The present disclosure relates generally to controlling a gaseous fuel internal combustion engine, and relates more particularly to limiting an error in tracking a desired state of an operating parameter of the engine dependent upon a fueling rate.
Gaseous fuel internal combustion engines are well known and widely used. Example applications include powering mobile machinery, electrical power generation, and driving pumps, compressors and the like. In recent years, gaseous fuel internal combustion engines have seen increasing application in environments where a supply of combustible gaseous fuel is readily available on-site, whereas conventional liquid fuels are more expensive or generally unavailable. Natural gas fields, pipeline stations and landfills are notable among such environments.
Many of the operating characteristics of gaseous fuel engines find analogy in liquid fuel engines. In general terms, a gaseous fuel is delivered to a combustion cylinder of the engine where it is ignited, commonly via a sparkplug or combustion of a pilot fuel, to combust with air and thus drive motion of a piston to rotate an engine crankshaft, in much the same way that liquid fuel engines operate. All things being equal, an amount of the gaseous fuel combusted in each engine cycle determines a power output and often a speed of rotation of the engine.
In one class of gaseous fuel internal combustion engines, the amount of fuel combusted per engine cycle is determined by injecting the gaseous fuel directly into the combustion cylinders, or into an intake conduit upstream, similar to the manner in which fuel injected liquid fuel engines work. In another class of gaseous fuel engines, rather than attempting to inject a measured quantity of gaseous fuel, the fuel is supplied to an intake conduit of the engine at a pressure greater than an intake air pressure, and enters the intake conduit by way of an admission valve. In both general types of systems, a common rail may be employed which contains the gaseous fuel at some pressure and feeds the gaseous fuel injectors or admission valves, as the case may be. The operating characteristics of these two general engine types may nevertheless be different, as are the problems likely encountered by engineers seeking to improve or tailor the functioning of such engines to various ends such as an emissions profile. U.S. Pat. No. 6,226,981 to Bruch et al. is directed to an air to fuel ratio control for gas engine and method of operation. In Bruch et al., a fuel system has exhaust gas monitors for signals related to exhaust gas mass flow, and an air to fuel controller that apparently adjusts the intake of gaseous fuel to maintain a desired level of exhaust gas mass flow. Bruch et al. note that variation in fuel composition may result in undesirably high emissions of certain types.
In one aspect, a method of controlling a gaseous fuel internal combustion engine is provided, where a fueling rate is determined by a pressure drop from a gaseous fuel common rail to an intake conduit configured to convey a mixture of gaseous fuel and air to a plurality of combustion cylinders in the engine. The method includes receiving a signal indicative of a desired state of an operating parameter of the engine dependent upon the fueling rate, and tracking the desired state at least in part by adjusting the pressure drop such that the fueling rate is adjusted toward a fueling rate accordant a with desired state. The method further includes limiting an error in the tracking at least in part by executing the adjustment of the pressure drop responsive to a disturbance to a fluid pressure within the intake conduit.
In another aspect, a gaseous fuel internal combustion engine system includes an engine having an engine housing and an intake conduit configured to convey a mixture of air and gaseous fuel to a plurality of cylinders formed in the engine housing. The engine further includes a common rail configured to deliver the gaseous fuel to the intake conduit at a fueling rate dependent upon a pressure drop from the common rail to the intake conduit, and a pressure control mechanism for the common rail. The engine system further includes an electronic controller configured to receive a signal indicative of a desired state of an operating parameter of the engine dependent upon the fueling rate. The electronic controller is in control communication with the pressure control mechanism, and configured to track the desired state of the operating parameter at least in part by adjusting the pressure drop via a control command to the pressure control mechanism, such that the fueling rate is adjusted toward a fueling rate accordant with the desired state. The electronic controller is further configured to limit an error in the tracking at least in part by determining the control command responsive to a disturbance to a fluid pressure within the intake conduit.
In still another aspect, an engine control system for a gaseous fuel internal combustion engine includes a pressure control mechanism configured to control a pressure of gaseous fuel within a common rail configured to deliver the gaseous fuel to an intake conduit of the engine at a fueling rate dependent upon a pressure drop from the common rail to the intake conduit. The control system further includes an electronic controller configured to receive a signal indicative of a desired state of an operating parameter of the engine dependent upon the fueling rate. The electronic controller is in control communication with the pressure control mechanism, and configured to track the desired state of the operating parameter at least in part by adjusting the pressure drop via a control command to the pressure control mechanism, such that the fueling rate is adjusted toward a fueling rate accordant with the desired state. The electronic controller is further configured to limit an error in the tracking at least in part by determining the control command responsive to a disturbance to a fluid pressure within the intake conduit.
Referring to
Engine 12 may further include an intake valve 24 configured to connect intake conduit 16 with cylinder 18, and an exhaust valve 26 configured to connect cylinder 18 with an exhaust manifold 38. Each of intake valve 24 and exhaust valve 26 may be cam-actuated in a practical implementation strategy. Engine 12 may further include a pre-combustion chamber 28 formed in engine housing 14 and having a sparkplug 30 positioned at least partially therein. Pre-combustion chamber 28 may receive gaseous fuel from common rail 20, which is spark-ignited to subsequently ignite a main charge of gaseous fuel and air within cylinder 18.
As noted above, intake conduit 16 conveys a mixture of air and gaseous fuel to cylinder 18 and such other cylinders as might be formed in engine housing 14, which mixture is ignited via one of the plurality of sparkplugs associated with each of a plurality of pre-combustion chambers. As also noted above, a fueling rate of engine 12 may depend upon a pressure drop from common rail 20 to intake conduit 16. In one embodiment, the gaseous fuel from common rail 20 may pass through a flow restriction orifice 62, thenceforth to an inlet port 37 in intake conduit 16, by way of an admission valve 34, which may also be cam-actuated.
Engine system 10 may further include a turbocharger 40 having a compressor 42 within intake conduit 16, and a turbine 44 within exhaust conduit 17. An after-cooler 50 may be positioned fluidly between compressor 42 and an intake manifold 36. Engine system 10 may further include a flow control element positioned within intake conduit 16, exhaust conduit 17, or both. To this end, engine 12 may further include a choke 46, such as a conventional butterfly valve choke, positioned within intake conduit 16 and having an electrical choke actuator 47 operably coupled therewith. Engine 12 may also include a waste gate 48 within a bypass conduit 53 enabling exhaust gases to bypass turbine 44, and having an electrical waste gate actuator 49 coupled therewith. Choke 46 and waste gate 48 can be operated to control an air to fuel ratio in engine system 10 in a manner that will be familiar to those skilled in the art.
It has been discovered that control of air to fuel ratio, such as by way of controlling choke 46 or waste gate 48 or both can induce disturbances in fluid pressure within intake conduit 16. It will be recalled that a fueling rate in engine system 10 is dependent upon a pressure drop from common rail 20 to intake conduit 16. Accordingly, disturbances in fluid pressure within intake conduit 16 could theoretically disturb the fueling rate in engine system 10, in turn affecting the state of one or more operating parameters of engine 10 which are dependent upon the fueling rate. In one embodiment an operating parameter of interest dependent upon the fueling rate which could be perturbed by disturbances in fluid pressure within intake conduit 16 is engine speed. In other instances, an operating parameter so perturbed might be engine output torque. Unless some compensation for the disturbances to fluid pressure within intake conduit 16 is performed, then errors in the operating parameters dependent upon fueling rate can be induced or increased. As will be further apparent from the following description, the present disclosure contemplates a control strategy and control logic which enable tracking a desired state of an operating parameter dependent upon fueling rate in a manner that is decoupled from fluid pressure disturbances within intake conduit 16.
To this end, engine system 10 further includes a control system 51 having an electronic controller 52 including a computer readable memory 54 and a data processor 56. Computer readable memory 54, which may include any suitable volatile or non-volatile memory, stores computer executable program instructions for tracking a desired state of an operating parameter such as engine speed or engine output torque which is dependent upon fueling rate. Data processor 56 is in control communication with mechanism 22 and configured via executing the instructions to track a desired state of the operating parameter at least in part by adjusting the pressure drop from common rail 20 to intake conduit 16. In a practical implementation strategy, electronic controller 52 receives a signal indicative of a desired state of the operating parameter dependent upon fueling rate, and tracks the desired state via outputting a control command to pressure control mechanism 22, such that the fueling rate is adjusted toward a fueling rate accordant with the desired state. As used herein, the term “accordant” should be understood to mean a fueling rate which can be expected at least under controlled conditions to impart the desired state of the operating parameter. For instance, a fueling rate of “x” grams per minute would be accordant with an engine speed of “y” rpm or engine output torque of “z” newton meters. Electronic controller 52 may be further configured to limit an error in the tracking at least in part by determining the control command to be sent to pressure control mechanism 22 responsive to a disturbance to a fluid pressure within intake conduit 16. Another way to understand this capability is that electronic controller 52 can execute an adjustment of the pressure drop from common rail 20 to intake conduit 16 responsive to a disturbance to fluid pressure within intake conduit 16. Such capabilities of engine system 10 will be further understood by way of the subsequent description herein of example operation and engine control.
It will be recalled that choke 46 and/or waste gate 48 may be used to control fluid pressure within intake conduit 16. When choke 46 is wide open, generally a full available pressure of air from compressor 42 is supplied to intake manifold 36. When choke 46 is closed as much as possible, the pressure of intake air supplied to intake manifold 36 will be lower. In the case of waste gate 48, those skilled in the art will appreciate that opening or closing waste gate 48 can vary an amount of exhaust energy applied to turbine 44, and thus affect the speed of rotation of compressor 42, hence also affecting intake air pressure. The control of fluid pressure in intake conduit 16, for purposes of controlling air to fuel ratio or for any other purpose, may be performed by a separate electronic controller 70. Electronic controller 70, which could be understood as or part of a separate air to fuel ratio control system in certain embodiments, includes a computer readable memory 72 and a data processor 74. Processor 74 may be configured to execute computer readable instructions stored on memory 72 to maintain or adjust an air to fuel ratio in engine system 10. In a practical implementation strategy, electronic controller 70 may be in control communication with choke actuator 47 and waste gate actuator 49 to perform appropriate adjustments to choke 46 and actuator 48 to maintain or adjust intake manifold pressure to obtain a desired lean ratio of air to gaseous fuel. Electronic controller 70 may receive data indicative of intake manifold pressure from an intake manifold pressure sensor 64, and can perform this control in a closed loop fashion.
Referring also now to
It will be recalled that the pressure drop from common rail 20 to intake conduit 16 may be a pressure drop across orifice 62, and to this end electronic controller 52 may monitor the pressure drop, or ΔP as mentioned above, via a sensing mechanism 58 including at least one sensor exposed to a fluid pressure of a fuel supply conduit 66 upstream of orifice 62 and a fluid pressure downstream of orifice 62. In a practical implementation strategy, an upstream pressure sensor 59 and a downstream pressure sensor 60 may be used. Pressure sensors 59 and 60 are also shown in a control block in plant 82. Output of pressure sensors 59 and 60 may be processed via a hardware filter in block 106 and an analog to digital converter in block 104. Control system 51 may also include an engine speed sensor 68 shown in plant 82 and also in
Another way to understand the control logic represented in
Referring now to
In a fourth graph 208, there is shown ΔP over time. From time t0 to time t1 ΔP is relatively constant. From time t1 time t2, ΔP increases then sharply decreases at time t2 before bottoming out and beginning to increase again thereafter. In a fifth graph 210, there is shown choke position over time. Choke position is relatively constant from time t0 to time t1, and also relatively constant from time t1 to time t2. At time t2, choke position begins to relatively sharply increase.
The increase in choke position shown at approximately time t2 will tend to cause a disturbance to fluid pressure within intake conduit 16 as discussed herein. Choke 46 might be opened to increase a fluid pressure within intake conduit 16 and thus intake manifold 36, for purposes of air/fuel ratio control. As a result, the drop in ΔP seen at about t2 in graph 208 represents a decreased difference between a pressure of common rail 20 and intake conduit 16 which could be expected to result from the increased fluid pressure.
Electronic controller 52 may meanwhile be tracking desired engine speed. Since an increase in desired engine speed has occurred at time t1, electronic controller 52 may be gradually changing a position of pressure control mechanism/fuel valve 22, for example, to increase a flow area through mechanism 22 and obtain an increased fueling rate accordant with the increased desired engine speed. Electronic controller 52 is also, however, tracking desired ΔP such that commands to valve 22 are responsive to a difference between desired and measured ΔP. This can been seen in the increased rate of change in fuel valve positioning following time t2. In
Referring now to
In
The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the full and fair scope and spirit of the present disclosure. Other aspects, features and advantages will be apparent upon an examination of the attached drawings and appended claims.