Exhaust gas recirculation control in an internal combustion engine
11624341 · 2023-04-11
Assignee
Inventors
- Xin Yuan (Palo Alto, CA, US)
- Shikui Kevin CHEN (Leander, TX, US)
- Jennifer K. Light-Holets (Greenwood, IN, US)
- Scott R. Bardakjy (Columbus, IN, US)
Cpc classification
F02D2200/0406
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/146
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D2200/101
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F02D41/0052
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M35/10393
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/0087
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/1461
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/0072
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/43
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M26/05
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02M26/43
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D41/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A system and method of integrating an engine having dynamic skip fire control with an exhaust gas recirculation system in a turbocharged internal combustion engine is described. An engine control system determines an appropriate firing pattern based at least in part on a desired exhaust gas recirculation flow rate. Signals from sensors in the intake manifold and exhaust system may also be used as part of a feedback loop to determine a desired exhaust gas recirculation flow rate.
Claims
1. A method of selecting cylinders to deactivate in an internal combustion engine, the engine having an intake manifold and an exhaust system, comprising: determining a desired exhaust gas recirculation flow rate; determining a position of an exhaust gas recirculation valve; deactivating selected cylinders based at least in part on the desired exhaust gas recirculation flow rate and the position of the exhaust gas recirculation valve; and determining an engine speed; determining a boost pressure in the intake manifold; and regulating a maximum exhaust gas recirculation rate based at least in part on the engine speed and the boost pressure.
2. The method as recited in claim 1, wherein a pattern of firings and deactivation is fixed for certain cylinders over an extended number of engine cycles.
3. The method as recited in claim 1, further comprising: comparing the desired exhaust gas recirculation flow rate with the maximum exhaust gas recirculation flow rate.
4. The method as recited in claim 3, further comprising: selecting different cylinders to deactivate if the desired exhaust gas recirculation flow rate exceeds the maximum gas recirculation flow rate.
5. The method as recited in claim 1, further comprising: determining a valve timing; and calculating the maximum exhaust gas recirculation rate based at least in part on the valve timing.
6. The method as recited in claim 5, further comprising: comparing the desired exhaust gas recirculation flow rate with the maximum exhaust gas recirculation flow rate.
7. The method as recited in claim 6, further comprising: selecting different cylinders to deactivate if the desired exhaust gas recirculation flow rate exceeds the maximum gas recirculation flow rate.
8. The method as recited in claim 1, further comprising: determining an oxygen level in the intake manifold; adjusting cylinders to deactivate or the exhaust gas recirculation valve position if the oxygen level deviates from a desired oxygen level by more than a pre-defined threshold amount.
9. The method as recited in claim 1, further comprising: determining a level of nitrogen oxides in the exhaust system; adjusting cylinders to deactivate or the exhaust gas recirculation valve position if the level of nitrogen oxides exceeds a pre-defined threshold.
10. The method as recited in claim 1, wherein the selection of cylinders to deactivate does not result in firings being as evenly distributed as possible.
11. The method as recited in claim 1, wherein among cylinders not selected to be deactivated fire, more cylinders that directly vent into a first exhaust manifold are fired than cylinders that do not directly vent into the first exhaust manifold.
12. The method as recited in claim 1, wherein at least one working cycle having a deactivated cylinder is a pumping working cycle.
13. The method as recited in claim 1, wherein selecting cylinders to deactivate reduces engine-cycle-to-engine-cycle fluctuations in a number of cylinder firings venting into the first exhaust manifold.
14. The method as recited in claim 1, wherein selecting cylinders to deactivate has more engine-cycle-to-engine-cycle fluctuations in a number of cylinder firings venting into the second exhaust manifold than a number of cylinder firings venting into the first exhaust manifold.
15. An internal combustion engine, the engine having an intake manifold, an exhaust gas recirculation system, and an exhaust system having at least two exhaust manifolds, the engine comprising: an exhaust gas recirculation feed line connected to the exhaust system, wherein the exhaust gas circulation feed line has a more direct fluid connection to a first exhaust manifold than to a second exhaust manifold; and an engine control system configured to: deactivate at least one cylinder based at least in part on a desired exhaust gas recirculation flow rate; determine an engine speed; determine a boost pressure in the intake manifold; and regulate a maximum exhaust gas recirculation rate based at least in part on the engine speed and the boost pressure.
16. The engine as recited in claim 15, further comprising: an oxygen sensor located in the intake manifold, wherein a signal from the oxygen sensor is used as part of a feedback loop to determine the desired exhaust gas recirculation flow rate.
17. The engine as recited in claim 15, further comprising: a nitrogen oxides sensor to measure a level of nitrogen oxides located in the exhaust, wherein a signal from the nitrogen oxides sensor is used as part of a feedback loop to determine the desired exhaust gas recirculation flow rate.
18. An internal combustion engine, the engine having an intake manifold, an exhaust gas recirculation system, and an exhaust system having at least two exhaust manifolds, comprising: an exhaust gas recirculation feed line connected to the exhaust system, wherein the exhaust gas circulation feed line has a more direct fluid connection to a first exhaust manifold than to a second exhaust manifold; and an engine control system for selecting cylinders to deactivate based at least in part on a desired exhaust gas recirculation flow rate, wherein the engine control system uses a first control algorithm to select a first set of cylinders to deactivate for cylinders that vent into the first exhaust manifold and a second control algorithm to select a second set of cylinders to deactivate for cylinders that vent into the second exhaust manifold.
19. The engine as recited in claim 18, wherein selecting cylinders to deactivate does not result in firings being as evenly distributed as possible.
20. The engine as recited in claim 18, wherein the engine has a plurality of cylinders and a selected firing pattern has a repeating pattern length that is at least twice a number of cylinders in the engine.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
(2)
(3)
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DESCRIBED EMBODIMENTS
(6) In this patent application, numerous specific details are set forth to provide a thorough understanding of the concepts underlying the described embodiments. It will be apparent, however, to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the underlying concepts.
(7) As discussed above, skip fire controlled engines deactivate cylinders when they are not needed to generate a requested torque output from the engine. Cylinder deactivation reduces engine pumping losses and generally results in more efficient combustion in fired working cycles. Cylinder deactivation also allows better control of exhaust gas temperature, which is especially important in Diesel engines where lean burn combustion may result in exhaust temperatures too low for efficient removal of noxious emissions by an aftertreatment system.
(8)
(9) The turbine 120 may be part of a variable geometry or variable nozzle turbocharger system. In this case, an internal mechanism within the turbine 120 alters a gas flow path through the turbine 120 to optimize turbine operation as the exhaust gas flow rate through the turbine 120 changes. If the turbine 120 is part of a variable geometry or variable nozzle turbocharger system, the waste gate 122 may not be required.
(10) Various sensors may optionally be positioned in various locations within the engine 100. For example, sensor 128 may provide a signal related to conditions within the intake manifold 108. Sensor 128 may provide a signal related to the oxygen level in the intake manifold, which provides a measure of the ratio of exhaust gas to air within the intake manifold 108. The sensor 128 signal may be used in a feedback loop as described below. Additional intake manifold sensors may include, but are not limited to, a pressure sensor, a temperature sensor, and a humidity sensor. Similarly, one or more sensors 130 and 132 may provide signals related to conditions at various locations within the exhaust system. For example, sensor 130 may monitor conditions in the first exhaust manifold 112 and sensor 132 may monitor conditions in the second exhaust manifold. The sensors 130 and 132 may provide a signal related to the oxygen level in the first exhaust manifold and second exhaust manifold, respectively. Additional exhaust system sensors may include, but are not limited to, a pressure sensor, a temperature sensor, and a NO.sub.x sensor. These exhaust system sensors may be distributed at different points in the exhaust system as required.
(11) In operation, the intake manifold pressure can change significantly with speed and load. Typically, it can be as low as ambient pressure (nominally 14.7 pounds per square in inch (psi) or 100 kPa absolute) at light loads to as high as 250-300 kPa at peak power. The intake manifold pressure relative to atmospheric pressure is often referred to as a boost pressure. Similarly, an exhaust manifold pressure can also change significantly, from as low as (slightly higher than) ambient pressure (100 kPa) to as high as 300 to 350 kPa at peak power. The exhaust manifold pressure is normally higher than intake manifold pressure, so that exhaust gas can to flow back into the intake manifold 108 resulting in exhaust gas recirculation. The gas pressure entering the turbine 120 must also be above atmospheric pressure for the turbine 120 to operate. Arrows in
(12) Inspection of
(13) To give a specific example, the engine 100 depicted in
(14) To control an EGR flow rate under while the engine 100 is operating in a dynamic skip fire (DSF) mode, the firing pattern at certain firing fractions should be considered. For example, when running firing fraction of ½ described above, the firing pattern 1-S-3-S-2-S will be preferred if a high EGR flow rate is required and the firing pattern S-5-S-6-S-4 could be used a low EGR flow rate is required. Similar consideration would also apply to firing fractions of ¼ and ¾.
(15) To maintain a consistent EGR flow rate, some rotating firing patterns may need to be avoided at certain operating conditions. Here a rotating firing pattern refers to a firing pattern that fires or skips all cylinders. For example, a firing fraction of 1/7 is a rotating firing pattern. A firing fraction of 1/7 fires one of the cylinders that feed into the first exhaust manifold 112 (cylinder 1, 2, or 3) once every 14 firing opportunities.
(16)
(17) To better understand operation of the engine control system 300 consider the table 400 in
(18) It should be noted that any number of the skipped cylinders in any of the patterns described in
(19) In another embodiment, a signal from an oxygen sensor located in the intake manifold 108 may be used to determine the ratio of exhaust gas to air in the intake manifold 108. If the oxygen level deviates from a desired oxygen level by more than a pre-defined threshold amount, a position of EGR valve 124 may adjusted and/or a firing pattern may be changed. If the oxygen level is high (insufficient EGR flow) a firing pattern that predominately fires cylinders 1-3 rather than cylinders 4-6 may be selected to increase the EGR flow rate. Similarly, if the oxygen level is low (excessive EGR flow) a firing pattern that predominately fires cylinders 4-6 rather than cylinders 1-3 may be selected to decrease the EGR flow rate.
(20) In another embodiment, a signal from an oxygen sensor located in one or both of the exhaust manifolds 112 and 114 may be used to determine the ratio of exhaust gas to air in the exhaust manifold. If the oxygen level deviates from a desired oxygen level by more than a pre-defined threshold amount, a position of EGR valve 124 may adjusted and/or a firing pattern may be changed. If the oxygen level is high (insufficient EGR flow) a firing pattern that predominately fires cylinders 1-3 rather than cylinders 4-6 may be selected to increase the EGR flow rate. Similarly, if the oxygen level is low (excessive EGR flow) a firing pattern that predominately fires cylinders 4-6 rather than cylinders 1-3 may be selected to decrease the EGR flow rate.
(21) In other embodiments, rather placing an oxygen sensor in the intake manifold or exhaust system, a model of the oxygen level at these locations may be used to generate a signal representative of the oxygen level. This signal may be used in an analogous manner as a signal from an oxygen sensor.
(22) In another embodiment, a signal from a NO.sub.x sensor located in the exhaust system may be used to determine a NO.sub.x level in the exhaust gas. If the NO.sub.x level in the exhaust gas exceeds a pre-determined threshold, the EGR valve 124 may be opened and/or firing patterns that predominately fire cylinders 1-3 rather than cylinders 4-6 may be selected to increase the EGR gas flow rate. A model of the NO.sub.x level may be used in place a signal from an NO.sub.x sensor in some embodiments.
(23) While operating the engine using firing patterns with the fired working cycles spaced out as evenly as possible and having a low denominator firing fraction is generally desirable, this mode of operation is not a requirement. Particularly, while operating with light loads and in vehicles with an auxiliary torque source/sink, such as a hybrid powertrain, firing patterns in which the firings are not as evenly spaced as possible may be used. Also, firing fractions having larger denominators, for example, denominators greater than 7 may be used. In some cases the firing fraction denominator may be an integer multiple of the number of cylinders in the engine. In hybrid vehicles an electric motor may be used to mitigate the effects of engine vibration by applying a smoothing torque as described in U.S. Pat. Nos. 9,512,794, 10,060,368, and 10,344,692. In this case, a skip fire algorithm that determines which cylinder to fire and which cylinder to skip may operate with two selection algorithms. A first algorithm may be applied to cylinders directly venting into the first exhaust manifold 112 and a second algorithm may be applied to cylinders directly venting into the second exhaust manifold 114. The first control algorithm and second control algorithm may coordinate with each other to maintain the firing spacings in as even a manner as possible.
(24) As previously described, in the exemplary engine 100 shown in
(25) The firing fraction in the above example is 7/12, i.e. four firings in the first engine cycle and three firings in the second engine cycle. In this case the repeating firing pattern length is twice the number of cylinders in the engine. Engine control by using a combination of the first control algorithm and the second control algorithm may often yield firing patterns having a repeating firing pattern length that is equal to an integer multiple of the number of engine cylinders, wherein the integer multiple is two or more. As in the above example, firing patterns may be selected such that the selected firing pattern reduces engine-cycle-to-engine-cycle fluctuations in a number of cylinder firings venting into the first exhaust manifold to maintain a steadier flow into the EGR system. Firing patterns may also be selected such that the firing pattern has more engine-cycle-to-engine-cycle fluctuations in a number of cylinder firings venting into the second exhaust manifold than a number of cylinder firings venting into the first exhaust manifold, since variation of the exhaust flow into the second exhaust manifold has less impact on the EGR flow rate.
(26) The invention has been described primarily in the context of operating a turbocharged, 4-stroke, internal combustion piston engines suitable for use in motor vehicles. However, it should be appreciated that the described applications are very well suited for use in a wide variety of internal combustion engines. These include engines for virtually any type of vehicle—including cars, trucks, boats, aircraft, motorcycles, scooters, etc.; and virtually any other application that involves the firing of working chambers and utilizes an internal combustion engine. The various described approaches work with engines that operate under a wide variety of different thermodynamic cycles—including virtually any type of two stroke piston engines, diesel engines, Otto cycle engines, Dual cycle engines, Miller cycle engines, Atkinson cycle engines, Wankel engines and other types of rotary engines, mixed cycle engines (such as dual Otto and diesel engines), hybrid engines, radial engines, etc. It is also believed that the described approaches will work well with newly developed internal combustion engines regardless of whether they operate utilizing currently known, or later developed thermodynamic cycles. Naturally aspirated engines may also benefit from the invention described herein.
(27) The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.
(28) The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
(29) While the embodiments have been described in terms of particular embodiments, there are alterations, permutations, and equivalents, which fall within the scope of these general concepts. It should also be noted that there are alternative ways of implementing the methods and apparatuses of the present embodiments. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the described embodiments.