Catalyst temperature estimation device

Abstract

In a fuel cut period, an adsorbed CO quantity calculation section calculates the amount CATco of CO adsorbed on a catalyst, and an exhaust O2 quantity calculation section calculates the amount GASo2 of O2 in exhaust gases. CO oxidation reaction heat ΔHr produced when the calculated amount CATco of absorbed CO reacts with the calculated amount GASo2 of O2 in the exhaust gases is calculated by a ΔHr calculation section, and used in estimation of the temperature of the catalyst.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The nature of this invention, as well as other objects and advantages thereof, will be explained in the following with reference to the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures and wherein:

FIG. 1 is a diagram showing the entire configuration of an embodiment of the catalyst temperature estimation device;

FIG. 2 is a control block diagram showing the processing performed by a fuel-cut-period reaction heat calculation section of an ECU;

FIG. 3 is a control block diagram showing the processing performed by an exhaust-catalyst heat transfer calculation section of the ECU;

FIG. 4 is a control block diagram showing the processing performed by a fuel-recovery-period conversion heat calculation section of the ECU;

FIG. 5 is a control block diagram showing the processing performed by an O₂ adsorption ratio calculation section of the ECU;

FIG. 6 is a control block diagram showing how the processing by a catalyst temperature estimation section of the ECU goes on; and

FIG. 7 shows a test result showing how the catalyst temperature is estimated when the fuel cut and fuel recovery is repeated with a short period.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A catalyst temperature estimation device which is an embodiment of the present invention will be describe below.

FIG. 1 is a diagram showing the entire configuration of this embodiment of the catalyst temperature estimation device. An engine 1 is a direct-injection spark-ignition four-cylinder-in-line gasoline engine. A spark plug 2 and an electromagnetic fuel injection valve 3, provided for each cylinder, are fitted to a cylinder head of the engine 1. From the fuel injection valve 3, fuel is injected directly into a combustion chamber. The cylinder head has intake ports 4a formed for the respective cylinders, which extend almost upright. The intake ports 4a are connected to a throttle valve 5 through an intake manifold 4, and the throttle valve 5 is connected to an intake passage (not shown).

The cylinder head also has exhaust ports 6a extending almost horizontally, and the exhaust ports 6a are connected to an exhaust passage 7 through an exhaust manifold 6. An early catalytic converter 8 is disposed in the upstream part of the exhaust passage 7, while an underfloor catalytic converter 9 is disposed in the downstream part of the exhaust passage 7. The early catalytic converter 8 and the underfloor catalytic converter 9 are three-way catalytic converters carrying a precious metal such as platinum (Pt), rhodium (Rh) or the like. In the present embodiment, temperature estimation is performed for the underfloor catalytic converter 9. It is, however, to be noted that the temperature estimation is not limited to the underfloor catalytic converter 9 but can be carried out for the early catalytic converter 8 or an NOx adsorption catalytic converter for conversion of NOx (not shown), for example. Upstream of the underfloor catalytic converter 9, an air-fuel ratio sensor 10 (exhaust air-fuel ratio detection element) is provided. The air-fuel ratio sensor 10 detects the air-fuel ratio of exhaust gases flowing into the underfloor catalytic converter 9.

In a vehicle compartment, an ECU (electronic control unit) 21 including an input-output device, memory (ROM, RAM, nonvolatile RAM, etc.), a central processing unit (CPU), a timer counter, etc. is installed. To the input of the ECU 21, various sensors, such as the above-mentioned air-fuel ratio sensor 10, a throttle sensor 22 for detecting the opening of the throttle valve 5, a revolving rate sensor 23 for detecting the revolving rate of the engine 1, and a water temperature sensor 24 for detecting the temperature of a coolant, are connected. From these sensors, detection information is fed to the ECU. To the output of the ECU 21, various devices, such as the above-mentioned spark plugs 2 and fuel injection valves 3, are connected.

The ECU 21 determines ignition timing and fuel injection timing on the basis of the detection information from the sensors, and makes the engine 1 operate by drive-controlling the spark plugs 2 and fuel injection valves 3 on the basis of determined control quantities. When the conditions set for fuel cut, such that the vehicle is being decelerated with an accelerator deactivated and that the vehicle speed is greater than or equal to a determined value, are satisfied, the ECU 21 stops fuel injection by performing a fuel cut, and when the conditions set for fuel recovery, such that the accelerator is activated, are satisfied, the ECU 21 resumes fuel injection.

As stated under the subheading “Description of the Related Art”, in the fuel cut period and the fuel recovery period, the catalyst temperature T_catf is difficult to estimate due to a rapid rise in temperature in the underfloor catalytic converter 9, which necessarily makes it difficult to appropriately perform engine control on the basis of the catalyst temperature T_catf in order to suppress a rise in temperature. Thus, in the present embodiment, temperature estimation for the underfloor catalytic converter 9 is performed taking account of reaction heat produced in the fuel cut period and the fuel recovery period. This temperature estimation will be described below in detail.

Prior to entering the description of the temperature estimation, reactions taking place on the catalyst in the fuel cut period and the fuel recovery period and the influences of those reactions on the catalyst temperature T_catf will be described.

As in the other operating states, also in the fuel cut period and the fuel recovery period, the rise in catalyst temperature basically depends on heat transfer ΔH_t between the exhaust gases and the catalyst 9. Thus, the estimation of the catalyst temperature T_carf needs to take account of the heat transfer ΔH_t. In the fuel cut period, in addition to the rise in catalyst temperature due to the heat transfer ΔH_t, the catalyst temperature T_catf rises due to reaction heat produced when CO and HC that were adsorbed onto the catalyst 9 before the fuel cut (both are unburnt fuel components; Note that in the description below, to represent both of these CO and HC, the term “CO” will be used representatively) are oxidized by O₂ in the exhaust gases. Thus, the estimation of the catalyst temperature T_carf needs to take account of this oxidation reaction heat ΔH_r.

Meanwhile, in the fuel recovery period, the catalyst temperature T_catf rises due to reaction heat produced when CO and HC in the exhaust gases (both are unburnt fuel components; Note that in the description below, to represent both of these CO and HC, the term “CO” will be used representatively) are converted by O₂ that was adsorbed onto the catalyst 9 during the fuel cut. Thus, the estimation of the catalyst temperature T_carf needs to take account of this conversion reaction heat ΔH_c. Accordingly, as will be described below, in the fuel cut period, the catalyst temperature T_catf is estimated taking account of the oxidation reaction heat ΔH_r in addition to the heat transfer ΔH_t between the exhaust gases and the catalyst 9, and in the fuel recovery period, the catalyst temperature T_catf is estimated taking account of the conversion reaction heat ΔH_c in addition to the heat transfer ΔH_t.

First, the calculation of the CO oxidation reaction heat ΔH_r in the fuel cut period will be described.

FIG. 2 is a control block diagram showing the processing performed by a fuel-cut-period reaction heat calculation section 50 of the ECU 21. In the fuel cut period, a phenomenon that CO is desorbed from the catalyst through reaction with O₂ in the exhaust gases and a phenomenon that CO is adsorbed onto the catalyst take place in parallel. Both phenomena together affect the CO adsorption ratio θco of the catalyst 9, and therefore the oxidation reaction heat ΔH_r in the fuel cut period. Thus, in the calculation of the CO oxidation reaction heat ΔH_r, the adsorbed CO quantity CATco, namely the amount of CO adsorbed on the catalyst 9 is calculated taking account of the desorption of CO from the catalyst and the adsorption of CO onto the catalyst, and the CO oxidation reaction heat ΔH_r is calculated taking account of this adsorbed CO quantity CATco.

In FIG. 2, a desorption constant calculation section 51 of the fuel-cut-period reaction heat calculation section 50 obtains a desorption rate constant K_red, referring to a map prepared in advance, on the basis of the catalyst temperature T_catf estimated in the last processing cycle. The desorption rate R_red at which CO is desorbed from the catalyst varies depending on the activated state of the catalyst 9. Thus, the desorption rate constant K_red is determined depending on the catalyst temperature T_catf which correlates with the activated state.

An adsorption constant calculation section 52 obtains an adsorption rate constant K_ad, referring to a map prepared in advance, on the basis of the catalyst temperature T_catf and the exhaust air-fuel ratio A/F detected by the air-fuel ratio sensor 10. The adsorption rate R_ad at which CO is adsorbed onto the catalyst 9 is affected by not only the activated state of the catalyst 9 but also the composition of the exhaust gases which varies depending on the exhaust air-fuel ratio A/F. Thus, the adsorption rate constant K_ad is determined depending on the catalyst temperature T_catf and the exhaust air-fuel ratio A/F. It is to be noted that the exhaust air-fuel ratio A/F may be estimated from the engine operating state, etc., according to a known estimation method.

An adsorption sites calculation section 53 obtains the number ρco (mol) of all the adsorption sites of the catalyst 9 capable of adsorbing CO, referring to a map prepared in advance, on the basis of the catalyst temperature T_catf. The number ρco of the adsorption sites is proper to the catalyst but varies depending on the activated state of the catalyst 9. Thus, the number ρco of the adsorption sites is determined depending on the catalyst temperature T_catf which correlates with the activated state.

A CO concentration calculation section 54 determines CO concentration Pco (atm) in the exhaust gases, referring to a map prepared in advance, on the basis of the exhaust air-fuel ratio A/F. Since the CO concentration Pco correlates with the exhaust air-fuel ratio A/F, the CO concentration Pco is determined depending on the exhaust air-fuel ratio A/F.

Meanwhile, in the calculation of the oxidation reaction heat ΔH_r in the last processing cycle, the CO adsorption ratio θco of the catalyst 9 has been calculated, and between the CO adsorption ratio θco and the number ρco of the adsorption sites, there exists a relationship expressed by the equation (1) below:

θco=rρco/ρco  (1)

where rρco is the number of the adsorption sites of the catalyst 9 at which CO is really adsorbed.

The CO adsorption ratio θco, the desorption rate constant K_red calculated by the desorption constant calculation section 51, and the number ρco of the adsorption sites calculated by the adsorption sites calculation section 53 are fed to a desorption rate calculation section 55. Using these input values, the desorption rate calculation section 55 calculates the CO desorption rate R_red (mol/sec) at which CO is desorbed from the catalyst, according to the equation (2) below (desorption rate calculation element):

R _red =K _red ·ρco·θco  (2)

The CO adsorption ratio θco is also fed to a subtraction section 56, and the subtraction section 56 subtracts the CO adsorption ratio θco from 1 (1−θco). The value obtained by the subtraction section 56, the adsorption rate constant K_ad calculated by the adsorption rate constant calculation section 52, the number ρco of the adsorption sites calculated by the adsorption sites calculation section 53, and the CO concentration Pco calculated by the CO concentration calculation section 54 are fed to an adsorption rate calculation section 57, and using these input values, the adsorption rate calculation section 57 calculates the CO adsorption rate R_ad (mol/sec) at which CO is adsorbed onto the catalyst, according to the equation (3) below (adsorption rate calculation element):

R _ad =K _ad ·ρco·(1−θco)·Pco  (3)

Further, the CO concentration Pco calculated by the CO concentration calculation section 54, total pressure 1 (atm), and the total substance quantity per unit time n_all (mol/sec) of the exhaust gases, namely the amount of all the substances in the exhaust gases in unit time are fed to a partial pressure calculation section 58, and the partial pressure calculation section 58 calculates the exhaust CO quantity GASco (mol/sec), namely the amount of CO in the exhaust gases, in terms of partial pressure, according to the equation (4) below. It is to be noted that the total substance quantity per unit time n_all of the exhaust gases is calculated according to a known calculation method, from the intake quantity Q, the amount of air and of fuel in terms of mole, the exhaust air-fuel ratio A/F, etc., of which the detailed explanation will be omitted.

GASco=Pco/1·n_all  (4)

The CO adsorption rate R_ad on the catalyst and the exhaust CO quantity GASco are fed to a minimum-value selection section 59, and the minimum-value selection section 59 chooses a smaller one of these input values, thereby determining the definitive CO adsorption rate R_ad on the catalyst. Specifically, the CO adsorption rate R_ad represents the capacity of the catalyst 9 to adsorb CO. When the exhaust CO quantity GASco is greater than or equal to the CO adsorption rate R_ad, CO is actually adsorbed onto the catalyst at the CO adsorption rate R_ad. When the exhaust CO quantity GASco is less than the CO adsorption rate R_ad, the rate at which CO is actually adsorbed onto the catalyst is limited to the exhaust CO quantity GASco. For this reason, the minimum-value selection section 59 chooses a smaller one of the input values.

The CO desorption rate R_red calculated by the desorption rate calculation section 55 and the CO adsorption rate R_ad on the catalyst definitively determined by the minimum-value selection section 59 are fed to an adsorbed-CO-quantity-per-unit-time calculation section 60, and the adsorbed-CO-quantity-per-unit-time calculation section 60 calculates the adsorbed CO quantity per unit time Δadθco, namely the amount of CO adsorbed onto the catalyst 9 in unit time, according to the equation (5) below:

Δadθco=R_ad−R_red  (5)

The adsorbed CO quantity per unit time Δadθco thus calculated, the number ρco of the adsorption sites of the catalyst 9, and the processing period f of the ECU 21 (0.1 msec, for example) are fed to an adsorption-ratio change calculation section 61, and the adsorption-ratio change calculation section 61 calculates a change Δθco in CO adsorption ratio θco in the processing period f, according to the equation (6) below:

Δθco=Δadθco/ρco·f  (6)

The change Δθco in CO adsorption ratio θco and the CO adsorption ratio θco are fed to an adsorption ratio calculation section 62, and the adsorption ratio calculation section 62 takes this CO adsorption ratio θco as a value θco(n−1) in the last processing cycle, and calculates the present CO adsorption ratio θco(n), according to the equation (7) below:

θco(n)=θco(n−1)+Δθco  (7)

Then, the CO adsorption ratio θco(n), the number ρco of the adsorption sites, and the processing period f of the ECU 21 are fed to an adsorbed CO quantity calculation section 63, and the adsorbed CO quantity calculation section 63 calculates the adsorbed CO quantity per unit time (mol/sec) corresponding to the amount of CO adsorbed on the catalyst 9 at present, according to the equation (9) below (adsorbed unburnt-fuel-component quantity calculation element):

CATco=θco(n)·ρco/f  (9)

Meanwhile, an O₂ concentration calculation section 64 obtains O₂ concentration Po₂, referring to a map prepared in advance, on the basis of the exhaust air-fuel ratio A/F. Like the above-mentioned CO concentration Pco, the O₂ concentration Po₂ is determined depending on the exhaust air-fuel ratio A/F, but, for the convenience of substitution in the later-mentioned equation (10) representing the reaction rate, the map is prepared to give the square root Po₂^1/2 of the O₂ concentration Po₂.

A reaction rate constant calculation section 65 obtains a reaction rate constant K_r for the reaction of CO and O₂, referring to a map prepared in advance, on the basis of the catalyst temperature T_catf. Since the rate of reaction of CO and O₂ varies depending on the activated state of the catalyst 9, the reaction rate constant K_r is determined depending on the catalyst temperature T_catf.

The O₂ concentration Po₂^1/2 calculated by the O₂ concentration calculation section 64, the reaction rate constant K_r calculated by the reaction rate constant calculation section 65, the CO adsorption ratio θco and the number ρco of the adsorption sites are fed to a reaction rate calculation section 66, and the reaction rate calculation section 66 calculates the maximum reaction rate r (mol/sec) at which CO and O₂ can react, according to the equation (10) below (reaction rate calculation element):

r=K _r ·ρco·θco(Po₂)^1/2  (10)

Specifically, since the maximum reaction rate r at which CO and O₂ react on the catalyst is determined depending on the product of the CO quantity CATco (=ρco·θco) and the O₂ concentration Po₂, and since the mole ratio of CO to O₂ in the reaction is “2” as seen from the equation (11) below, the above equation (10) includes the O₂ concentration in the form of square root PO₂^1/2.

CO+1/2O₂→CO₂  (11)

The reaction mole ratio “2” determined from the equation (11), the O₂ concentration Po₂^1/2 calculated by the O₂ concentration calculation section 64, total pressure 1 (atm), and the total substance quantity per unit time n_all of the exhaust gases are fed to an exhaust O₂ quantity calculation section 67, and the exhaust O₂ quantity calculation section 67 calculates the exhaust O₂ quantity GASo₂ (mol/sec), namely the amount of O₂ in the exhaust gases, according to the equation (12) below (exhaust O₂ quantity calculation element).

GASo ₂=2·Po₂/1·n_all  (12)

The adsorbed CO quantity CATco on the catalyst calculated by the adsorbed CO quantity calculation section 63, the reaction rate r calculated by the reaction rate calculation section 66, and the exhaust O₂ quantity GASo₂ calculated by the exhaust O₂ quantity calculation section 67 are fed to a minimum-value selection section 68, and the minimum-value selection section 68 chooses the smallest one of these input values, thereby determining the reacting CO quantity R_ct, namely the amount of CO taking part in the reaction. While the quantity of CO reacting with O₂ is basically determined depending on a smaller one of the adsorbed CO quantity CATco and the exhaust O₂ quantity GASo₂, the reaction at a rate higher than the reaction rate r is impossible. Thus, the smallest one of the three quantities including the reaction rate r is chosen as the reacting CO quantity R_ct.

The reacting CO quantity R_ct calculated by the minimum-value selection section 68 and the value of a fuel-cut flag, which is at a ON-value while the fuel cut is being performed on the engine 1, are fed to a fuel-cut determination section 69. When determining that the fuel cut is not being performed from the fuel-cut flag reset to an OFF-value, the fuel-cut determination section 69 chooses “0”, and when determining that the fuel cut is being performed from the fuel-cut flag set to the ON-value, chooses the reacting CO quantity R_ct. The value chosen by the fuel-cut determination section 69, reaction heat produced by fuel (283 kJ/mol, for example), and the processing period f of the ECU 21 are fed to a ΔH_r calculation section 70, and using these input values, the ΔH_r calculation section 70 calculates the CO oxidation reaction heat ΔH_r produced by the CO oxidation reaction on the catalyst (oxidation reaction heat calculation element). Thus, while the fuel cut is not being performed, the fuel-cut-period reaction heat calculation section 50 sends out “0”, and while the fuel cut is being performed, sends out the CO oxidation reaction heat ΔH_r.

The value (R_ct or “0”) chosen by the fuel-cut determination section 69 and the number ρ_co of the adsorption sites are fed to an adsorption-ratio decrease calculation section 71, and using these input values, the adsorption-ratio decrease calculation section 71 calculates a decrease Δ_rθco in adsorption ratio of the catalyst caused by the reaction of CO. The decrease Δ_rθco in adsorption ratio thus calculated and the CO adsorption ratio θco(n) calculated by the adsorption ratio calculation section 62 in the present processing cycle are fed to an adsorption ratio update section 72, and the adsorption ratio update section 72 calculates the latest CO adsorption ratio θco, according to the equation (13) below:

θco=θco(n)−Δ_rθco  (13)

The CO adsorption ratio θco calculated by the adsorption ratio update section 72 is limited by an upper clipping section 73 to the upper limit 1.0, and limited by a lower clipping section 74 to the lower limit 0. The processing by the clipping sections 73 and 74 is provided for an improper CO adsorption ratio θco which may possibly be produced for some reason. The CO adsorption ratio θco after this processing is used in the next processing cycle of the ECU 21.

Next, the calculation of heat transfer ΔH_t (kJ/sec) between the exhaust gases and the catalyst 9 will be described.

FIG. 3 is a control block diagram showing the processing performed by an exhaust-catalyst heat transfer calculation section 80 of the ECU 21. The heat transfer ΔH_t between the exhaust gases and the catalyst 9 depends on temperature difference between the exhaust gases and the catalyst 9, contact area between the exhaust gases and the catalyst 9, and a coefficient of heat transfer. Between these quantities, there exists a relationship expressed by the equation (14) below:

ΔH_t=h·S_v·(T_ex−T_catf)·V_cat  (14)

where S_v is the specific surface area of the catalyst 9, h is a coefficient of heat transfer, T_ex is the temperature of the exhaust gases obtained by estimation, T_catf is the temperature of the catalyst, and V_cat is the volume of the catalyst. It is to be noted that although here, the exhaust gas temperature T_ex is assumed to be obtained by estimation, it may be detected using an exhaust temperature sensor 11 as shown in FIG. 1.

In FIG. 3, a contact area calculation section 81 of the heat transfer calculation section 80 calculates the effective contact area S_cat of the catalyst 9, referring to a map prepared in advance, on the basis of the intake quantity Q. The effective contact area S_cat is the area of the catalyst 9 subjected to contact with the exhaust gases, and corresponds to the product of the specific surface area S_v and the volume V_cat of the catalyst 9 in the equation (14).

A heat transfer coefficient calculation section 82 calculates a heat transfer coefficient h, referring to a map prepared in advance, on the basis of the intake quantity Q and the exhaust gas temperature T_ex. A temperature difference calculation section 83 calculates a difference ΔT between the exhaust gas temperature T_ex and provisional catalyst temperature T_cat (catalyst temperature before subjected to filtering).

The effective contact area S_cat, the heat transfer coefficient h, the temperature difference ΔT, and the processing period f of the ECU 21 are fed to a ΔH_t calculation section 84, and using these quantities together, the ΔH_t calculation section 84 calculates the heat transfer ΔH_t (kJ/sec), according to the equation (14) (heat transfer calculation element).

Next, the calculation of the CO conversion reaction heat ΔH_c, namely the heat produced by the reaction in which CO is converted by O₂ adsorbed on the catalyst 9, in the fuel recovery period.

FIG. 4 is a control block diagram showing the processing performed by a fuel-recovery-period conversion heat calculation section 110 of the ECU 21, and FIG. 5 is a control block diagram showing the processing performed by an O₂ adsorption ratio calculation section 90 of the ECU 21. The CO conversion reaction heat ΔH_c, namely the heat produced by the conversion of CO on the catalyst depends on the operating state of the engine 1, specifically, engine revolving rate Ne, charging efficiency Ec, and air-fuel ratio on the catalyst, and can be determined from these quantities. For the air-fuel ratio on the catalyst, basically the exhaust air-fuel ratio A/F can be used, while the air-fuel ratio on the catalyst is affected by the O₂ storage function of the catalyst 9, which needs consideration. Specifically, the catalyst 9 has a function of maintaining the exhaust air-fuel ratio A/F at the stoichiometric air-fuel ratio (=14.7), by adsorbing O₂ at lean exhaust air-fuel ratios and desorbing O₂ at rich exhaust air-fuel ratios. Thus, when the catalyst is exhibiting this O₂ storage function, the air-fuel ratio on the catalyst is maintained at the stoichiometric, although the exhaust air-fuel ratio A/F is not the stoichiometric. Meanwhile, when the catalyst is not exhibiting the O₂ storage function, the air-fuel ratio on the catalyst equals the exhaust air-fuel ratio A/F.

Thus, in the calculation of the CO conversion reaction heat ΔH_c, the O₂ adsorption ratio θo₂ which correlates with the O₂ storage function of the catalyst 9 is calculated, and the calculated O₂ adsorption ratio θo₂ is used to calculate the CO conversion reaction heat ΔH_c (kJ/sec). First, the calculation of the O₂ adsorption ratio θo₂ will be described.

Like the behavior of CO on the catalyst in the fuel cut period, in the fuel recovery period, a phenomenon that O₂ is desorbed from the catalyst through reaction with CO in the exhaust gases and a phenomenon that O₂ in the exhaust gases is adsorbed onto the catalyst take place in parallel. Both phenomena together affect the O₂ adsorption ratio θo₂ of the catalyst 9, and therefore the CO conversion reaction heat ΔH_c in the fuel recovery period. Thus, in the calculation of the CO conversion reaction heat ΔH_c, the adsorbed O₂ quantity, namely the amount of O₂ adsorbed on the catalyst 9 is calculated taking account of the desorption of O₂ from the catalyst and the adsorption Of O₂ onto the catalyst, and the CO conversion reaction heat ΔH_c is calculated taking account of this adsorbed O₂ quantity.

In FIG. 5, an adsorption sites calculation section 91 of an O₂ adsorption ratio calculation section 90 obtains the number ρo₂ (mol) of all the adsorption sites of the catalyst 9 capable of adsorbing O₂, referring to a map prepared in advance, on the basis of the catalyst temperature T_catf. As in the case of the CO adsorption sites, the number ρo₂ of the adsorption sites is proper to the catalyst but varies depending on the activated state of the catalyst 9. Thus, the number ρo₂ of the adsorption sites is determined depending on the catalyst temperature T_catf which correlates with the activated state. Between the number ρo₂ of the adsorption sites and the O₂ adsorption ratio θo₂, there exists a relationship expressed by the equation (15) below:

θo₂=rρo₂/ρo₂  (15)

where rρo₂ is the number of the adsorption sites of the catalyst 9 at which O₂ is really adsorbed.

The number ρo₂ of the adsorption sites calculated by the adsorption sites calculation section 91 and the O₂ adsorption ratio θo₂ in the last processing cycle are fed to an O₂ desorption capacity calculation section 92, and using these input values, the O₂ desorption capacity calculation section 92 calculates the present O₂ desorption capacity C_red (mol) of the catalyst 9, according to the equation (16) below:

C _red =ρo ₂ ·θo ₂·(−1)  (16)

It is to be noted that in the equation (16), the O₂ desorption capacity C_red is obtained as a negative value by multiplying −1, considering that the desorption of O₂ decreases the O₂ adsorption ratio θo₂.

A subtraction section 93 subtracts the O₂ adsorption ratio θo₂ from 1 (1−θo₂). The value obtained by the subtraction and the number ρo₂ of the adsorption sites calculated by the adsorption sites calculation section 91 are fed to an O₂ adsorption capacity calculation section 94, and using these input values, the O₂ adsorption capacity calculation section 94 calculates the present O₂ adsorption capacity C_ad(mol) of the catalyst 9, according to the equation (17) below:

C _ad=ρo₂·(1−θo₂)  (17)

Meanwhile, an O₂ excess/deficiency calculation section 95 obtains O₂ excess/deficiency ΔO₂ (vol %) in the exhaust gases, referring to a map prepared in advance, on the basis of the exhaust air-fuel ratio A/F. The O₂ excess/deficiency ΔO₂ means the amount by which O₂ exceeds or falls below the stoichiometric quantity, and is determined depending on the exhaust air-fuel ratio A/F. The O₂ excess/deficiency ΔO₂ thus obtained and the total substance quantity per unit time nail (mol/sec) of the exhaust gases are fed to a conversion section 96, and the conversion section 96 converts the O₂ excess/deficiency ΔO₂ to the quantity per unit time (mol/sec).

To an O₂ expenditure calculation section 97, the reacting CO quantity R_ct (mol/sec) from the fuel-cut determination section 69 of the fuel-cut-period reaction heat calculation section 50 and the mole ratio “2” between CO and O₂ in the reaction are fed, and using these input values, the O₂ expenditure calculation section 97 calculates the O₂ expenditure expΔO₂ in the exhaust gases, namely the amount of O₂ in the exhaust gases which was consumed in the reaction with CO on the catalyst during the fuel cut, according to the equation (18) below:

expΔO₂=R_ct/2  (18)

To a subtraction section 98, the O₂ excess/deficiency ΔO₂ after the conversion by the conversion section 96, and the O₂ expenditure expΔO₂ calculated by the O₂ expenditure calculation section 97 are fed, and the subtraction section 98 calculates the stoichometric required O₂ quantity Δado₂, which means the amount per unit time of O₂ required to make the composition of the exhaust gases stoichiometric (or in other words, to completely convert CO in the exhaust gases), according to the equation (19) below. Specifically, when the exhaust air-fuel ratio A/F is rich so that CO in the exhaust gases needs to be oxidized by O₂, the stoichometric required O₂ quantity Δado₂ to be calculated is the amount of O₂ which needs to be desorbed from the catalyst (negative value), and when the exhaust air-fuel ratio A/F is lean so that excess O₂ needs to be adsorbed, the stoichometric required O₂ quantity Δado₂ to be calculated is the amount of O₂ which needs to be adsorbed onto the catalyst (positive value). The stoichometric required O₂ quantity Δado₂ thus calculated is fed to a conversion section 99 and converted to the quantity Δadθo₂ in the processing period f, according to the equation (20) below.

Δado₂=ΔO₂−expΔO₂  (19)

Δadθo₂=Δado₂·f  (20)

The stoichometric required O₂ quantity Δadθo₂ after the conversion, the O₂ desorption capacity C_red and the O₂ adsorption capacity C_ad of the catalyst 9, and the exhaust air-fuel ratio A/F are fed to an O₂ desorption/adsorption quantity calculation section 100. When the exhaust air-fuel ratio is rich, namely richer than the stoichiometric air-fuel ratio, so that it is inferred that O₂ is being desorbed from the catalyst, the O₂ desorption/adsorption quantity calculation section 100 chooses a greater quantity between the O₂ desorption capacity C_red and the stoichometric required O₂ quantity Δadθo₂ (namely, the quantity having a smaller absolute value, since both quantities are negative). When the exhaust air-fuel ratio A/F is lean, namely leaner than the stoichiometric air-fuel ratio, so that it is inferred that O₂ is being adsorbed onto the catalyst, the O₂ desorption/adsorption quantity calculation section 100 chooses a smaller quantity between the O₂ adsorption capacity C_ad and the stoichometric required O₂ quantity Δadθo₂.

Specifically, when the O₂ quantity required to make the composition of the exhaust gases stoichiometric (Δadθo₂) exceeds the capacity (C_red, C_ad) of the catalyst, the amount of O₂ actually used is limited to the capacity of the catalyst. Meanwhile, when the capacity (C_red, C_ad) of the catalyst exceeds the O₂ quantity required to make the composition of the exhaust gases stoichiometric (Δadθo₂), the amount of O₂ actually used is the required O₂ quantity. The processing of the O₂ desorption/adsorption quantity calculation section 100 is provided in view of this.

The value chosen by the O₂ desorption/adsorption quantity calculation section 100 (C_red or C_ad or Δadθo₂) and the number ρo₂ of the adsorption sites are fed to an adsorption-ratio decrease calculation section 101, and using these input values, the adsorption-ratio decrease calculation section 101 calculates a decrease Δrθo₂ in adsorption ratio of the catalyst caused by the reaction of O₂. The decrease Δrθo₂ in adsorption ratio thus calculated and the O₂ adsorption ratio θo₂ in the last processing cycle are fed to an adsorption ratio update section 102, and the adsorption ratio update section 102 calculates the latest O₂ adsorption ratio θO₂ according to the equation (21) below (O₂ storage index calculation element)

θO₂=θO₂+Δrθo₂  (21)

The O₂ adsorption ratio θO₂ calculated by the adsorption ratio update section 102 is limited by an upper clipping section 103 to the upper limit 1.0, and limited by a lower clipping section 104 to the lower limit 0.

The O₂ adsorption ratio θO₂ of the catalyst 9 calculated in the above-described manner is fed to an air-fuel ratio determination section 111 of the fuel-recovery-period conversion heat calculation section 110 shown in FIG. 4. When determining that the catalyst 9 is not exhibiting the O₂ storage function from the O₂ adsorption ratio θO₂ being 0 (O₂ desorption limit) or 1.0 (O₂ adsorption limit), the air-fuel ratio determination section 111 chooses the exhaust air-fuel ratio A/F for the air-fuel ratio on the catalyst (air-fuel ratio estimation element). When determining that the catalyst 9 is exhibiting the O₂ storage function from the O₂ adsorption ratio θO₂ satisfying the condition 0<θo₂<1.0, the air-fuel ratio determination section 111 chooses the stoichometric air-fuel ratio for the air-fuel ratio on the catalyst (air-fuel ratio estimation element).

The air-fuel ratio on the catalyst determined by the air-fuel ratio determination section 111, the engine revolving rate Ne detected by the revolving rate sensor 23 (operating state detection element) and the charging efficiency Ec calculated on the basis of the operating state of the engine 1 (operating state detection element) are fed to a ΔH_c calculation section 112, and the ΔH_c calculation section 112 calculates the CO conversion reaction heat per unit time ΔH_c (kJ/sec), referring to a map prepared in advance, on the basis of the engine revolving rate Ne, the charging efficiency Ec and the air-fuel ratio on the catalyst (conversion reaction heat calculation element).

The CO conversion reaction heat ΔH_c thus calculated and the value of the fuel-cut flag are fed to a fuel-cut determination section 113. When determining that the fuel cut is not being performed from the fuel-cut flag reset to the OFF-value, the fuel-cut determination section 113 chooses the CO conversion reaction heat ΔH_c, and when determining that the fuel cut is being performed from the fuel-cut flag set to the ON-value, the fuel-cut determination section 113 chooses “0”. The value chosen by the fuel-cut determination section 113 and the processing period f of the ECU 21 are fed to a period conversion section 114, and using these input values, the period conversion section 114 calculates the CO conversion reaction heat ΔH_c (kJ) in the processing period f. Thus, while the fuel cut is not being performed, the fuel-recovery-period conversion heat calculation section 110 sends out the CO conversion reaction heat ΔH_c, and while the fuel cut is being performed, sends out “0”.

Next, the estimation of the definitive catalyst temperature T_catf will be described.

FIG. 6 is a control block diagram showing how the processing by a catalyst temperature estimation section 120 of the ECU 21 goes on. The CO oxidation reaction heat ΔH_r in the fuel cut period calculated by the fuel-cut-period reaction heat calculation section 50, the CO conversion reaction heat ΔH_c in the fuel recovery period calculated by the fuel-recovery-period reaction heat calculation section 110, the heat transfer ΔH_t between the exhaust gases and the catalyst calculated by the heat transfer calculation section 80 are fed to a total heat calculation section 121. As stated above, in the fuel cut period, the CO oxidation reaction heat ΔH_r and the exhaust-catalyst heat transfer ΔH_t are calculated as effective values, while in the fuel recovery period, the CO conversion reaction heat ΔH_c and the exhaust-catalyst heat transfer ΔH_t are calculated as effective values. Thus, in either case, the total heat calculation section 121 sums the two effective values, thereby obtaining total heat ΣH that causes a rise in catalyst temperature.

The total heat ΣH thus calculated is fed to a temperature rise calculation section 122, which calculates a temperature rise ΔT of the catalyst 9 from the total heat ΣH and the heat capacity of the catalyst 9 set in advance, and feeds it to a catalyst temperature calculation section 123. The catalyst temperature calculation section 123 calculates provisional catalyst temperature T_cat in the present processing cycle, by adding the temperature rise ΔT to the provisional catalyst temperature T_cat (catalyst temperature before subjected to the filtering described below) in the last processing cycle. The provisional catalyst temperature T_cat thus calculated is stored for use as a previous value in the next processing cycle, and on the basis of this provisional catalyst temperature T_cat, definitive catalyst temperature T_catf is calculated by a three-stage filter simulating thermal conduction in the catalyst (catalyst temperature estimation element).

A gain calculation section 124 of the three-stage filter sets a filter gain K_ca, referring to a map prepared in advance, on the basis of the intake quantity Q. As shown in FIG. 6, filter gain K_ca increases with intake quantity Q. The filter gain K_ca thus set and the provisional catalyst temperature T_cat are fed to a first filter section 125. On the basis of the provisional catalyst temperature T_cat, the filter gain K_ca, and first catalyst temperature cell T_f1 (catalyst temperature after first filtering) in the last processing cycle, the first filter section 125 calculates first catalyst temperature cell T_f1 in the present processing cycle, and the first catalyst temperature cell T_f1 thus calculated is stored and also sent to a second filter section 126.

The second filter section 126 calculates second catalyst temperature cell T_f2 in the present processing cycle, on the basis of the first catalyst temperature cell T_f1, the filter gain K_ca, and second catalyst temperature cell T_f2 (catalyst temperature after second filtering) in the last processing cycle, and the second catalyst temperature cell T_f2 thus calculated is stored and also sent to a third filter section 127.

The third filter section 127 calculates third catalyst temperature cell T_f3 in the present processing cycle, on the basis of the second catalyst temperature cell T_f2, the filter gain K_ca, and third catalyst temperature cell T_f3 (catalyst temperature after third filtering) in the last processing cycle, and the third catalyst temperature cell T_f3 thus calculated is stored and also sent out as the definitive catalyst temperature T_catf. When the intake quantity Q is greater and therefore the filter gain K_ca is greater, the filter sections 125 to 127 each produces an output value less affected by a previous value and more affected by a current value. Consequently, the definitive catalyst temperature T_catf taking account of the thermal conduction in the catalyst which correlates with the intake quantity Q is calculated.

As explained above, the present embodiment of the catalyst temperature estimation device calculates, in the fuel cut period, the CO oxidation reaction heat ΔH_r produced when CO adsorbed on the catalyst in the quantity CATco reacts with O₂ existing in the exhaust gases in the quantity GASo₂, and estimates the temperature of the catalyst of the underfloor catalytic converter 9 on the basis of this CO oxidation reaction heat ΔH_r and the exhaust-catalyst heat transfer ΔH_t. Meanwhile, in the fuel recovery period, it calculates the CO conversion reaction heat ΔH_c produced when CO in the exhaust gases is converted by O₂ adsorbed on the catalyst, and estimates the temperature of the catalyst of the underfloor catalytic converter 9 on the basis of this CO conversion reaction heat ΔH_c and the heat transfer ΔH_t. Thus, in either of the fuel cut period and the fuel recovery period, the movements of the catalyst temperature T_catf can be estimated accurately. By appropriately performing engine control on the basis of this catalyst temperature T_catf, the catalytic converter 9 can be prevented from being damaged by a temperature rise beyond the allowable temperature limit.

FIG. 7 is a test result showing how the catalyst temperature is estimated by the present invention and by the conventional technique, when the fuel cut and fuel recovery is repeated with a short period. Such operating state can be produced when the driver repeats activation and deactivation of the accelerator frequently. Due to the CO oxidation reaction heat ΔH_r produced in the fuel cut period and the CO conversion reaction heat ΔH_c produced in the fuel recovery period, the actual catalyst temperature rises rapidly compared with the exhaust gas temperature T_ex. The values estimated by the conventional technique hardly reflect this temperature rise. Meanwhile, by the estimation method of the present embodiment, estimated values T_catf extremely close to the actual catalyst temperature are obtained. This test result confirms the positive effects of the present invention.

Further, the present embodiment of the catalyst temperature estimation device calculates the amount CATco of CO adsorbed on the catalyst 9 at present, on the basis of the CO desorption rate R_red at which CO is desorbed from the catalyst and the CO adsorption rate R_ad at which CO is adsorbed onto the catalyst, which rates are obtained according to the actual process. In addition, when the amount GASco of CO in the exhaust gases is less than the CO adsorption rate R_ad on the catalyst so that the CO adsorption rate R_ad is limited to the CO quantity GASco, the CO quantity GASco is chosen for the CO adsorption rate R_ad. This allows the adsorbed CO quantity CATco and therefore the CO oxidation reaction heat ΔH_r to be calculated with improved accuracy.

Further, the calculation of the CO oxidation reaction heat ΔH_r takes account of not only the amount CATco of CO adsorbed on the catalyst and the amount GASo₂ of O₂ in the exhaust gases, but also the rate r of reaction of CO and O₂. This allows the CO oxidation reaction heat ΔH_r to be calculated with more improved accuracy.

In the above, an embodiment of the present invention has been described. The present invention is, however, not limited to the described embodiment. For example, although in the above embodiment, the catalyst temperature T_carf is estimated in both the fuel cut period and the fuel recovery period, the estimation of the catalyst temperature T_carf in the fuel recovery period is not indispensable. For example, the embodiment may be modified to estimate the catalyst temperature T_carf only in the fuel cut period, on the basis the CO oxidation reaction heat ΔH_r. Further, although in the described embodiment, the engine 1 is a direct-injection spark-ignition four-cylinder-in-line gasoline engine, the present invention is not limited to this type of engine; the present invention is applicable to that type of gasoline engine in which fuel is supplied to the intake ports, and also to the diesel engine.

Claims

1. A catalyst temperature estimation device, comprising: a catalytic converter carrying a catalyst disposed in an exhaust passage of an engine for converting exhaust gases to less harmful substances,an adsorbed unburnt-fuel-component quantity calculation element for calculating the amount of an unburnt fuel component adsorbed on the catalyst in a fuel cut period of the engine,an exhaust O2 quantity calculation element for calculating the amount of O2 in the exhaust gases in the fuel cut period,an oxidation reaction heat calculation element for calculating reaction heat produced when the absorbed unburnt fuel component in the amount calculated by the adsorbed unburnt-fuel-component quantity calculation element reacts with O2 in the exhaust gases in the amount calculated by the exhaust O2 quantity calculation element, anda catalyst temperature estimation element for estimating the temperature of the catalyst in the fuel cut period, on the basis of the reaction heat calculated by the oxidation reaction heat calculation element.

2. The catalyst temperature estimation device according to claim 1, further comprising a heat transfer calculation element for calculating heat transfer between the exhaust gases from the engine and the catalyst in the fuel cut period, whereinthe catalyst temperature estimation element estimates the temperature of the catalyst from the heat transfer calculated by the heat transfer calculation element and the reaction heat calculated by the heat transfer calculation element.

3. The catalyst temperature estimation device according to claim 1, further comprising an operating state detection element for detecting the operating state of the engine,an O2 storage index calculation element for calculating an O2 storage index correlating with the amount of O2 adsorbed on the catalyst,an air-fuel ratio estimation element for estimating air-fuel ratio on the catalyst, anda conversion reaction heat calculation element for calculating reaction heat produced by a conversion reaction on the catalyst in a fuel recovery period of the engine, on the basis of the operating state of the engine detected by the operating state detection element, the O2 storage index calculated by the O2 storage index calculation element, and the air-fuel ratio estimated by the air-fuel ratio estimation element, whereinthe catalyst temperature estimation element estimates the temperature of the catalyst in the fuel cut period on the basis of the reaction heat calculated by the oxidation reaction heat calculation element, and in the fuel recovery period on the basis of the reaction heat calculated by the conversion reaction heat calculation element.

4. The catalyst temperature estimation device according to claim 3, wherein when, from the O2 storage index calculated by the O2 storage index calculation element, determining that the catalyst is at a level close to the upper or lower limit of O2 adsorption, the air-fuel ratio estimation element determines that the air-fuel ratio on the catalyst equals the exhaust air-fuel ratio detected by an exhaust air-fuel ratio detection element, and when determining that the catalyst is not at a level close to the upper or lower limit of adsorption, determines that the air-fuel ratio on the catalyst is the stoichiometric air-fuel ratio.

5. The catalyst temperature estimation device according to claim 1, further comprising an adsorption rate calculation element for calculating the adsorption rate at which the unburnt fuel component is adsorbed onto the catalyst in the fuel cut period, anda desorption rate calculation element for calculating the desorption rate at which the unburnt fuel component is desorbed from the catalyst in the fuel cut period, whereinthe adsorbed unburnt-fuel-component quantity calculation element calculates the amount of the unburnt fuel component adsorbed on the catalyst, on the basis of the adsorption rate calculated by the adsorption rate calculation element and the desorption rate calculated by the desorption rate calculation element.

6. The catalyst temperature estimation device according to claim 5, wherein when the amount of the unburnt fuel component in the exhaust gases is less than the calculated adsorption rate of the unburnt fuel component, the adsorption rate calculation element determines that the adsorption rate equals the amount of the unburnt fuel component in the exhaust gases.

7. The catalyst temperature estimation device according to claim 1, further comprising a reaction rate calculation element for calculating the reaction rate at which the unburnt fuel component on the catalyst reacts with O2 in the exhaust gases, on the basis of the activated state of the catalyst, whereinthe oxidation reaction heat calculation element calculates the reaction heat on the basis of the smallest one of the amount of the unburnt fuel component adsorbed, the amount of O2 in the exhaust gases, and the reaction rate calculated.

8. The catalyst temperature estimation device according to claim 1, wherein the catalyst temperature estimation element corrects the estimated temperature of the catalyst, by means of a three-stage filter simulating thermal conduction in the catalyst.