Patent Grant
11808223
This application is a U.S. National Stage application of PCT/EP2019/056984, filed Mar. 20, 2019, and published on Sep. 24, 2020, as WO 2020/187415 A1, all of which is hereby incorporated by reference in its entirety.
The invention relates to a method and a control system for controlling an internal combustion engine in a vehicle.
The invention can be applied in heavy-duty vehicles, such as trucks, articulated trucks, buses and construction equipment, which vehicles may be manned or driven autonomously. Although the invention will be described with respect to a heavy-duty land vehicle, the invention is not restricted to this particular vehicle, but may also be used in other vehicles such as buses, articulated haulers, wheel loaders and other working machines or marine vessels comprising an internal combustion engine with an exhaust after-treatment system.
In some internal combustion engine (ICE) applications the exhaust after-treatment system (EATS) can experience problems during long periods with idle and/or low load operation. Under such conditions, an EATS comprising a diesel particulate filter (DPF) and a selective catalytic reduction (SCR) unit, also termed catalytic converter, can experience problems due to relatively low exhaust temperatures.
During cold start operation, a common strategy is to operate the engine using a rich air-fuel mixture until the EATS reaches its operational temperature, or light-off. However, this mode of operation has a detrimental effect on fuel consumption and engine emissions.
During low load operation the exhaust temperature can be reduced below the temperature required for operating the SCR unit, and for regenerating the DPF. This can be a problem for the DPF, as an over-filled filter increases the back pressure in the exhaust system and can trigger a “limp-home” function that limits the output of the engine. Also, an over-filled particulate filter that can no longer be regenerated must either be removed for cleaning or be replaced. One way of overcoming this problem is to perform regular and time-consuming parked regeneration. This requires the vehicle to be stationary during the regeneration process and results in increased fuel consumption as well as down time for the vehicle owner. In addition, frequent regeneration cycles can also reduce the lifetime of the DPF and the SCR unit.
An alternative way of overcoming this problem is to use hot exhaust gas recirculation (EGR) and intake air throttling of the engine, which is costly in terms of fuel consumption and emissions. When a clogged DPF is detected, an engine control unit (ECU) activates a regeneration process to increase the DPF temperature to a desired level. The engine is then set for EGR operation and up to eight times more fuel per stroke can be injected to produce a high amount of NO2, which will help oxidize the particulates in the DPF, and to increase the temperature as the exhaust gases pass through the DPF and the SCR unit.
The invention provides an improved method and a control system for controlling an ICE, in order to maintain the functionality of the EATS, and aims to solve the above-mentioned problems
An object of the invention is to provide a method and a control system for controlling an ICE, which solves the above-mentioned problems.
The object is achieved by a method according to claim 1.
In the subsequent text, the abbreviations ICE, EATS, DPF and SCR as indicated above will be used in the subsequent text. The term “engine control unit” is referred to as an ECU or “control unit”. The engine control unit is an electronic controller connected to sensors measuring a number of variables required for controlling and/or monitoring the operation of the ICE. Only the measured variables required for performing the method according to the invention will be described in the appended text. The engine control unit is able to initiate and control engine operation by means of various electrical, hydraulic and/or pneumatic actuators in response to detected engine conditions.
A conventional exhaust after-treatment system or EATS comprises a DPF unit arranged downstream of an ICE, a SCR unit arranged downstream of said DPF unit, and an injector for feeding reducing agent, e.g. urea, into the exhaust gas immediately upstream of the SCR unit. The EATS can also comprise a NO2 reduction catalyst, such as a diesel oxygen catalyst (DOC) arranged upstream of the DPF, or downstream of the DPF unit and upstream of the SCR unit. A further injector can be provided for feeding a reducing agent, e.g. fuel, into the exhaust gas upstream of said NO2 reduction catalyst. The DOC provides NO- and HC-oxidation of the exhaust gas prior to the SCR and can control the supply of NO2 to the SCR unit. The above terms will be adhered to in the subsequent text.
According to one aspect of the invention, the object is achieved by means of a method performed in order to maintain the functionality of the EATS. The method involves heating exhaust gases to a selected specific temperature by fuel injection control in an internal combustion engine (ICE) operated in a four stroke cycle, which ICE comprises a control unit registering the currently requested load and determining a required fuel amount in response to the requested load.
The method involves performing the steps of:
The initial step involves monitoring and registering whether or not the internal combustion engine is operated at low load, that is, idling or operated at low speed and low load. When a low load operation is registered, the method proceeds to check if it has been registered that a predetermined condition has been detected in the EATS. A non-exhaustive list of examples of such conditions comprises detecting that back-pressure in the manifold or a pressure drop across the DPF unit has exceeded a predetermined limit, indicating that a regeneration of the DPF unit is required. A further condition is that the temperature of the exhaust leaving the engine or the temperature in any one of the EATS units has dropped below a desired value. Alternatively, it can be detected that a measured temperature is dropping at a rate that is higher than expected or desired.
Depending on the detected condition, the ECU can determine an exhaust temperature requirement for the detected condition and calculates a target exhaust temperature. The value of the calculated target exhaust temperature is dependent on the condition that must be corrected. Typically, an exhaust temperature required for regenerating the DPF unit is higher than the exhaust temperature required for operating the SCR unit.
The ECU can then select a group of cylinders from the total number of cylinders to be regulated for achieving the target exhaust temperature. A relatively small temperature increase can require a group numbering less than half of the available cylinders, while a larger temperature increase can require a group numbering at least half of the available cylinders. According to the invention, the selected group of cylinder cannot include all the available cylinders. The selected group of cylinders is preferably distributed evenly over the firing order sequence of the engine.
In the case of a V6 engine, the engine has two banks of cylinders where the respective banks are numbered 1-3 and 4-6 in consecutive order. The firing order is 1-5-3-6-2-4. For instance, if two out of six cylinders in a V6-engine are used, then cylinders 1 and 6 are regulated while cylinders 2, 3, 4 and 5 are operated normally at the currently requested load. Similarly, if three out of six cylinders in a V6-engine are used, then cylinders 1, 2 and 3 are regulated while cylinders 4, 5 and 6 are operated normally at the currently requested load. A similar cylinder distribution can be used for both in-line and V-type engines. If four out of six cylinders in a V6-engine are used, then cylinders 1, 2, 5 and 6 are regulated while cylinders 3 and 4 are operated normally at the currently requested load. A similar cylinder distribution can be used for both in-line and V-type engines. The above examples should only be considered to be non-limiting, as the group of cylinders can be selected freely within the scope of the invention,
It should be noted, in this and any subsequent example, that non-selected cylinders are operated normally at the currently requested load. This can entail that the power output of these cylinder will need to be increased, depending on the regulation of the selected group of cylinders. For instance, when the target exhaust temperature is relatively high, then the ratio defining the offset between an increased 1st fuel amount and a reduced 2nd fuel amount will be relatively large. If the 2nd fuel amount has been reduced to zero, then the power output in the subsequent power stroke will also be zero. Further, the 1st fuel amount will at this point comprise at least twice the fuel amount for the requested load. This will result in an incomplete combustion in the subsequent power stroke and a significantly reduced power output. Hence, the non-selected cylinders will be controlled to compensate for this loss of power output and to maintain engine operation at the requested load. Non-combusted fuel from the regulated cylinders will oxidize in the exhaust manifold, causing the increase in exhaust temperature and pressure required for achieving the target exhaust temperature.
The ECU will also calculate a ratio for desired 1st and 2nd fuel amounts to be injected alternately in consecutive induction strokes for the selected group of cylinders to achieve the target exhaust temperature. By increasing the 1st fuel amount to be injected in one regulated cylinder of the selected group of cylinders and reducing 2nd fuel amount to be injected for the intermediate induction stroke in a subsequent regulated cylinder, the exhaust leaving the engine is heated towards the target exhaust temperature.
Using the examples outlined above, if two out of six cylinders in a V6-engine are used, then cylinders 1 and 6 are regulated while cylinders 2, 3, 4 and 5 are operated normally at the currently requested load. In this case, the increased 1st fuel amount would be injected in cylinder 1, while the reduced 2nd fuel amount would be injected in cylinder 6. Thus, cylinder 1 will continuously receive the increased fuel amounts and cylinder 6 will continuously receive the decreased fuel amounts.
On the other hand, if three out of six cylinders in a V6-engine are used, then cylinders 1, 2 and 3 are regulated while cylinders 4, 5 and 6 are operated normally at the currently requested load. In this case, the increased 1st fuel amount would be injected in cylinder 1, while the reduced 2nd fuel amount would be injected in cylinder 2. The subsequent increased 1st fuel amount would be injected in cylinder 3, while the subsequent reduced 2nd fuel amount would be injected in cylinder 1, and so on. Hence, the distribution of the increased and the decreased fuel amounts will follow the firing order of the regulated cylinders 1-3.
In accordance with the invention, the cylinders not selected for regulation are instead operated normally at the currently requested load. The amount of fuel injected for the requested load is either determined by the ECU, in the case of idling, or by the driver controlling an accelerator pedal or similar engine control means, in the case of low load operation for a vehicle in motion. An advantage of this operation is that the normally operated cylinders will assist the engine in running smoothly, in particular when reduced 2nd fuel amount approaches zero.
According to one example, the method involves monitoring the exhaust temperature using available sensors and adjusting the ratio for the desired 1st and 2nd fuel amounts to be injected in order to achieve the target exhaust temperature. The amount of heat delivered to the EATS can thereby be regulated by controlling the relative difference in volume between the 1st and 2nd fuel amounts to be injected.
According to a further example, the method involves monitoring the exhaust temperature and adjusting the number of selected cylinders to be regulated for achieving the target exhaust temperature. The amount of heat delivered to the EATS can thereby be regulated by increasing or reducing the number of selected cylinders to be regulated.
According to a further example the exhaust temperature can be regulated by a combination of regulating the relative difference in volume between the 1st and 2nd fuel amounts to be injected and increasing and reducing the number of selected cylinders to be regulated.
The strategy selected for controlling the exhaust temperature can vary depending on the detected condition, the operating state of the vehicle or the ICE, or on other factors such as ambient conditions. Examples of ambient conditions can be air temperature, humidity or atmospheric pressure. According to one example, the ECU can detect that the DPF unit is within its desired operating parameters, but that the exhaust temperature is insufficient for maintaining the SCR unit at a desired temperature. In response the ECU checks whether the vehicle is operated at low load, and if so, calculates a target exhaust temperature and selects a group of cylinders based on stored values, a look-up table or similar. The ECU will then control the ICE according to the inventive method until the target exhaust temperature is achieved. If the ECU detects that the target exhaust temperature cannot be achieved, then the ratio for the 1st and 2nd fuel amounts to be injected is corrected and/or the number of cylinders in the selected group is increased.
The ICE is controlled in this way until the target exhaust temperature is achieved or until it is detected that low load operation is interrupted.
As indicated above, a ratio is calculated for the desired 1st and 2nd fuel amounts to be injected alternately in consecutive induction strokes for the selected group of cylinders. Particularly, an increase of the 1st fuel amount is balanced by a corresponding reduction of the 2nd fuel amount. The 1st fuel amount can be increased to an amount up to or in excess of the combined 1st fuel amount and 2nd fuel amount when the 2nd fuel amount is reduced to zero. According to an alternative example, the 1st fuel amount can be increased up to 130% of the combined 1st fuel amount and 2nd fuel amount when the 2nd fuel amount is reduced to zero. The latter increase can be used to compensate for the friction losses in cylinders not producing a positive torque output.
According to the invention, the ratio calculated for the desired 1st fuel amount and 2nd fuel amount increases with an increased exhaust temperature requirement. In this way, the offset defined by said ratio changes so that an increased 1st fuel amount is balanced by a corresponding reduction of the 2nd fuel amount until the 2nd fuel amount reaches zero. When calculating the ratio between the desired 1st fuel amount and 2nd fuel amount in all the above examples, the starting point is that both fuel amounts are equal to the required fuel amount in response to the requested load at the time the regulation is started.
According to a second aspect, the invention relates to a control system to heat exhaust gases to a selected specific temperature by fuel injection control wherein the control system is operated using the method as described above.
According to a second aspect, the invention relates to a computer program comprising program code means for performing all the steps of the method as described above when said program is run on a computer.
According to a second aspect, the invention relates to a computer program product comprising program code means stored on a computer readable medium for performing all steps of anyone of the method as described above when said program product is run on a computer.
An advantage of the method of operation described above is that the exhaust temperature can be balanced to a specific target exhaust temperature and keep the DPF and SCR working during low load operation of the ICE. This mode of operation will also reduce the fuel consumption and the emissions during low load and idle operation. During a cold start, an effect of the method is that the time for the SCR to become operational is reduced. The described function will also minimize or prevent parked regeneration, which is an undesirable and time consuming event for the driver. Reducing the number of parked regeneration will also increase the life time for DPF and SCR. A side effect of the method is that the higher exhaust temperature provided by the operating mode can be used to heat the cabin, which reduces the need for an external heater.
Further advantages and advantageous features of the invention are disclosed in the following description and in the dependent claims.
With reference to the appended drawings, below follows a more detailed description of embodiments of the invention cited as examples. In the drawings:
The ICE 212 is further connected to an exhaust gas recirculation (EGR) system 230, arranged to return exhaust gas from the exhaust manifold 220 to the intake air manifold 206. The (EGR) system 230 comprises a first conduit 231 and a second conduit 232, wherein the first conduit leads to controllable valve 234 via a cooling arrangement 233 for cooling recirculated exhaust gas. The second conduit 232 is a bypass conduit leading past cooling arrangement 233 directly to the controllable valve 234. The controllable valve 234 is operated by an ECU 215 to selectively open a first valve 235 or a second valve 236, in order to supply recirculated exhaust gas from the first conduit 231 or the second conduit 232, respectively, to the air intake manifold 206, vial a flow modulating unit 237 that regulates the amount of recirculated exhaust gas supplied to the air intake manifold 206.
The ICE 212 is controlled by the driver or automatically via an engine control unit (ECU) 215, e,g, during engine idling. The ECU 215 is provided with control algorithms for controlling the ICE 212 independently or in response to a throttle pedal input requested by the driver. The ICE 212 is further controlled by the ECU 215, which issues commands to a number of actuators in response to input signals from multiple sensors detecting ICE and EATS related parameters. A non-exhaustive list of monitored ICE related parameters comprises intake air temperature, CAC temperature, engine coolant temperature, intake manifold pressure, throttle sensor, fuel injector pressure, EGR cooler temperature, EGR gas pressure, etc. Similarly, monitored EATS related parameters can comprise exhaust manifold pressure, DPF inlet and/or outlet pressure, DPF temperature, SCR pressure, SCR temperature, exhaust NH3-/NOx-/O2-levels, etc. In response to input from the sensor indicated above, the ECU issues commands to actuators controlling intake air flow rate, fuel injection volume and timing, intake and exhaust valve timing, EGR flow rate, etc. Standard operation of a compression ignition engine is considered to be well known and will not be discussed in further detail here.
In operation, the ICE 212 can be controlled in accordance with the invention to perform a method in order to maintain the functionality of the EATS 221. The method involves heating exhaust gases leaving the ICE to a selected specific temperature by fuel injection control, wherein the ECU 215 initially registers the currently requested load and determines a required fuel amount in response to the requested load.
The method involves registering that the ICE 212 is currently being operated in a low load condition, that is, the ICE is idling or operated at low speed and at a low load. To register low load operation, an idle signal indicating no driving torque request or accelerator pedal actuation can be used during idle. Low load operation above idling speed can be registered using a signal indicating a low driving torque request from the driver or that an acelerator pedal actuation is below a predetermined angle at current engine load. The ECU 215 then registers an input from at least one EATS sensor indicating a detected predetermined condition. EATS sensor signals can be received, for example, from an exhaust temperature sensor 240 downstream of the turbocharger turbine unit 219, pressure sensors 241, 243 at the inlet and outlet of the DPF unit 222, a DPF temperature sensor 242 and a SCR temperature sensor 244. The detected predetermined condition can be that the pressure difference across the DPF unit 222 has exceeded a desired value, indicating that a regeneration sequence is required to burn off and remove collected particles. Alternatively, the predetermined condition can be that the SCR temperature is being reduced at a rate exceeding a desired rate, or that the SCR temperature is below the operating temperature of the SCR unit 223.
When such a predetermined condition is detected, the ECU 215 determines an exhaust temperature requirement for the detected condition and calculates a target exhaust temperature. The target exhaust temperature, as the operating temperature for the SCR unit 223 is in the range 250-450° C., depending on e.g. the catalyst material, while the temperature required for regenerating the DPF unit 222 can be in excess of 600° C. Depending on the required target exhaust temperature, the ECU 215 selects a group of cylinders to be regulated for achieving this temperature. The number of cylinders can be selected from a table of stored values giving a minimum number of cylinders suitable for achieving the target exhaust temperature. The number of cylinders selected will increase with an increase in target temperature. For instance, a relatively small temperature increase for the SCR unit can require a group numbering less than half of the available cylinders, while a larger temperature increase for regeneration of the DPF unit can require a group numbering at least half of the available cylinders. According to the invention, the selected group of cylinder cannot include all the available cylinders. The selected group of cylinders is preferably distributed evenly over the firing order sequence of the engine.
The ECU 215 then calculates a ratio for desired 1st and 2nd fuel amounts to be injected alternately in consecutive induction strokes for the selected group of cylinders to achieve the target exhaust temperature. The ratio defines an offset between an increased 1st fuel amount to be injected in a cylinder of the selected group of cylinders for every second induction stroke, and a reduced 2nd fuel amount to be injected for the intermediate induction strokes. The initial ratio can be calculated or be selected from a table of stored values giving a minimum ratio suitable for achieving the target exhaust temperature. By monitoring the exhaust temperature, the ECU 215 can then recalculate and correct the ratio to increase or decrease the exhaust temperature. Increasing the ratio will cause a further increase of the 1st fuel amount and a simultaneous, corresponding reduction of the 2nd fuel amount, as well as an increase in the mass flow of exhaust gas, resulting in an increased exhaust temperature.
If required to reach the target exhaust temperature, the regulation of the ratio can continue until the 1st fuel amount can be increased to an amount up to or in excess of the combined 1st fuel amount and 2nd fuel amount when the 2nd fuel amount is reduced to zero. At the time when the 2nd fuel amount reaches zero the fuel balance is 100/0, so that the cylinder is alternating between a power stroke at lambda 0.5 and skipping a power stroke. If required, the reduction of torque output can be compensated for by increasing the 1st fuel amount up to 130% of the initial combined 1st fuel amount and 2nd fuel amount when the 2nd fuel amount is reduced to zero. This can be used to compensate for the friction and pumping losses when the cylinder is not producing a positive torque output.
The current example relates to a V6-engine having two banks of cylinders where the respective banks are numbered 1-3 and 4-6 in consecutive order, as shown in
If necessary due to e.g. low ambient temperatures, the ICE can adjust the exhaust temperature by controlling the 1st and 2nd fuel amounts up or down to achieve the target exhaust temperature. The ECU will monitor the exhaust temperature during the adjustment of the fuel amounts. If the ECU detects that the target exhaust temperature cannot be achieved at the maximum ratio for the 1st and 2nd fuel amounts, then the number of cylinders in the selected group is increased. Consequently, when ratio for the 1st and 2nd fuel amounts has reached its maximum value and the ECU detects that the exhaust temperature is no longer increasing towards the target exhaust temperature, then the ECU can adjust the number of cylinders in the selected group. Based on stored values and the current difference between the exhaust temperature and the target exhaust temperature, the number selected cylinders is increased by at least one.
The current example relates to a V6-engine having two banks of cylinders where the respective banks are numbered 1-3 and 4-6 in consecutive order, as shown in
From
If necessary due to e.g. low ambient temperatures, the ICE can adjust the exhaust temperature by controlling the 1st and 2nd fuel amounts up or down to achieve the target exhaust temperature. If the ECU detects that the target exhaust temperature cannot be achieved at the maximum ratio for the 1st and 2nd fuel amounts, then the number of cylinders in the selected group is increased.
From
If necessary due to e.g. low ambient temperatures, the ICE can adjust the exhaust temperature by controlling the 1st and 2nd fuel amounts up or down to achieve the target exhaust temperature. If the ECU detects that the target exhaust temperature cannot be achieved at the maximum ratio for the 1st and 2nd fuel amounts, then the number of cylinders in the selected group is increased.
The present disclosure also relates to a computer program, computer program product and a storage medium for a computer all to be used with a computer for executing said method.
The memory 742 also has a second memory part 744, in which a program for measuring torque and other engine related parameters according to the invention is stored. In an alternative embodiment, the program for measuring engine related parameters is stored in a separate non-volatile storage medium 745 for data, such as, for example, a CD or an exchangeable semiconductor memory. The program can be stored in an executable form or in a compressed state. When it is stated below that the data-processing unit 741 runs a specific function, it should be clear that the data-processing unit 741 is running a specific part of the program stored in the memory 744 or a specific part of the program stored in the non-volatile storage medium 745.
The data-processing unit 741 is tailored for communication with the storage memory 745 through a data bus 751. The data-processing unit 741 is also tailored for communication with the memory 742 through a data bus 752. In addition, the data-processing unit 741 is tailored for communication with the memory 746 through a data bus 753. The data-processing unit 741 is also tailored for communication with a data port 748 by the use of a data bus 754. The method according to the present invention can be executed by the data-processing unit 741, by the data-processing unit 741 running the program stored in the memory 744 or the program stored in the non-volatile storage medium 745.
Reference signs mentioned in the claims should not be seen as limiting the extent of the matter protected by the claims. Their sole function is to make claims easier to understand. It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2019/056984 | 3/20/2019 | WO |
| Publishing Document | Publishing Date | Country | Kind |
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| WO2020/187415 | 9/24/2020 | WO | A |
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| Number | Date | Country | |
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