1. Field of the Invention
This invention relates generally to a corona ignition system, and a method of controlling corona discharge and arc formation provided by the corona ignition system.
2. Related Art
Corona discharge ignition systems provide an alternating voltage and current, reversing high and low potential electrodes in rapid succession. These systems include a corona igniter with an electrode charged to a high radio frequency voltage potential and creating a strong radio frequency electric field in a combustion chamber. The electric field causes a portion of a mixture of fuel and air in the combustion chamber to ionize and begin dielectric breakdown, facilitating combustion of the fuel-air mixture. During typical operation of the corona ignition system, the electric field is ideally controlled so that the fuel-air mixture maintains dielectric properties and corona discharge occurs, also referred to as a non-thermal plasma. The ionized portion of the fuel-air mixture forms a flame front which then becomes self-sustaining and combusts the remaining portion of the fuel-air mixture. The corona discharge has a low current and can provide a robust ignition without requiring a high amount of energy and without causing significant wear to physical components of the ignition system.
In a corona ignition system, good ignition characteristics are due to the corona discharge spreading over a large volume in a large number of filaments or streamers. If too much energy is applied to the corona igniter, it is possible for the corona discharge to extend from the high voltage source far enough to reach a grounded engine component. When this happens, a conductive path, referred to as an arc, is formed to the grounded component. The arc formation comprises a relatively high current flow and thus concentrates the ignition energy into a very limited volume, reducing ignition efficiency. It is typically desirable to avoid this situation. Conversely, it is difficult to be certain that a corona igniter is fed with enough energy to produce a large enough corona, as there is no direct method of obtaining the volume of the corona discharge.
One aspect of the invention provides a corona ignition system for controlling the volume and duration of corona discharge during a single corona event, i.e. intra-event control. The corona event is a single continuous duration of time extending from a start time to a stop time. During the corona event, a corona igniter receives energy at a voltage level and a current level, and emits an electric field. A driver circuit provides the energy to the corona igniter during the corona. Immediately after any occurrence of arc formation, the driver circuit provides no energy to the corona igniter for a duration of time. The driver circuit also obtains information about the at least one occurrence of the arc formation. This information typically includes at least one of: timing of at least one occurrence of the arc formation relative to the start time of the corona event, duration between two consecutive occurrences of the arc formations, and number of occurrences of the arc formation over a period of time during the corona event. A control unit receives the information about the arc formation from the driver circuit and adjusts at least one of the voltage level and the current level based on the information about the arc formation. The driver circuit then provides an adjusted energy level to the corona igniter after the duration of time wherein no energy is provided to the corona igniter. The adjusted energy level includes at least one of the adjusted voltage level and the adjusted current level.
Alternatively, the control unit adjusts the duration of time wherein no energy is provided to the corona igniter after any arc formation is detected, based on the information about the arc formation detected. The driver circuit then applies this adjusted duration of time after a subsequent occurrence of the arc formation during the corona event. According to another embodiment, the control unit adjusts the stop time of the corona event based on the information about the arc formation.
Another aspect of the invention provides a method of controlling a corona ignition system. The method comprises the steps of: providing energy to the corona igniter during the corona event; providing no energy to the corona igniter for a duration of time immediately after any occurrence of an arc formation. The method further includes obtaining information about the arc formation. The information includes at least one of: timing of at least one occurrence of the arc formation relative to the start time of the corona event, duration between two consecutive occurrences of the arc formations, and number of occurrences of the arc formation over a period of time during the corona event. The method then includes adjusting at least one of the voltage level, the current level, the stop time of the corona event, and the duration of time wherein no energy is provided to the corona igniter based on the information about the arc formation. This adjusting step occurs during the same corona event.
Another aspect of the invention provides a method of controlling a corona discharge ignition system. The method includes providing energy to a corona igniter during a corona event; and providing the energy to the corona igniter at a voltage level and current level causing the corona igniter to provide corona discharge for a majority of the duration of the corona event. The voltage level and current level of the energy provided to the corona igniter also causes the corona igniter to provide at least one occurrence of the arc formation following the corona discharge before a predetermined stop time of the corona event.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
One aspect of the invention provides a corona ignition system for an internal combustion engine. The system includes a corona igniter 20 providing corona discharge 22, an engine control system 24, a control unit 26, a power supply 28, and a driver circuit 30. An exemplary system is generally shown in
The engine control system 24 initiates the start of the corona event in order to ignite a mixture of fuel and air in a combustion chamber 32 and power the internal combustion engine. The corona event is a single continuous duration of time extending from a start time to a stop time, during which the corona igniter 20 receives energy and provides the corona discharge 22. The duration of the corona event is typically predetermined and set as a function of engine operation parameters. Typically, the duration of the corona event ranges from 20 to 3,500 microseconds. The engine control system 24 starts the corona event at the start time by conveying an enable signal 34 to the control unit 26, which actives the control unit 26. In this example, the engine control system 24 also stops the corona event by conveying a signal to the control unit 26 at the stop time, which deactivates the control unit 26. In the embodiment of
In response to the enable signal 34, the control unit 26 turns on the driver circuit 30 by conveying a command signal 36 to the driver circuit 30. The control unit 26 also conveys a power control signal 38 to the power supply 28, instructing the power supply 28 to provide the energy to the driver circuit 30, which ultimately reaches the corona igniter 20, at a predetermined voltage level and a predetermined current level. Thus, the control unit 26 controls the energy provided to the corona igniter 20. In the exemplary system, the predetermine voltage level ranges from 100 to 1500 V and the predetermined current level ranges from 0.5 to 15 A. Ideally, the corona igniter 20 receives the high radio frequency voltage and current and provides a strong radio frequency electric field, i.e. the corona discharge 22, in the combustion chamber 32. In the system of
The control unit 26 typically reads the predetermined voltage level and the predetermined current level from a table or map stored in the control unit 26 or the engine control system 24. Initially, the predetermined voltage level and the predetermined current level are typically based on engine parameters or operating conditions in the combustion chamber 32. However, these predetermined levels stored in the control unit 26 or engine control system 24 can optionally be adjusted based on information about a previous corona event, which will be discussed further below.
The driver circuit 30 receives the energy from the power supply 28 at the predetermined voltage level and the predetermined current level. In response to the command signal 36 from the control unit 26, the driver circuit 30 provides the energy to the corona igniter 20 at the predetermined voltage level and the predetermined current level. The corona igniter 20 receives the energy from the driver circuit 30, and emits the corona discharge 22. In an ideal situation, the corona discharge 22 would rapidly form in the combustion chamber 32, grow to a maximum volume, which is the largest possible volume without reaching a grounded component, and remain at the maximum volume until the end of the corona event. Thus, the corona discharge 22 would provide a high quality ignition by igniting a large volume of the air-fuel mixture in the combustion chamber 32.
However, at some point during the corona event, the corona igniter 20 typically receives too much energy, causing the corona discharge 22 grow too large and reach a grounded component, such as a wall 42 of the combustion chamber 32 or a piston 44 reciprocating in the combustion chamber 32. At this time, a conductive path, referred to as an arc formation, forms between the corona igniter 20 and the grounded component. In other words, the corona discharge 22 transforms into the arc formation. The corona discharge 22 is preferred over the arc formation because it has a lower current and spreads over a larger volume, and thus is able to provide a higher quality ignition of the fuel-air mixture.
Any occurrence of arc formation in the combustion chamber 32 is immediately detected by the driver circuit 30. An exemplary method used to detect the onset of the arc formation is described in U.S. patent application Ser. No. 13/438,116. This method does not rely on measuring current, voltage, or impedance parameters related to the corona discharge 22. Rather, the method detects the arc formation by identifying a variation in an oscillation period of the resonant frequency, and provides a positive detection in nanoseconds or microseconds, and typically less than 2 μs. Accordingly, it is an easily implemented method allowing for very rapid feedback indicating the occurrence of arc formation. However, other methods can be used to detect the arc formation. Also, although any occurrence of an arc formation during the corona event is detected, there is not necessary an arc formation detected during the corona event, as the corona event could occur without any arcing.
When the driver circuit 30 detects the occurrence of the arc formation, the driver circuit 30 conveys a feedback signal 46 to the control unit 26 indicating the occurrence of the arc formation.
An exemplary method used to shut off the energy provided to the corona igniter 20 for the short duration of time is described in U.S. patent application Ser. No. 13/438,127. Although nothing is done to prevent the first occurrence of the arc formation, upon the first detection, the system takes action to prevent future arc formations. In the exemplary method, the energy is immediately shut off in response to the arc formation, rather than reduced, because the voltage required to maintain the arc formation is much less than the voltage required to maintain the corona discharge 22, and thus reducing the voltage applied to the corona igniter 20 will most likely not dissipate the arc formation. The steps of detecting the occurrence of the arc formation and shutting off the energy are repeated throughout the corona event.
Upon detection of the arc formation, the driver circuit 30 also obtains information about the arc formation. This information is more than just a “yes or no” result, and the information is used to infer information about the volume and duration of the corona discharge 22. The information about the arc formation includes at least one of the following characteristics: timing of the occurrence of the arc formation relative to the start time of the corona event, duration between two consecutive occurrences of the arc formations, and number of occurrences of the arc formation over a period of time during the corona event.
The driver circuit 30 then conveys the information about the arc formation in the feedback signal 46 to the control unit 26. This can be the same feedback signal 46 sent in response to the detection of the arc formation, or a separate signal.
In addition to shutting off the energy provided to the corona igniter 20 in response to the arc formation, the control unit 26 uses the information about the arc formation to adjust the energy provided to the corona igniter 20 during the same corona event, in order to achieve the maximum volume and duration of the corona discharge 22 later on during the same corona event. For example, the control unit 26 can use the information to determine whether the energy should be increased or decreased. In other words, the control unit 26 uses the information about the arc formation to control the energy provided to the corona igniter 20 on an intra-event basis.
After the duration of time wherein no energy is provided to the corona igniter 20 and the arc formation dissipates, the control unit 26 again instructs the driver circuit 30 to provide energy to the corona igniter 20. However, this time, the control unit 26 instructs the power supply 28 to adjust the energy provided to the driver circuit 30, based on the information about the arc formation, and reduce the likelihood of an occurrence of an arc formation, at least until the very end of the corona event. In other words, in order to enhance the size and/or duration of the corona discharge 22, the control unit 26 conveys the power control signal 38 to the power supply 28 instructing the power supply 28 to adjust the energy provided to the driver circuit 30 and ultimately to the corona igniter 20 during the same corona event, i.e. intra-event, based on the information about the arc formation. The control unit 26 can also adjust the timing of the command signal 36 to the driver circuit 30, in order to adjust the duration of time during which the driver circuit 30 provides energy to the corona igniter 20.
Typically, the control unit 26 adjusts at least one of the voltage level, the current level, the total duration of the corona event, and the duration of time wherein no energy is provided to the corona igniter 20 in order to improve the quality of the corona discharge 22. If the feedback signal 46 to the control unit 26 indicates multiple arc formations occurred early in the corona event, and repeated throughout the corona event, for example traces 1-3 of
In cases where the first occurrence of an arc formation is at the very end of the corona event, for example traces 5-8 of
Typically, at least one of the voltage level and the current level are adjusted by a factor depending on the information about the arc formation. For example, if the arc formation is detected at or close to the start time of the corona event, or if the duration between consecutive occurrences of the arc formation is short, then the voltage level is reduced by a larger factor than if the arc formation is detected toward the end of the corona event or if only one arc formation is detected.
In response to the information about the arc formation, the method can also include adjusting the duration of time wherein no energy is provided to the corona igniter 20 by a factor based on the information about the arc formation. This factor can be the same or different from the factors used to adjust the voltage and current levels. For example, if the first occurrence of the arc formation is very close to the start time, or if the successive arc formations are very close together, then the duration of time wherein no energy is provided to the corona igniter 20 is increased by a larger factor.
As stated above, after the duration of time wherein no energy is provided to the corona igniter 20, the method includes providing the adjusted energy to the corona igniter 20 to form a stronger corona discharge 22 and limit the arc formation during the same corona event. If another occurrence of arc formation is detected, the control unit 26 again ceases the energy provided to the corona igniter 20 and adjusts the energy subsequently provided to the corona igniter 20 during the same corona event, i.e. intra-event control.
The system and method of the present invention can optionally include control on an inter-event basis. In this embodiment, after the stop time indicating the end of the corona event, at least one of the predetermined voltage level and the predetermined current level stored in the control unit 26 are adjusted. The predetermined voltage level and/or current level is adjusted based on at least one of: timing of an occurrence of arc formation relative to the start time of the corona event, duration between two consecutive occurrences of arc formations, number of occurrences of arc formation over a period of time during the corona event, timing of an occurrence of the arc formation relative to the stop time of the corona event, total number of occurrences of arc formation, and at least one of the voltage level and the current level provided to the corona igniter 20 at the stop time of the corona event. This adjusted voltage level and/or adjusted current level is then stored in the control unit 26, and used in a future corona event to obtain a stronger corona discharge 22 and limit arc formations. In other words, in a future corona event, the control unit 26 instructs the power supply 28 to provide the energy ultimately to the corona igniter 20 at the adjusted voltage level and/or the adjusted current level.
In another embodiment, after the end of corona event, the predetermined shut off time in response to a detected arc formation is adjusted. Thus, in a future corona event, the control circuit instructs the driver circuit 30 to cease energy provided to the corona igniter 20 for this adjusted duration of time, in order to enhance the quality of the corona discharge 22. The total duration of a future corona event could also be adjusted based on the information about the arc formation of a prior corona event, in order to enhance the quality of the corona discharge 22 in the future event.
The control unit 26 sends a command signal 36 to the driver circuit 30 to enable the corona discharge 22, and a timer is started. The timer measures the duration of the active corona discharge 22 before an arc formation is detected. The timer stops when the corona discharge 22 ends, in which case the enable signal 34 from the engine control system 24 ends the corona event, or when arc formation is detected, in which case a feedback signal 46 is transmitted to the control unit 26.
In the system
The timer is stopped upon detection of the arc formation, and thus provides the duration of corona discharge 22 before arc formation. The driver circuit 30 is also turned off using the command signal 36, such that the energy applied to the corona igniter 20 is turned off, and timing of this shutdown begins, referred to as timer shutdown. The duration of the shutdown may be fixed, may be taken from a map depending on operating conditions, or may be adapted according to the arc formations previously detected. The arc formations are recorded for feedback and diagnostic purposes and the factor is modified according to a suitable function, for example as shown in
The control signal to the power supply 28 instructs the power supply 28 to provide a voltage level reduced according to the factor, subject to externally-set minimum and maximum limits. This reduces the voltage level applied to the corona igniter 20 and hence lowers the voltage obtained at the igniter tip 40 when the driver circuit 30 is re-energized. When the shutdown timer completes, the corona igniter 20 is re-enabled and operation of the corona igniter 20 continues. The enable signal 34 eventually causes the corona discharge 22 to shut off and optional inter-event processing can take place, as shown in the left branch of
After the corona event, the final values of voltage level, current level, and/or shutdown time, as well as the recorded number and timing of arc formations detected, are provided to the control unit 26 through the feedback signal 46 and to the engine control system 24 through a feedback interface 48. This data may optionally be processed and used to modify the starting values used in the next corona event, as shown in the left branch of
Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims.
This U.S. utility patent application claims the benefit of U.S. provisional patent application No. 61/740,781, filed Dec. 21, 2012, and U.S. provisional patent application No. 61/740,796, filed Dec. 21, 2012, the entire contents of which are incorporated herein by reference in their entirety.
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