The present invention relates to a method for diagnosing the operational state of a variable valve actuation (VVA) device using a knock signal.
Historically, the performance of an internal combustion engine has been limited by fixed valve lift profiles, i.e., fixed timing of the opening and closing of the valves relative to the angular position of the engine crankshaft and fixed lift of the valves. However, modern internal combustion engines may utilize one of several methods and/or devices to vary the valve lift profile to, at least in part, control the flow of gas and/or air into and/or out of the engine cylinders. Modern internal combustion engines may utilize devices, such as, for example, variable valve actuating mechanisms, two-step cam profile switching mechanisms (i.e., variable valve lift devices (VVL)), and deactivation valve lifters to vary the amount by which the valves of an engine are lifted (i.e., opened). Furthermore, engines may utilize devices, such as variable valve actuating (VVA) mechanisms and cam phasers, to vary the timing of the opening and/or closing of the engine valves relative to the angular position of the engine crankshaft. These VVA devices each have multiple modes of operation. For example, a variable valve lift (VVL) device has a “low lift” mode of operation and a “high lift” mode of operation. As a further example, a cylinder deactivation device has a “deactivation on” mode and a “deactivation off” mode. The selected mode of operation therefore alters the operation of the engine.
The addition of such variable valve actuation (VVA) hardware subsystems to internal combustion engines (e.g., both spark ignited and compression ignited) as described above introduces the challenge of detecting proper function as well as diagnosing improper function of one or more elements of the VVA subsystem (e.g., is the VVA device operating in the proper mode of operation?). There are differing diagnostic requirements of rigor based on whether the failure mode and its associated strategy is for OBD II compliance, Comprehensive Components compliance, or for device protection. Moreover, there are hardware consequences to the product designer for an inability to diagnose improper function during operation. For example, for a 2-step VVL device, the inability to diagnose “failure to achieve high lift” would require that the low-lift cam profile be robust to high engine speeds (e.g., redline), and this may force compromises in the design that can erode fuel economy benefits of low-lift operation. Type 2 cylinder deactivation hardware faces similar design issues.
Conventional diagnostic approaches taken to date have their practical limitations. As the primary function of VVA subsystems is to modify the pumping characteristics of the engine, and thus its combustion and torque characteristics, early implementations of VVA diagnostic algorithm strategies focused on using the existing engine sensors that monitor engine pumping and combustion parameters. However, as DOHC style engines—engines with more than 2 valves/cylinder—have become more common, it has been observed that this configuration has had the effect of reducing the signal-to-noise (S/N) ratio of such diagnostics.
For example, U.S. Pat. No. 7,047,924 entitled “METHOD FOR DIAGNOSING THE OPERATIONAL STATE OF A TWO-STEP VARIABLE VALVE LIFT DEVICE” issued to Waters et al., owned by the common assignee of the present invention and incorporated in its entirety herein, disclose a diagnostic method involving a comparison of estimated and expected engine cylinder pressures (e.g., a combustion parameter). The concept being that there may be a factor of 1.5 to 2 of separation between the cylinder pressures for the two modes of operation of the cylinders of an engine including a two-step variable valve lift device.
Finally, market pressure to minimize vehicle-level on-cost of these VVA technologies makes it desirable for any candidate diagnostic strategy to make use of the existing functionality wherever possible.
There is therefore a need for a low or no additional cost method for diagnosing a variable valve actuation (VVA) device or subsystem in an automotive vehicle.
The present invention is directed to a method for determining whether a variable valve actuation (VVA) device or subsystem is operating in an improper mode of operation. The method may performed in real-time by an embedded engine or powertrain controller configured to monitor and evaluate an already-available knock sensor (or sensors) output signal(s) obtained during a predetermined sampling window. The knock sensor signal can be processed to detect the presence (or absence) of an engine valve closing event. When a valve closing event is detected during the sampling window (i.e., the window being set-up in advance so as to include the expected valve closing event when the VVA device is operating properly), then the method can confirm proper function (i.e., no malfunction). Conversely, failure to detect valve closing events when they are expected to occur is indicative of a VVA malfunction.
A method according to the invention is therefore provided for diagnosing a variable valve actuation (VVA) device (or subsystem) associated with at least one valve in an engine. The VVA device is capable of operating in a plurality of operational modes. In one embodiment, the VVA device is a cylinder deactivation device (e.g., valve lifters). In another embodiment, the VVA device is a variable valve lift device (e.g., 2-step VVL device). In a still further embodiment, the VVA device may be a camshaft phasing device configured to adjust the phasing of a camshaft relative to a crankshaft angular position. The method includes several steps.
The first step involves defining a sampling window as a function of a selected operational mode of the VVA device. The VVA device being diagnosed will have an expected status during the defined-in-advance sampling window, corresponding to either the presence or the absence of a valve (or valves) closing event(s). The particulars of the sampling window (e.g., start time, duration, etc.) may be defined in either the time domain or the crankshaft angle domain. The next step of the method involves determining an actual status of the VVA device based on a knock sensor signal (or alternatively signals) obtained during the sampling window. The actual status corresponds to the presence or absence of a valve (or valves) closing event(s). The final step of the method involves recording a VVA device fault indicating that the VVA device is operating in an improper operating mode when the actual status (determined from the knock sensor signal) differs from the expected status.
The present invention, by utilizing a precisely determined sampling window (or multiple windows) is capable of sharing (e.g., with a spark knock control system) the output signal from an existing spark knock sensor with no additional cost beyond electronic controller resources (e.g., RAM, ROM and throughput).
While the present invention will find particular advantage as a diagnostic process embedded in an on-board controller of an automotive vehicle, it is also contemplated that the present invention may be alternatively embodied in automotive service and repair devices, for example, such as those that may be available for use by technicians in a dealer service bay (e.g., Tech-2 type devices).
Other features and advantages of the present invention are also presented.
The present invention will now be described, by way of example, with reference to the accompanying drawings.
Referring now to the drawings, wherein the Figures are for the purpose of illustrating an embodiment of the invention only,
Engine 12 may be a spark-ignition engine that includes a number of base engine components, sensing devices, output systems and devices, and a control system. And while the description of the present invention will take the form of a diagnostic method embedded in controller 14 of vehicle 11, it should be understood that other embodiments, such as, for example, stand-alone devices of the type used in a dealer service center, may be alternatively configured in accordance with the present invention as well.
With continued reference to
While a more detailed description of the various components shown in
VVA device 25 is controlled in accordance with a control signal 68 generated by electronic controller 14 pursuant to various pre-programmed strategies consistent with the type of VVA embodiment, as known. Additionally, each embodiment of VVA device 25 may be described as operating in one of a plurality of different operating modes. For example, for a cylinder deactivation valve lifter device, a first mode may be a “cylinder deactivation on” mode, while a second, different mode may be a “cylinder deactivation off” mode. Likewise, for a two-step variable valve lift (VVL) embodiment, a first mode of operation may be a “low lift” mode and a second, different mode of operation may be a “high lift” mode. For a cam phaser embodiment, various modes of operation correspond to the various, corresponding camshaft adjustments which result in differing valve opening/closing times with respect to the crankshaft angular position. One of ordinary skill in the art will recognize these and the many other variations that are possible.
Diagnostics are desired and/or required to have varying levels of detection and reporting capability with respect to any variable valve actuation (VVA) device included in vehicle 11. For example only, the so-called on board diagnostics II (OBD-II) regulations, “Comprehensive Components” requirements, and the like specify particular diagnostic capabilities to ensure that key operating features and components of the vehicle are not malfunctioning.
A first aspect of the present invention therefore involves determining proper VVA function, and is based on detecting the sound of the valve closing events of the VVA valve-lines of interest using one or more knock sensors 48. By utilizing a precise sampling window, either in the time domain or the crank angle domain, it is possible for both the spark knock control system and a VVA diagnostic system to share the output signal of the existing knock sensor or sensors, with no additional on-cost beyond processor resources (RAM, ROM and throughput).
A second aspect of the present invention involves verifying that the engine (and its rotating and/or reciprocating subsystems) is otherwise (i.e., other than its VVA device(s)) healthy before relying on the knock signal-based diagnostic to determine proper VVA device or subsystem function. As described above, a sampling window(s), either in the time domain or the crank angle domain, may be established for testing for the presence or absence of valve closing events. In this second aspect, an additional sampling window or multiplicity of sampling windows may be established for specifically targeting a quiet zone of “no expected valve closing events”. The electronic controller 14 is configured to monitor the valve-lines for proper operation, as a rationality check. This is to prevent the diagnostic algorithm for detecting VVA malfunction from falsely identifying a catastrophic failure elsewhere in the valve-line as a VVA device malfunction.
Step 88 involves defining a sampling window as a function of a selected operational mode. The VVA device or subsystem being diagnosed will have an expected status during the sampling window corresponding to either the presence or absence of a valve (or valves) closing event(s). That is, in a preferred embodiment, the sampling window is defined/selected (specifically with respect to timing and duration) so as to include the expected valve closing event. Note, as the mode of operation changes, so too will the particulars of the sampling window. The particulars of the sampling window (e.g., start time, duration, etc.) may be defined in either the time domain or the crankshaft angle domain. The method then proceeds to step 90.
Step 90 involves determining an actual status of the VVA device based on a knock sensor output signal (or alternatively multiple knock sensor output signals) obtained during the sampling window or windows. The actual status of the VVA device or subsystem (e.g., “active” or “inactive”) corresponds to the presence or absence of a valve (or valves) closing event(s). The method then proceeds to step 92.
Step 92 involves recording a VVA device or subsystem fault, indicating that the VVA device or subsystem is operating in an improper operating mode, when the actual status (i.e., determined from the knock sensor output signal) differs from the expected status.
In step 96, the method captures the knock sensor output signal obtained during the sampling window. The controller 14, in the method, is configured to determine whether the observed knock sensor output is indicative of the presence of a valve closing event (“ACTIVE”) or indicative of the absence of any valve closing events (“INACTIVE”). The method then proceeds to step 98.
In step 98, the method compares the windowed knock sensor status determined in step 96 to the VVA device or subsystem status (“ACTIVE” or “INACTIVE”), for example as maintained by controller 14. If the comparison indicates a match, then the knock sensor output in effect confirms that the VVA device/subsystem is operating in the proper mode of operation. However, if the comparison indicates a mismatch, then a counter is incremented. The method then proceeds to step 100.
In step 100, the method is configured to apply predetermined fault counter logic. The purpose of this logic is to ensure that noise or other transient influences do not falsely cause a fault flag to be set by the method. In the illustrated embodiment, a predetermined number (“X”) of counter increments (“bad votes”) must be incurred before the method will set a VVA fault flag. The method then proceeds to step 102.
In step 102, the method determines whether the VVA fault flag has been set. If the fault flag has not been set, then the VVA device/subsystem is operating properly, in the expected mode of operation. In this case, the method proceeds to steps 104 and 106, which confirm that the valve closing event(s) were as expected for the particular operating mode and that the VVA device/subsystem is clearly operating properly. The main diagnostic loop then proceeds through step 108, where mainline execution by controller 14 is resumed.
However, if the VVA fault flag has been set, then the answer in step 102 is that the VVA device/subsystem is not operating properly (i.e., not in the proper mode of operation, or otherwise malfunctioning). The method proceeds to steps 110 and 112, which confirm that any valve closing events were not as expected, and that the VVA device/subsystem is clearly operating improperly. The method proceeds to step 114.
In step 114, the method is further configured to activate a VVA diagnostic (e.g., an alert or the like), and, in one embodiment, command that a malfunction indicator lamp (MIL) be illuminated (observable to an operator or technician, for example, as known). The main diagnostic loop then proceeds through step 116, where mainline execution by controller 14 is resumed.
In step 120, the method defines one or more verification windows as a function of at least the available operating modes of the VVA device/subsystem so as to ensure that no valve closing events occur during the verification window (“quiet zone”). Then, the knock sensor output captured during the verification window is evaluated by controller 14 to determine the actual status, i.e., the presence (“ACTIVE” status) or absence (“INACTIVE” status) of valve closing events. The method proceeds to step 122.
In step 122, controller 14 compares the actual status determined in step 120 with an expected valve (or valve-line) activity status, which is either “ACTIVE” or “INACTIVE”. As above with the VVA device diagnostic method, when the comparison yields a match, activity is as expected and no malfunction is present. However, when the actual status does not match the expected status, then a base unhealthy engine fault counter is incremented. While the windowing function will inherently exclude episodes of actual spark knock for the subject cylinder since combustion does not occur at or around valve closing, an additional safeguard is warranted. Specifically, active spark knock occurring in adjacent cylinders, for some engine configurations, may occur at the same time as a valve closing event in the subject cylinder. Therefore, the present invention provides for an additional check and will exclude activity that could possibly be active spark knock occurring in an adjacent cylinder. The method proceeds to step 124.
In step 124, the method applies predetermined fault counter logic. The purpose of this logic is to ensure that noise or other transient influences do not falsely cause a base unhealthy engine fault flag to be set. In the illustrated embodiment, a predetermined number (“X”) of base unhealthy engine fault counter increments (“bad votes”) must be incurred before the method will set an unhealthy engine fault flag. The method then proceeds to step 126.
In step 126, the method determines whether the unhealthy engine fault flag has been set. If the unhealthy engine fault flag has not been set, then the base engine (apart from whether or not the VVA device/subsystem is operating properly) is in fact operating properly. In this case, the method proceeds to steps 128 and 130, which confirm that the engine was “quiet” when no valve closing event(s) were expected, and that the engine rotating and reciprocating subsystems are operating properly. The main diagnostic loop then proceeds through steps 132/134 where mainline execution by controller 14 is resumed.
However, if the unhealthy engine fault flag has been set, then the answer in step 126 is that the base engine (apart from VVA device/subsystem) is not operating properly. The method proceeds to steps 136 and 138, which confirm that the engine was “noisy” when no possible valve closing events (or when no possible active spark knock from adjacent cylinders) were expected, and that either the rotating and/or reciprocating subsystems of the engine are malfunctioning in some regard. The method proceeds to step 140.
In step 140, the method is further configured to activate a base engine diagnostic (e.g., alert or the like), disable the VVA device/subsystem diagnostic method (i.e., as set forth in steps 94-116), and, in one embodiment, command that a malfunction indicator lamp (MIL) be illuminated. The main diagnostic loop then proceeds through steps 142, 134 where mainline execution by controller 14 is resumed.
The present invention uses precise windowing of an already-available knock signal to diagnose the proper function of a VVA device or subsystem. This diagnostic capability can be added without any additional cost other than for processor resources (RAM, ROM and throughput).
With reference now again to
The base engine components of engine 12 include an engine block 16 with a plurality of cylinders, one of which is shown in
The system 10 includes a variety of sensors. The plurality of sensing devices of the exemplary internal combustion engine 12 are operable to measure ambient conditions, various engine conditions and performance parameters, and operator inputs. Typical sensors include a crankshaft position sensor 46, a camshaft position sensor 66, a manifold absolute pressure (MAP) sensor, one or more spark knock sensors 48, a throttle position sensor (not shown), a mass air flow sensor 50, an intake air temperature (IAT) sensor (shown as an element of the mass air flow sensor 50), a coolant temperature sensor 52, an exhaust gas recirculation (EGR) position sensor 54, and one or more oxygen sensors or other exhaust gas sensors 56.
The plurality of output systems and devices of the exemplary internal combustion engine 12 are operable to control various elements of engine 12, and include an air intake system, a fuel injection system, an ignition system, an exhaust gas recirculation (EGR) valve 56 and related system, a purge control system (not shown) and exhaust system 42, 44. The air intake system is operable to deliver filtered air to the combustion chamber 30 when the intake valve(s) 24 are open. The air intake system preferably includes an air filtering system fluidly connected to air control valve 32, which is fluidly connected to the intake manifold.
While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims.