p.sub.inj). The curve of the quantity derivative, i.e. the fuel flow, is exemplarily chosen as a rectangular function, and the area under the rectangular curve represents the fuel quantity at the inlet of the respective injector, which is the sum of the quantity effectively injected into the respective combustion chamber and any dynamic leakages only occurring during the injection. These dynamic leakage effects may be considered fixed for the respective injector. Hence, the equation further above shall be adapted to already take this into account.

(26) However, if leakages occur, the pressure of the fuel rail 170 not only depends on performed fuel injections, but also on a leakage flow, be it caused by a pressure regulator, fuel injectors 160 or other components. FIG. 5 demonstrates that the leakage may have a linear effect on the pressure of the pressure rail 170, which is indicated by a dashed line having a constant slope. In other words, the measured pressure on the pressure rail 170 substantially constantly decreases irrespective of the injection process. A strategy of the method presented in this disclosure is to determine the slope of this linear pressure component, i.e. the pressure deviation per time, to isolate the leakage induced pressure drop.

(27) Besides other techniques, a third sample is acquired not too far away from the second sample, i.e. in an angular region of the crankshaft where the injection has already ended, and to measure the pressure p.sub.0 at this sample. From the pressure difference p.sub.0p.sub.B the slope of the leakage induced pressure curve can be obtained in this angular region of the crankshaft, which is referred to as . By extrapolation of the linear pressure drop over the angular region of interest, i.e. , the leakage induced pressure drop can be calculated for the whole fuel injection process. Hence, the relevant injection pressure difference, as stated above, may be calculated by the formula p.sub.inj=(p.sub.Ap.sub.B)p.sub.leak, which results in p.sub.inj=(p.sub.Ap.sub.B)(p.sub.0p.sub.B)*/. Again, the fuel quantity follows to Q.sub.inlet=f(p.sub.inj). Consequently, p.sub.inj and p.sub.leak may easily be discerned and monitored.

(28) If the method described in this disclosure is applied to an internal combustion engine 110 that does not show leakage induced pressure drops, the extrapolation of the pressure difference between the third and the second sample will lead to extrapolating substantially zero onto the sampled pressure signals. Hence, the method is generally applicable to an internal combustion engine with and without leakage conditions.

(29) The term sample, in the context of first sample, second sample and third sample, is intended to indicate a data reading from a signal sequence (e.g., pressure signal sequences) at a particular moment or instant in time. Although the terms first, second and third may be used herein to describe various samples in the crankshaft angle, these should not be limited by these terms. These terms may be only used to distinguish one sample from another sample. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first sample could be termed a second sample without departing from the teachings of the example embodiments. In particular, the second sample and the third sample do not need to have this order in the crankshaft angular domain, since the leakage induced pressure drop may also be calculated if the third sample follows after the second sample or if the third sample is before the second sample.

(30) The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

(31) While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the disclosure as set forth in the appended claims and the legal equivalents thereof.