1. Field of the Invention
The present invention is generally related to a method for controlling a fuel system of a marine propulsion engine and, more particularly, to a method for controlling a canister purge valve in order to manage the fuel vapor associated with a fuel supply module.
2. Description of the Related Art
Many different types of fuel handling systems associated with marine propulsion systems are well known to those skilled in the art. Fuel vapor separators and other types of fuel system modules are used to segregate fuel vapor from liquid fuel and to direct the fuel vapor away from fuel pumps whose operation can be adversely affected by the presence of vapor within the fuel supply.
U.S. Pat. No. 3,835,822, which issued to Mickle et al. on Sep. 17, 1974, discloses a cooled fuel pump for internal combustion engines. The pump includes a cast aluminum housing. A water cooling tube is embedded in the housing and connected directly to the inlet of the main cooling system of the engine such that upon initial starting of the engine, cooling water is immediately supplied to the fuel pump to reduce its temperature, and thereby eliminate vapor lock conditions.
U.S. Pat. No. 4,844,043, which issued to Keller on Jul. 4, 1989, discloses an anti-vapor lock carbureted fuel system. A marine fuel system includes a first crankcase pressure driven fuel pump supplying fuel from a remote fuel tank to a vapor separator, and a second crankcase pressure driven fuel pump supplying vapor-free fuel from the vapor separator to the carburetors of the engine. In combination, a squeeze bulb and one-way check valve supply fuel from the remote fuel tank directly to the carburetors for starting the engine.
U.S. Pat. No. 5,103,793, which issued to Riese et al. on Apr. 14, 1992, discloses a vapor separator for an internal combustion engine. The assembly includes a bowl member and a cover member. A fuel pump is located in the internal cavity of the bowl member and has its inlet located in the lower portion of the bowl member cavity, for supplying fuel thereto. The fuel pump is secured in position within the bowl member by engagement of the cover member with a fuel pump. The cover member includes a mounting portion for mounting a water separating filter element to the vapor separator assembly. The cover member includes structure for routing fuel from the discharge of the water separating filter element to the interior of the bowl member internal cavity.
U.S. Pat. No. 5,389,245, which issued to Jaeger et al. on Feb. 14, 1995, discloses a vapor separating unit for a fuel system. The unit includes a closed tank having a fuel inlet through which fuel is fed to the tank by a diaphragm pump. The liquid level in the tank is controlled by a float-operated valve. An electric pump is located within the vapor separating tank and has an inlet disposed in the tank and an outlet connected to a fuel rail assembly of the engine. Excess fuel from the fuel rail assembly is conducted back to the upper end of the vapor separator tank. A vapor venting mechanism is incorporated in the tank to vent vapor from the tank.
U.S. Pat. No. 6,253,742, which issued to Wickman et al. on Jul. 3, 2001, discloses a fuel supply method for a marine propulsion engine. The method uses a lift pump to transfer fuel from a remote tank to a vapor separator tank. Only one level sensor is provided in the vapor separator tank and an engine control unit monitors the total fuel usage subsequent to the most recent filling of the tank. When the fuel usage indicates that the fuel level of the vapor separator tank has reached a predefined lower level, a lift pump is activated to draw fuel from a remote tank and provide that fuel to the vapor separator tank.
U.S. Pat. No. 6,553,974, which issued to Wickman et al. on Apr. 29, 2003, discloses an engine fuel system with a fuel vapor separator and a fuel vapor vent canister. The system provides an additional fuel chamber, associated with a fuel vapor separator, that receives fuel vapor from a vent of the fuel vapor separator. In order to prevent the flow of liquid fuel into and out of the additional fuel chamber, a valve is provided which is able to block the vent of the additional chamber. In addition, a sensor is provided to provide a signal that represents a condition in which liquid fuel within the additional fuel chamber exceeds a predetermined level.
U.S. Pat. No. 6,694,955, which issued to Griffiths et al. on Feb. 24, 2004, discloses a marine engine with primary and secondary fuel reservoirs. The system comprises first and second fuel reservoirs connected in fluid communication with each other. The first fuel reservoir is a fuel vapor separator which has a vent conduit connected in fluid communication with a second fuel reservoir. Under normal conditions, fuel vapor flows from the fuel vapor separator and into the second fuel reservoir for eventual discharge to the atmosphere. Any liquid fuel caused to flow out of the vent conduit of the fuel vapor separator is contained within the second fuel reservoir and prevented from being discharged into the cavity under the cowl of an outboard motor and eventually into a body of water in which the marine system is operated.
U.S. Pat. No. 6,718,953, which issued to Torgerud on Apr. 13, 2004, discloses a fuel vapor separator with flow directing components within a fuel recirculating flow path. A fuel delivery system for a marine engine provides first, second, and third reservoirs of a fuel vapor separator and first, second, and third pumps to cause fuel to be drawn from the fuel tank and provided to the combustion chambers of an internal combustion engine. A flow directing component is provided to inhibit recirculated fuel from mixing directly with fuel within the fuel vapor separator that has not yet been pumped to a fuel rail. The flow directing component receives recirculated fuel and also receives fuel from a second reservoir through an orifice formed through a surface of the flow directing component.
The patents described above are hereby expressly incorporated by reference in the description of the present invention.
It would be significantly beneficial if a fuel system of a marine propulsion engine could control the pressure within a fuel reservoir, such as a fuel vapor separator or fuel system module, in such a way that both a lift pump and a high pressure pump within the fuel vapor separator can work properly with the pressure within the fuel system module.
A method for controlling a fuel system of a marine propulsion engine, in accordance with a particularly preferred embodiment of the present invention, comprises the steps of providing a flow control device, or purge valve, which is connected in fluid communication with a fuel reservoir of the fuel system, determining a desired venting command for venting gaseous fuel from the fuel reservoir, selecting a plurality of intermediate venting commands as a function of the desired venting command, and actuating the flow control device according to the selected plurality of intermediate venting commands.
In a particularly preferred embodiment of the present invention, the method comprises the further step of measuring an operating parameter of the marine propulsion engine. The determining step comprises the step of determining the desired venting command as a function of the operating parameter, which can be the operating speed of the marine propulsion engine. The method can further comprise the step of determining a current venting command associated with the flow control device. Each of the plurality of intermediate venting commands can be selected as a dual function of the desired venting command and the current venting command. The plurality of intermediate venting commands can comprise a series of sequentially increasing venting commands. The fuel reservoir can be a canister that is disposed in fluid communication between a fuel system module and an air intake manifold of the marine propulsion engine. The desired venting command can be a pulse width modulated (PWM) signal transmitted to the flow control device by a microprocessor. The plurality of intermediate venting commands can be a series of pulse width modulated signals transmitted to the flow control device, or canister purge valve, by the microprocessor at a predetermined frequency. In certain embodiments of the present invention, the fuel reservoir is a canister which is disposed in fluid communication between a fuel system module, or fuel vapor separator, and an air intake manifold of the marine propulsion engine. The fuel system module can comprise a lift pump and high pressure pump disposed therein. The lift pump is disposed in fluid communication with a fuel tank of a marine vessel and the high pressure pump is disposed in fluid communication with a fuel rail of the marine propulsion engine.
The present invention will be more fully and completely understood from a reading of the description of the preferred embodiment in conjunction with the drawings, in which:
Throughout the description of the preferred embodiment of the present invention, like components will be identified by like reference numerals.
In certain marine propulsion systems, a fuel supply module (FSM) is located under a cowl and in close proximity to the engine. As a result, it is located within an environment which can experience high temperatures during certain operating conditions. Particularly when a volatile fuel, such as winter blend gasoline, is used, high vapor pressure is created within the fuel supply module because of the vaporization of the fuel. If the vapor pressure is relieved rapidly, as is done in certain known fuel systems for outboard motors, the high pressure pump contained within the fuel supply module can become vapor locked because of an excess amount of vapor bubbles within the liquid fuel volume of a fuel supply module. The rapid decrease in pressure within the fuel supply module causes the bubbles to rapidly form. Another problem can exist in relation to the lift pump which can also be located within the fuel supply module. The lift pump, under certain circumstances, cannot properly draw fuel from the fuel tank of a marine vessel into the fuel supply module because of the high pressure that exists within the fuel supply module. Therefore, the high pressure pump requires pressure to be relieved slowly in order to avoid the creation of bubbles from the liquid fuel while the lift pump requires the pressure to be relieved quickly in order to assist the lift pump in drawing fuel from the fuel tank of the marine vessel. These two requirements are contradictory.
Another problem can exist when the operator of a marine vessel starts the engine, after the temperature of the fuel system is elevated, and then allows the engine to operate at idle speed. The engine has a finite limit of fuel vapor that it can ingest before the fuel/air mixture provided to the cylinders becomes too rich and causes a misfire condition to occur. Therefore, the vapor pressure must be relieved quickly enough within the fuel supply module so that the lift pump can replenish consumed fuel into the fuel supply module, but the vapor must be metered to the intake slowly enough such that the engine does not stall due to the rich air/fuel ratio.
Certain known fuel systems for marine engines utilize a canister located between the fuel supply module and an air intake manifold of the engine. The canister is intended to trap liquid fuel that escapes the FSM during the purging of fuel vapor. A valve is provided which allows a controlled flow of fuel vapor to pass from the FSM to the air intake module. In known fuel systems, the canister purge valve associated with a canister between the fuel supply module and the air intake manifold is a simple solenoid valve that is spring loaded to a closed position. When voltage is applied to the valve, the valve is forced open and vapor from the fuel supply module flows to the air intake manifold. A typical known strategy for use in this type of system incorporates a pulse width modulated (PWM) control signal at approximately ten Hertz and approximately an eighty percent duty cycle at rated engine speed. This type of calibration setting provides a very free flowing orifice to the vapor from the canister and causes a rapid pressure decay within the cavity of the fuel supply module. At idle engine speed, the same ten Hertz frequency is used, but at approximately a fifteen percent duty cycle. In other words, known fuel systems incorporate two duty cycles, one for idle speed and one at rated speed.
The present invention uses a more sophisticated control strategy which compensates for the tradeoff between the requirements of the high pressure pump and the lift pump. The present invention tailors the change in flow rate of fuel vapor through the canister purge valve to suit both the lift pump and the high pressure pump in such a way that both of these pumps are operated at acceptable pressures. The method of the present invention allows the pressure within the fuel supply module to decay slowly during a transient acceleration, giving the high pressure pump time to move the vapor through the system, but it then opens the canister purge valve to relieve the pressure rapidly allowing the lift pump to move the vapor, which is formed in the inlet filter, into the fuel supply module at near atmospheric pressure. This same strategy works favorably during extended idle operation, because the canister purge valve holds pressure within the fuel supply module and allows it to slowly decay over time. It then rapidly opens to allow the lift pump to provide fresh liquid fuel into the fuel supply module. This occurs through the use of software calibration in the determination of the venting profile as will be described in greater detail below.
With continued reference to
The rate of fuel vapor flow through the canister purge valve 70 is advantageously controlled as a function of the operating speed of the engine 10. In known systems, as described above, the canister purge valve 70 is typically controlled in such a way that it is always in one of two states. A low flow state, in which the canister purge valve is provided with a relatively low duty cycle, such as fifteen percent, allows a minimal flow of vapor from the canister 68 to the air intake manifold 80. A high flow condition of the canister purge valve 70 allows an eighty percent duty cycle. This limited choice of high flow and low flow conditions of the canister purge valve is generally not sufficient to satisfy the most advantageous operating conditions of the lift pump 34 and high pressure pump 40.
With continued reference to
As described above, systems known to those skilled in the art use canister purge valves 70 in association with canisters 68 and fuel supply modules 30. However, known systems use no more than two magnitudes of pulse width modulated signals for the canister purge valve 70. In other words, the canister purge valve 70 is operated either at a low flow rate or a high flow rate. Although the low flow rate may be greater than zero, it is typically selected to provide a minimal vapor flow to vent the fuel supply module 30 at a slow rate. Accordingly, the high flow rate is selected to provide maximum venting of the ullage 62 when the engine 10 is operating at higher speeds.
Rather than limit the system in this way, the present invention provides multiple magnitudes of signals from the engine control module 90 to the canister purge valve 70 in order to tailor, or calibrate, the rate of pressure decay within the fuel supply module 30 which adequately suits the needs of both the lift pump 34 and the high pressure pump 40.
It should be understood that the terminology used to describe the present invention utilizes the term “plurality” in conjunction with the steps of intermediate venting commands to mean more than simply a low venting rate and a high venting rate. It is recognized that the low and high venting rates of the prior art comprise two rates and, as such, can be considered to be a “plurality”, but the use of that terminology in the description of the present invention is intended to incorporate within its meaning more than simply a low rate and a high rate or, alternatively, an off condition and an on condition. Instead, the term “plurality” is intended to incorporate within its meaning the use of two or more duty cycle commands above the minimal duty cycle which, in known systems, would either be zero percent duty cycle or, in the example described above, a fifteen percent duty cycle. Since that minimal duty cycle is considered herein to be essentially insignificant venting, it will be considered to be generally equivalent to a zero duty cycle. Therefore, the use of the term “plurality” in conjunction with the number of intermediate venting commands or steps of the method of the present invention shall mean at least two magnitudes of venting commands above the minimal magnitude and including the maximum magnitude. This use of the term “plurality” will be clear from the following description of the preferred embodiment of the present invention.
In
With continued reference to
With continued reference to
Line 102 in
It can be seen that the various rates of closure between the current venting command from the engine control module 90 and the desired magnitude of eighty-five percent can be tailored to suit the characteristics of both the lift pump 34 and the high pressure pump 40. It should be understood, however, that each marine propulsion system may require different rates of pressure decay within the fuel supply module 30. The present invention provides a technique which allows different operating characteristics of different lift pumps and high pressure pumps to be accommodated by selectively controlling the rate of pressure decay within the fuel supply module.
It should be understood that the illustration in
With reference to
The method of the present invention provides a flow control device 70, or canister purge valve, that is connected in fluid communication with a fuel reservoir 30 of the fuel system. It then determines a desired venting command, such as through the use of the table in
Although the present invention has been described with particular specificity and illustrated to show various preferred embodiments, it should be understood that alternative embodiments are also within its scope.
This application is a continuation of U.S. patent application Ser. No. 11/434,090, filed May 15, 2006, which is incorporated by reference in its entirety.
Number | Name | Date | Kind |
---|---|---|---|
3835822 | Mickle et al. | Sep 1974 | A |
4683861 | Breitkreuz et al. | Aug 1987 | A |
4844043 | Keller | Jul 1989 | A |
5103793 | Riese et al. | Apr 1992 | A |
5231958 | Takahashi et al. | Aug 1993 | A |
5389245 | Jaeger et al. | Feb 1995 | A |
6253742 | Wickman et al. | Jul 2001 | B1 |
6253744 | Saruwatari et al. | Jul 2001 | B1 |
6321735 | Grieve et al. | Nov 2001 | B2 |
6390871 | Wickman et al. | May 2002 | B1 |
6553974 | Wickman et al. | Apr 2003 | B1 |
6694955 | Griffiths et al. | Feb 2004 | B1 |
6718953 | Torgerud | Apr 2004 | B1 |
7124021 | Moskwa et al. | Oct 2006 | B2 |
7263969 | Sakamoto | Sep 2007 | B2 |
7367326 | Shikama et al. | May 2008 | B2 |
20040045538 | Tagami et al. | Mar 2004 | A1 |
Number | Date | Country |
---|---|---|
0 322 790 | Jul 1989 | EP |
1 308 604 | May 2003 | EP |
2001-140720 | May 2001 | JP |
Number | Date | Country | |
---|---|---|---|
Parent | 11434090 | May 2006 | US |
Child | 13954105 | US |