Patent Grant
11549455
The present invention relates to methods and systems for operating an internal combustion engine used to power a vehicle in a skip fire manner More specifically, if the engine receives a request for zero or negative torque, the engine can operate in a deceleration cylinder cut-off mode or a skip cylinder compression braking mode, in which some working cycles operate as a compression release brake.
Most vehicles in operation today (and many other devices) are powered by internal combustion (IC) engines. Internal combustion engines typically have a plurality of cylinders or other working chambers where combustion occurs. Under normal driving conditions, the torque generated by an internal combustion engine needs to vary over a wide range in order to meet the operational demands of the driver. Over the years, a number of methods of controlling internal combustion engine torque have been proposed and utilized. Some such approaches contemplate varying the effective displacement of the engine. Engine control approaches that vary the effective displacement of an engine can be classified into two types of control, multiple fixed displacements and skip fire. In fixed multiple displacement control some fixed set of cylinders is deactivated under low load conditions; for example, an 8-cylinder engine that can operate on the same 4 cylinders under certain conditions. In contrast, skip fire control operates by sometimes skipping and sometimes firing any given cylinder. In general, skip fire engine control is understood to offer a number of potential advantages, including the potential of significantly improved fuel economy in many applications. Although the concept of skip fire engine control has been around for many years, and its benefits are understood, skip fire engine control has only recently started to be used in commercially available engines.
It is well understood that operating engines tend to be the source of significant noise and vibrations, which are often collectively referred to in the field as NVH (noise, vibration and harshness). In general, a stereotype associated with skip fire engine control is that skip fire operation of an engine will make the engine run significantly rougher, that is with increased NVH, relative to a conventionally operated engine. In many applications such as automotive applications, one of the most significant challenges presented by skip fire engine control is vibration control. Indeed, the inability to satisfactorily address NVH concerns is believed to be one of the primary obstacles that has prevented widespread adoption of skip fire types of engine control.
Prior art U.S. Pat. No. 10,077,726 describes an engine capable of cylinder deactivation. The engine is capable of operating in a number of engine cylinder mode regions where only selected cylinder firing patterns can be activated. The boundaries of the engine cylinder mode regions may be adjusted based on the vehicle mass or vehicle weight. The patent describes making a boundary adjustment based on interpolation between a baseline weight and maximum gross vehicle weight. While this type of adjustment may provide acceptable performance in some cases, it fails to recognize how a change in a vehicle's mass or mass distribution may affect the position and magnitude of vehicle resonances that impact the transfer of engine noise and vibration into the engine cabin. The patent also fails to disclose how to select a cylinder firing pattern among the allowed firing patterns within an engine cylinder mode region. The present application describes improvements over the prior art that provide additional skip fire control features and enhancements that can improve performance in a variety of applications.
Compression release braking (CRB) is a method of opening a cylinder exhaust valve at or near top dead center (TDC) of a compression stroke of a working cycle. Compression release braking is commonly used in heavy trucks to provide engine braking, reducing use and wear of the truck's friction brakes. In the prior art, CRB is typically controlled manually by the truck operator using dashboard or stalk controls, which select fixed sets of cylinders to operate in CRB while the other cylinders operate in a fuel cutoff mode continuing to pumping air through the engine. For example, a 6-cylinder engine may operate with for example 2, 4 or 6 cylinders selected to operate with CRB. The overall level of engine braking is controlled by the operator's selection of transmission gear along with this multi-level choice of the number of CRB cylinders.
While the advantages of CRB are well known, manual determination of the number of CRB operating cylinders may be cumbersome is some situations. It would be desirable if use of CRB could be more automated so an appropriate level of engine braking may be determined automatically without driver intervention. It would also be desirable to deactivate cylinders that are not operating in CRB mode to reduce the pumping of air through the engine.
A method of operating an internal combustion engine having a plurality of working chambers mounted to a vehicle is described. The engine receives a request for zero or negative torque. A decision is made whether it is appropriate to have the internal combustion engine rotate without firing any working cycles. If operation without firing any working cycles is appropriate, the internal combustion engine operates in a deceleration cylinder cut off mode or a skip cylinder braking mode depending on the magnitude of the torque request. In the skip cylinder braking mode, selected working cycles of selected working chambers are operated in a compression release braking mode.
In another aspect, an engine controller for an internal combustion engine having a plurality of working chambers mounted to a vehicle is described. An operational skip fire profile module is arranged to determine whether it is appropriate to have the internal combustion engine rotate without firing any working cycles. If it is determined that operation without firing any working cycles is appropriate, the operational skip fire profile module directs the internal combustion engine to operate in a deceleration cylinder cut off mode or a skip cylinder braking mode depending on a magnitude of a torque request. In the skip cylinder braking mode, selected working cycles of selected working chambers are operated in a compression release braking mode.
The invention and the advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
In the drawings, like reference numerals are sometimes used to designate like structural elements. It should also be appreciated that the depictions in the figures are diagrammatic and not to scale.
The present invention relates to a system for operating an internal combustion engine in a skip fire manner to provide motive power to a platform, such as a vehicle, tractor trailer, locomotive, boat, or aircraft. More specifically, various implementations of the present invention take platform weight into account to help determine a suitable skip fire firing frequency, firing fraction, firing pattern, or firing sequence. In some embodiments, powertrain slip may also be adjusted based on vehicle weight. Use of the invention described herein may improve fuel economy when the platform is loaded heavily with occupants or cargo. For compression-ignition engines, use of the invention may reduce NOx and soot emissions in the engine exhaust. The invention generally results in fuel economy improvements and/or engine emission reductions in a platform operating with different cargo and occupant loads. Application of the invention may be especially useful in heavy duty/freight truck applications where the laden weight can be significantly higher (twice or more) than the unladen weight.
An internal combustion engine may be used as a power source to move a platform to which an internal combustion engine is mounted.
The invention described herein is broadly applicable to many types of motorized vehicles powered by an internal combustion engine that operate on roads or unimproved ground, such as sport utility vehicles, pick-up trucks, delivery vans, tractors, etc. The invention is also applicable to locomotives that operate on rails, ships that operate on water, or aircraft that fly in the air. The invention is applicable in any situation where an internal combustion engine supplies motive power to move a platform and the platform's characteristics, such as weight, weight distribution, towed load, etc. may differ at different times of operation.
The internal combustion engine may be a 4-stroke, internal combustion engines with pistons having reciprocating motion within a cylinder. A working cycle consists of a first, intake stroke, a second, compression stroke, a third, expansion, and a fourth, exhaust stroke. The stroke sequence is then repeated in a subsequent working cycle. For fired cylinders, the expansion stroke generates power from combusting fuel trapped within the enclosed volume defined by the piston, cylinder, and cylinder head. For skipped cylinders, no combustion occurs during the expansion stroke. A working cycle is deactivated if the intake or exhaust valve remain closed throughout the working cycle so that no air is pumped through the engine. As described below, a skipped working cycle may generally be deactivated, but there may be circumstances where skipped working cycles pump air through the engine. For a 4-stroke engine, an engine cycle represents two complete revolutions of the engine's crankshaft.
In vehicle applications, torque generated by the engine is transmitted to one or more of the vehicle's wheels. During operation of a motor vehicle, a driver in the vehicle cabin, or an autonomous control system, demands a wide range of engine torque levels and engine speeds to accommodate varying driving conditions. Most vehicles in operation today operate all engine working chambers or cylinders at a substantially equal load level to accommodate these variable torque requests. That is the load on each cylinder in the engine is approximately constant at any given time, but the cylinder load goes up and down to meet the varying torque request.
For naturally aspirated spark-ignition engines, working chamber load level is adjusted primarily through use of throttling air flow into the engine. Spark-ignition engines generally operate with a stoichiometric air/fuel ratio, so adjustment of the amount of inducted air with the throttle also results in a concomitant adjustment in the amount of injected fuel. Operation with a throttle is inefficient, since the working chambers are often operating far from maximum fuel efficiency conditions and throttling leads to pumping losses. Fuel efficiency can be significantly improved by operating the engine in a skip fire manner in which some working chambers are operating at or near an optimum fuel efficiency condition and the remaining working chambers are deactivated.
For compression-ignition engines, working chamber load level is adjusted primarily through use of adjusting an injected fuel mass into the working chamber. Compression-ignition engines can operate over a broad range of air/fuel ratios with relatively high efficiency; however, adjusting the working level load by adjustment of the injected fuel mass makes exhaust gas temperature control difficult. Also, excessively lean or rich air/fuel ratios can result in high levels of noxious combustion products in the exhaust gases, making clean up by an aftertreatment system difficult. Control over the air/fuel ratio and exhaust gas temperature can be significantly improved by operating the engine in a skip fire manner in which some working chambers are operating at or near an optimum combustion condition and the remaining working chambers are deactivated.
In general, skip fire engine control contemplates selectively skipping the firing of certain cylinders during selected firing opportunities. Thus, for example, a particular cylinder may be fired during one firing opportunity and then may be skipped during the next firing opportunity and then selectively skipped or fired during the next. This is contrasted with conventional variable displacement engine operation in which a fixed set of the cylinders are deactivated during certain low-load operating conditions. From an engine cycle perspective, skip fire control may have different sets of cylinders fired during sequential engine cycles to generate the same average torque, whereas conventional variable displacement operation fires the same set of cylinders.
One challenge with skip fire engine control is reducing noise, vibration and harshness (NVH) to an acceptable level. Generally, the acceptable NVH level is determined by providing a suitable comfort level for vehicle occupants. In the case of an unoccupied vehicle, the acceptable NVH level may be set by an acceptable level of noise emission into the environment or avoiding mechanical damage to powertrain elements. The noise and vibration produced by the engine can be transmitted to occupants in the vehicle cabin through a variety of paths. Some of these paths, for example the powertrain, can modify the amplitude of the various frequency components present in the engine noise and vibration signature. Specifically, lower transmission gear ratios tend to amplify vibrations, since the transmission is increasing the torque and the torque variation at the wheels. Engine noise and vibration can also excite various vehicle resonances, which can then couple into the vehicle cabin. Adding passengers and cargo to a vehicle increases the inertia of its body structure. For rigid body motion, the acceleration is inversely proportional to the inertia of the structure. This means that, at low frequencies (sometimes excited by skip fire operation), all other things being equal, a heavier vehicle body would have less vibration than a lighter vehicle body for the same excitation forces.
Some noise and vibration frequencies can be particularly annoying for vehicle occupants. In particular, low frequency, repeating patterns (e.g., frequency components in the range of 0.2 to 8 Hz) tend to generate undesirable vibrations perceived by vehicle occupants. The higher order harmonics of these patterns can cause noise in the passenger cabin. In particular, a frequency typically between 25 and 100 Hz may resonate within the vehicle cabin, the so called “boom” frequency. Commercially viable skip fire engine control requires operating at an acceptable NVH level while simultaneously delivering the desired or requested engine torque output and achieving fuel efficiency improvements or other gains.
A vehicle's NVH level varies with the vehicle weight, engine speed, firing fraction, and transmission gear. For example, consider an engine controller that selects a particular firing fraction that indicates a percentage of firings necessary to deliver a desired torque at a particular engine speed and gear. Based on the firing fraction, the engine controller generates a firing pattern to operate the working chambers of the engine in a skip fire manner. As is well known by those familiar with the art, at a given engine speed an engine that runs smoothly with some firing patterns may generate undesirable acoustic or vibration effects with other firing patterns. Likewise, a given firing pattern may provide acceptable NVH at one engine speed, but the same pattern may produce unacceptable NVH at other engine speeds. Engine induced noise and vibration is also affected by the cylinder load or working chamber output as described in U.S. Pat. No. 10,247,121, which is incorporated herein by reference in its entirety for all purposes. If less air and/or fuel is delivered to a cylinder, the firing of the cylinder will generate less output, as well as less noise and vibration. As a result, if the cylinder output is reduced, some firing patterns that were unusable due to their unacceptable NVH level at a high cylinder load may become usable at a low cylinder load. Similarly, if the vehicle weight changes, either due to an increased number of vehicle occupants or the vehicle carrying a cargo load, the NVH characteristics of the vehicle will change. Also, items externally attached to the vehicle, such as items in a roof rack or items in a towed trailer, may impact a vehicle's NVH characteristics. This is particularly true for tractor trailers, where the weight of the towed trailer can exceed the weight of the towing tractor. For vehicles towing a trailer, vehicle weight may refer to the combined weight of both the towing tractor and towed trailer. Obviously, in some situations the tractor operates without the trailer attached. The NVH characteristics of the tractor alone may differ from that of the tractor pulling an empty trailer.
The change in vehicle weight may be even more dramatic for vehicles such as, pick-up trucks, delivery trucks or tractor trailer combinations.
The impact of changing a vehicle's weight is depicted graphically in
Also shown in
The present application describes various engine controller implementations that take into account vehicle weight or load to provide fuel efficient, low emissions, operation with acceptable NVH characteristics. Generally, the engine controller is arranged to avoid or select particular firing frequencies, firing fractions, firing patterns or firing sequences, depending on the vehicle weight. The weight distribution may also be considered, such as the weight in a tractor relative to the weight in a trailer or cargo located in the trunk of a vehicle relative to occupants riding in the cabin. In some embodiments, slip in a powertrain disengagement element, such as a torque converter may also be adjusted based on vehicle weight or the presence or absence of a towed trailer.
For a skip fire controlled engine, there is a firing fraction or firing density at every engine speed and load condition which has optimal combustion characteristics, but does not necessarily have acceptable NVH characteristics. For a spark ignition engine, optimal combustion characteristics may correspond to combustion characteristics that provide for optimal fuel efficiency. For a compression ignition engine, optimal combustion characteristics may correspond to an air/fuel ratio which minimizes generation of noxious constituents in the exhaust stream and provides a suitable exhaust gas temperature for aftertreatment systems. At some engine speeds and cylinder loads there are some firing fractions, optimal for combustion characteristics, that exhibit unacceptable NVH in an empty or lightly loaded vehicle. These firing fractions may result in an acceptable NVH level if operating in a more heavily loaded vehicle. Improvements in fuel economy and/or vehicle emissions may be realized by using these formerly excluded firing fractions.
The engine generated NVH permitted for any particular vehicle may vary in accordance with the manufacturer's specifications. Generally, a vehicle is calibrated on a smooth test track with a baseline vehicle weight indicative of a lightly loaded vehicle. Current techniques for calibration of acceptable firing fractions in skip fire operation do not consider vehicle weight or inertial load variations. As a result, skip fire operation is limited by constraints set for a lightly loaded vehicle. These test conditions are often far different than real world driving conditions. For a skip fire controlled engine, this calibration procedure can unnecessarily limit the allowable operational firing fractions and thus reduce potential gains from skip fire operation.
The vibration response of a vehicle depends upon, among other things, the vehicle's mass. Given the same excitation, a more massive body will experience less vibrational acceleration in the low frequency range (vehicle rigid body motion) as depicted graphically in
Referring to
The base firing frequency calculator 102 receives input signal 114 (and when present other suitable inputs) and engine speed 132 and is arranged to determine a base firing frequency or firing fraction 111 that would be appropriate to deliver the desired output. The base firing frequency 111 is the firing frequency that delivers the requested torque with a cylinder load that corresponds to optimal or near optimal combustion conditions.
The base firing frequency 111 may be input into an operational skip fire profile module 136. The operational skip fire profile is determined based at least in part on the engine speed 132, a transmission gear 134, a vehicle weight 138, a torque converter slip 140 (if any) and other factors 142, which are all inputs to the operational skip fire profile module 136. The other factors 142 may include, but are not limited to road conditions, driver settings, accelerator pedal position, background cabin noise and vibration, ambient temperature, and the rate of change of the accelerator pedal position. As described in U.S. Pat. No. 9,739,212, which is incorporated herein by reference in its entirety for all purposes, some of these factors may influence what is perceived as an acceptable level of NVH. For example, road noise, use of an entertainment system, or other background noise and vibration, can mask engine generated NVH allowing an increase in the acceptable level of engine generated NVH.
The vehicle weight 138 used as an input into the operational skip fire profile module 136 may be a numerical value indicating the vehicle weight in pounds, kilograms or some other units. Alternatively, the vehicle weight may be converted into a smaller range of numbers denoting a level of loading or may be expressed as a percentage of maximum load. In an exemplary simple embodiment, vehicle weight signal 138 may be a variable denoted with three different states (1, 2, 3) corresponding to light loading, medium loading, and heavy loading as defined by a range of values for weight.
The input signal 114 may also serve as an input to the operational skip fire profile module 136. The operational skip fire profile module 136 determines an operational skip fire profile. The operational skip fire profile includes both an operational firing fraction (FFop) and a factor indicative of working chamber output, such as cylinder torque fraction, CTF, which indicates an actual cylinder load relative to a maximum cylinder load or some other reference cylinder load. Other indicators of cylinder load may be used in place of cylinder torque fraction, such as brake torque, cylinder load, net mean effective pressure, air per cylinder (APC), mass air charge (MAC), injected fuel mass, or any other parameter that is related to working chamber output. In various embodiments, the determination of the operational skip fire profile is based on various operating parameters, including but not limited to engine speed, transmission gear, vehicle weight, and torque request.
The operational skip fire profile module 136 takes into account multiple possible working chamber output levels when determining a suitable firing fraction. There are a wide variety of ways in which the operational skip fire profile module 136 can take into account different possible working chamber output levels. In some embodiments, for example, the operational skip fire profile module 136 references one or more lookup tables. The lookup tables may contain entries that indicate allowable engine speeds, cylinder loads and/or other engine parameters for particular firing fractions or frequencies, cylinder loads, gear ratios, and vehicle weights. There may be a discrete set of tables for discrete levels of vehicle loading (e.g. a different set of look-up tables for each 100 pound increase in weight). There may be three discrete set of tables corresponding to a lightly loaded, intermediately loaded, or heavily loaded vehicle.
One or more possible skip fire profiles are evaluated using the lookup tables. Each skip fire profile produces a desired engine torque via some combination of firing frequency and cylinder load. Some of these skip fire profiles will produce unacceptable NVH over certain engine speed ranges, gear settings and vehicle weights and will be excluded from consideration as the operational skip fire profile. Among the remaining skip fire profiles, the operational skip fire module 136 may advantageously select the skip fire profile having the combustion conditions as close as possible to optimal combustion conditions as the operational skip fire profile. Alternatively, the operational skip fire module 136 may use alternative criteria for making the determination of the operational skip fire profile.
In the illustrated embodiment shown in
The firing timing determination module 106 receives the operational firing fraction 117 from the operational skip fire profile module 136 and is arranged to issue a sequence of firing commands that cause the engine to deliver the percentage of firings dictated by an operational firing fraction 117. The sequence of firing commands (sometimes referred to as a drive pulse signal 116) outputted by the firing timing determining module 106 are passed to the firing control unit 110 which orchestrates the actual firings through firing signals 119 directed to the engine working chambers 112.
An advantage of various embodiments of the present invention is that they consider vehicle weight in determining an acceptable firing fraction. That is, they do not necessarily assume that the vehicle is in a lightly loaded condition. In some cases, a firing fraction or firing frequency that would be unacceptable with a lightly loaded vehicle may be acceptable for a heavily loaded vehicle. For example referring to the firing fraction depicted in
It should be appreciated that the engine controller 130 can determine the operational firing fraction 117 in a number of methods including one or more look-up tables. The format and structure of the data in the look-up tables, the number of entries, the inputs to the lookup table, the number of lookup tables and the values in the lookup table can, of course, be modified to suit the needs of different applications. Generally, the data from the aforementioned tables can be stored in or involve any suitable mechanism, data structure, software, hardware, algorithm or lookup table that indicates or represents usage constraints for particular types of firing-related operations, characteristics or firing fractions. For example, some lookup table structures may determine a firing fraction based on a set of input variables. Alternatively, some lookup table structures may determine a maximum cylinder load based on a different set of input variables. Other types of lookup table data structures may be used.
In particular, in some embodiments an operational skip fire profile may be determined without first determining a base firing frequency. In this case, a number of candidate skip fire profiles may be considered by the operational skip fire profile module 136 that deliver the requested torque. The operational skip fire profile module 136 may then select from these candidate skip fire profiles based on multiple criteria; including, but not limited to, NVH and combustion characteristics.
In additional embodiments of the present invention, multiple levels of acceptable NVH may be used. This effectively changes the height of the acceptable NVH criteria line 160 in
Any and all of the described operations may be arranged to refresh their determinations/calculations very rapidly. In some preferred embodiments, these determinations/calculations are refreshed on a firing opportunity by firing opportunity basis although, that is not a requirement. Skip fire control that makes firing decisions on a firing opportunity by firing basis may be referred to as dynamic skip fire (DSF) control. In some embodiments, for example, the selection of an operational skip fire profile is performed on a firing opportunity by firing opportunity basis. An advantage of firing opportunity by firing opportunity control of the various components is that it makes the engine very responsive to changed inputs and/or conditions. Although firing opportunity by firing opportunity operation is very effective, it should be appreciated that the various processes can be refreshed more slowly while still providing good control (e.g., the firing fraction determinations may be performed every revolution of the crankshaft, every two or more firing opportunities, etc.).
Any of the operations described herein may be stored in a suitable computer readable medium in the form of executable computer code. The operations are carried out when a processor executes the computer code. Such operations include but are not limited to any and all operations performed by the firing fraction calculator 102, the firing timing determination module 106, the firing control unit 110, the powertrain parameter adjusting module 108, operational skip fire profile module 136, the engine controller 130, or any other module, component or controller described in this application.
Other types of sensors or combinations of sensors can be used to infer the weight of a vehicle. In one method, the weight/loading of the vehicle may be derived by measuring the torsional speed fluctuation of a rotating component in the vehicle powertrain. Examples of rotating components that are commonly measured include, but are not limited, to an engine crankshaft, a transmission input/output/intermediate shaft, a propshaft, a half-shaft or a driven wheel(s). Other rotating component speeds could be sensed directly or indirectly. An increase in the vehicle's inertia would typically lead to a reduction in the amplitude of speed fluctuations of one or more of the rotating components mentioned above. This relationship can be stored in a table or recreated using a real-time model running in the engine controller.
In a table-based embodiment, a table contains expected torsional fluctuation values for one standard vehicle weight. The actual operating weight is estimated by comparing the actual measured torsional fluctuation with the standard table value. A lower actual measurement compared to the table would indicate a higher vehicle mass and vice versa. For a given firing fraction, mean engine speed, transmission gear, and engine torque, the expected torsional fluctuation is stored. This will be a four-dimensional (4D) table or a series of three-dimensional (3D) tables. If the torsional fluctuation varies linearly with engine torque, the table can be simplified to a single 3D table or a series of two-dimensional (2D) tables.
In another look-up table-based embodiment, multiple tables are stored corresponding to multiple vehicle weights. These would be multiple 4D tables with firing fraction, mean engine speed, engine torque, and transmission gear as variables (or multiple 3D tables if engine torque can be removed as a variable). The real-time measured torsional fluctuation may then be compared against these tables and the vehicle weight is estimated by interpolating/extrapolating from the table values for different vehicle weights.
In another embodiment, the expected torsional fluctuation is calculated by a model (physical, machine learning, or some other type of model). The model result may then be compared against the real-time measured torsional fluctuation in order to estimate the operational vehicle weight.
The torsional fluctuation of a rotating component may be calculated from a high speed measurement of rotational speed. The fluctuation can be separated from mean or average speed via high pass filtering the speed signal. The high pass filtered signal may be further processed by calculating a RMS (root mean square) value of speed fluctuations within a moving window. This signal provides a metric of the level of torsional speed fluctuation. There may be different methods to process the measured rotational speed to obtain a torsional fluctuation metric. The same method to calculate the real-time fluctuation during operation may be used to populate the calibration tables of expected values or used in the real-time model.
Another method to estimate a vehicle weight or mass is through measurement of various engine and vehicle parameters and vehicle speed or acceleration. Unlike the previously described method, this method uses average or slowly moving values for vehicle speed or acceleration, rather than rapid fluctuations in these values. Generally, the power generated by operating the engine (Peng) is used to propel the vehicle. The power generated by the engine (Peng) may be given by the product of the engine torque (T) and engine speed (w). Torque is generally estimated and engine speed is generally measured in modern vehicles, but estimates or measurements can be used for either or both. Various formulas may be used determine the power required to propel the vehicle (Pveh). An example of such a formula is shown in Eq. 1.
Pveh=(a+b*v+c*v2+I*α+m*(a+grade*gravity))*v (Eq. 1)
In Eq, 1 a, b, and c are constants that can be determined experimentally, or could be based on the vehicle's design, or could be estimated during operation of the vehicle. v is the vehicle velocity (speed), I is the effective rotational inertia, α is the angular acceleration of the engine, m is the vehicle mass, a is the linear acceleration of the vehicle, grade is the slope of surface on which the vehicle is located, and gravity is the gravitational acceleration on the vehicle. All of these quantities are generally known with the exception of the vehicle mass, which can vary greatly depending on the vehicle load as previously described.
Eq. 1 may be rearranged to solve for the vehicle mass and the engine power (T*ω) may be substituted for the vehicle power to yield Eq. 2 for the vehicle's mass.
m=(T*ω/v)−(a+b*v+c*v2+I*ω)/(a+grade*gravity) (Eq. 2)
All of these quantities on the right side of Eq. 2 are generally known, so Eq. 2 can be solved for the vehicle mass. As noted earlier, the vehicle mass can vary greatly depending on the vehicle load. In practice, the parameters in Eq. 2 may be measured multiple times under multiple driving conditions and Eq. 2 solved multiple times. An average of these various measurements and calculations may be used as an estimate for the vehicle weight. The equation and estimates can be adjusted for losses due to friction of, among other things, transmission, differentials, or wheel bearings. The vehicle may be a single unit or may be a platform composed of multiple, mechanically linked units, such as a tractor trailer. Any of the described systems and methods for measuring or estimating a vehicle weight may be used either individually or in combination.
In some cases, an additional input may be a signal(s) indicative of trailer weight. These trailer signals may be based on the same types of sensors used to infer the vehicle weight.
Input from the various weight sensors, or other sensors and calculations used to estimate weight, may be processed and calculated in the vehicle weight monitor 605 to approximate the vehicle's weight compared to its known empty curb weight. The difference between the two weights or the ratio of the two weights can then be used as an input to a CTF torque limit table modifier 610 to adapt firing decisions for the new vehicle inertia.
In one embodiment, the vehicle weight monitor 605 generates a signal that is indicative of vehicle weight and the weight of a towed trailer (if present). These signals may be based on levels (e.g., 2, 3 or more vehicle and trailer weight levels) or may be a continuously variable signal indicative of the vehicle's/trailer's weight. A CTF Torque Limit Table Modification Module 610 may utilize the outputs of the vehicle weight monitor 605 to determine modified CTF/Torque limits based on the vehicle and trailer weight. A trailer weight signal of zero means that no trailer is attached. The modified CTF/Torque limits are used by a firing fraction selector 615 to select an operational firing fraction for the current engine operating parameters, such as a torque request, engine speed, and gear setting. Generally, as the vehicle weight increases, the allowable cylinder load will increase as the increased vehicle mass reduces the amount of engine vibration that reaches the vehicle cabin. This allows more firing fractions to have acceptable NVH characteristics as the vehicle's weight increases.
In one embodiment, the vehicle weight monitor 605, CTF/Torque Limit Modification Module 610, and Firing Fraction Selector 615 are implemented as hardware, firmware, or software within the operational skip fire profile module 136 (see
In one embodiment, the CTF/Torque limits are modified from a base calibration. The modified CTF limits are then used to select the best firing fraction for optimal combustion and acceptable NVH given the vehicle and trailer weight levels for a given set of operating parameters, such as a torque request, engine speed, and gear.
Alternatively a discrete number of preloaded sets of CTF/Torque limit tables for various vehicle and trailer weight levels may be provided and used to adjust the CTF limit. For example, if the vehicle weight monitor has three vehicle weight output levels (e.g., light, intermediate, and heavy), then preloaded CTF limits may be provided for each level of vehicle weight.
The above calibrations may be loaded into the DSF engine controller either via lookup tables (for different weight ranges), as a real-time model based calculation, or as a simple multiplier on the baseline torque limit tables as a function of vehicle weight.
For an input with distinct levels, there are a distinct number of calibrations in terms of torque limits. This can be pre-loaded as separate tables or calculated using a multiplier corresponding to each loading level, adjusting the existing table values in real-time. For an input containing a continuous numerical value, the calculation may be an adjustment on the baseline tables based on a multiplier or function of the sensed weight.
It may be possible to update the above adjustments to the cylinder torque limits or firing fraction only when the vehicle comes to a stop, where loading or unloading of passengers and cargo may occur. The weight change on a moving vehicle may be small or slow enough that a weight-based adjustment need not be continuously updated. Making the weight-based adjustment only once during a drive cycle reduces computational load on an engine controller or other device that determines the weight-based adjustment. Adjustments in the calibration for higher or lower weights compared to a baseline weight may be either derived through measurements or through calculations.
In an alternative embodiment, slip in a disengagement element, such as a torque converter can be varied based on vehicle weight. Many vehicles deliberately use a calibrated level of slip in a torque converter to provide an acceptable level of NVH. As previously described, a heavily loaded vehicle generally experiences less NVH at a given engine operating condition than a lightly loaded vehicle. As a result, if an engine controller, such as engine controller 130, receives input indicating that a vehicle weight has increased from its empty curb weight, the amount of allowed slip in the torque converter may be reduced. This results in improved in fuel efficiency, since more of the engine rotation is transmitted to the wheels. It should be appreciated that the engine control may adjust both the operating firing fraction and torque converter slip in response to a change in the vehicle mass or it may adjust either individually. The adjustment may be based on adjustment of which powertrain operating parameter, firing fraction or slip, offers the greatest improvement in fuel efficiency. In some cases, such as vehicles with a manual transmission having a clutch, the disengagement element slip cannot be adjusted and only the firing fraction may be adjusted in response to a sensed increase in vehicle weight.
In some driving situations an engine controller 130 may receive a request for the internal combustion engine to deliver zero or negative torque, such as when decelerating or going down a hill. In this case, an engine may be operated in a deceleration cylinder cut off (DCCO) mode or a skip cylinder compression braking mode depending on the magnitude of the negative torque request. In the deceleration cylinder cut off mode, all of the engine's cylinders are deactivated. This results in little or no pumping of air through the engine and negative torque primarily arises from engine friction. This results in a relatively low level of engine braking. Operating an engine in a deceleration cylinder cut off mode has been disclosed in U.S. Pat. Nos. 9,790,867 and 10,167,799 assigned to the Applicant. An advantage of DCCO operation is that no air is pumped through the engine, which avoids flowing relatively cool air through an aftertreatment element that may be present in the exhaust system, reducing the temperature of the aftertreatment element. If adequate elevated temperatures are not maintained within the aftertreatment element, its temperature may drop such that it no longer effectively converts noxious engine emissions to more benign tailpipe emissions. In a lightly loaded vehicle DCCO may be used more often than in a heavily loaded vehicle, since less negative engine torque is required to maintain the vehicle on its desired speed trajectory. A decision whether to use DCCO or skip cylinder compression braking may thus be based at least in part on vehicle weight.
In the skip cylinder compression braking mode, selected working cycles of selected working chambers are operated in a compression release braking mode. The other working chambers may operate so that they are not fired. The not fired working cycles may be either deactivated or operate to pump air through the engine. In other words, selected working cycles of selected working chambers may be deactivated, such that their exhaust valve stays closed during selected working cycles. Still other selected working cycles of selected working chambers may open their exhaust valve during an exhaust stroke, essentially in the same manner as if the cylinder were fired, but with no fuel injection or combustion. These working cycles may be referred to as pumping working cycles. This mode of operation is described in U.S. Pat. No. 9,328,672, which is assigned to the Applicant. Alternatively, for engines equipped with a compression release or Jake brake® (a registered trademark of Jacobs Vehicle Systems, Bloomfield, Conn.) system the exhaust valve may be opened at or near the end of the compression stroke when the piston is close to its top dead center position. Opening the exhaust valve at or near the end of the compression stroke generally results in more aggressive braking as compared to opening the exhaust valve during the exhaust stroke. Skip cylinder compression braking has at least some cylinders operating as a compression release brake. Compression release braking may be referred to as retarder braking; however, retarder brakes may take other forms such as hydraulic or electrical.
Skip cylinder compression braking may be combined with wheel mounted friction brakes to slow a vehicle or control a vehicle's speed while moving downhill. If is often desirable to use skip cylinder compression braking as much as possible to minimize wear and prolong the service life of the friction brakes. The desired amount of braking can be inferred from the brake pedal position, and from this [and other inputs, such as the engine speed, vehicle weight, road grade, and other variables] a desired engine braking force can be calculated. This, in turn, may be used to derive a ‘skipping fraction’ which can be input to an algorithm that determines a skipping pattern. The algorithm may use a sigma delta converter, such as a first order sigma delta converter, or use a lookup table to determine a skipping pattern that provides the desired amount of braking. The skipping pattern may include cylinders operating as a compression release brake (open exhaust valve near top dead center), cylinders operating as air pumps (open exhaust valve near bottom dead center), or deactivated cylinders (exhaust valve remains closed through the working cycle). An algorithm determines the number of cylinders on average that are operating in compression release manner, i.e. the density of compression release braking working cycles. As the magnitude of the negative torque request increases the density of compression release braking working cycles increases, increasing the magnitude of the engine braking. The algorithm may use the acoustic response characteristics of the exhaust system to prevent acoustic excitations at frequencies or frequency ranges that would result in objectionable NVH. A driver also may repeatedly tap the brakes generating a signal for an increased density of compression release braking working cycles.
Flowchart 700, shown in
The control sequence illustrated in
As noted above that there may be a number of no engine torque operating conditions in which it might not be desirable to go into DCCO mode. For example, in most non-hybrid engines, it is desirable to keep the crankshaft rotating at some minimum speed (e.g. at an idle speed) while the vehicle is being operated. Therefore, the engine operating rules may dictate that a DCCO mode will only be entered when the crankshaft is spinning at speeds above a designated DCCO entry engine speed threshold thereby preventing entry into the DCCO mode when the engine is operating at an idle or near idle engine speed. Similarly, in many applications it may not be possible to fully decouple the crankshaft from the driveline. Thus, the engine operating rules may dictate that the DCCO mode may not be entered when the vehicle is stopped or moving slowly—e.g., traveling a speed lower than a DCCO entry threshold vehicle speed—which may vary as a function of gear or other operating conditions. For turbocharged engines, DCCO operation may be prohibited if the turbocharger rotation rate falls below a threshold value. In another example, DCCO may be inappropriate while certain diagnostic tests are being performed. DCCO operation may also be undesirable (or specifically desirable) during certain types of traction control events, etc. It should be appreciated that these are just a few examples and there are a wide variety of circumstances in which DCCO may be deemed appropriate or inappropriate. The actual rules defining when DCCO operation is and is not appropriate can vary widely between implementations and are entirely within the discretion of the engine control designer.
In a similar manner there may be certain circumstances when vehicle braking is required, but it is not appropriate to operate in a skip cylinder compression braking mode. For example, skip cylinder compression braking may produce unacceptable NVH in some circumstances. Vehicle location may be determined automatically using an on-board global positioning system (GPS), so the engine controller can know automatically if compression release braking is allowed. For turbocharged engines, there may be a limitation on the density of deactivated working cycles to maintain a minimum turbocharger rotation rate. A mix of compression release braking working cycles and pumping working cycles may be used to maintain air flow through the engine to sustain turbocharger rotation. Thus, a pattern of compression release braking working cycles, deactivated working cycles, and pumping working cycles may be based at least in part on maintaining a turbocharger rotation rate above a threshold value.
When DCCO or skip cylinder compression braking mode is entered, there are several ways that the cylinders may be controlled. In some circumstances, each of the cylinders is deactivated in the next controllable working cycle after the decision to enter a DCCO mode is made (i.e., effective immediately). In other circumstances, it may be desirable to more gradually ramp the firing fraction down to DCCO using a skip fire approach in which some working cycles are fired and other working cycles are skipped. The skip fire ramp down approach works well when the engine is transitioning from a skip fire mode to a DCCO mode. However, it should be appreciated that the skip fire ramp down approach can also be used to facilitate transitioning to DCCO from all cylinder operation of an engine, or to DCCO from a variable displacement mode with a reduced displacement is being used (e.g., when operating using 4 of 8 cylinders, etc.).
In a similar manner when transitioning into skip cylinder compression braking mode the transition may be done gradually. For example, as an engine transitions from producing positive torque to negative torque there may be one or more engine cycles where the engine operates in a DCCO mode before some cylinders switch from being deactivated to compression release braking.
As noted above, there may be times when it is desirable to decouple the crankshaft from the transmission or other portion of the driveline. Therefore, when the DCCO mode is entered, the powertrain controller may optionally direct a torque converter clutch (TCC) or other clutch or driveline slip control mechanism to at least partially decouple the crankshaft from the transmission to reduce the coupling between vehicle speed and engine speed as represented by step 724. The extent of the decoupling that is possible will tend to vary with the specific driveline slip control mechanism(s) that is/are incorporated into the powertrain. There are a number of operating conditions where it may be desirable to mechanically decouple the engine from the driveline. For example, decoupling is desirable when the vehicle speed is zero, but the engine speed is not. During deceleration is may also be desirable to decouple the engine from the driveline, especially when a friction braking is being used. Other conditions such as transmission shifts also frequently benefit from decoupling the engine from the driveline. Gear shift status may therefore be used as a variable in determining whether it is appropriate to transition to use of DCCO or skip cylinder compression braking.
A characteristic of DCCO (deceleration cylinder cutoff) is that the engine has less resistance than it would during DFCO (deceleration fuel cutoff) due to the reduction of pumping losses. In practice, the difference is quite significant and can readily be observed when the engine is effectively disengaged from the transmission. If permitted, DFCO pumping losses would cause many engines to slow to a stop within a period on the order of a second or two at most, whereas the same engine may take 5-10 times as long to slow to a stop under DCCO (cylinder cutoff). Since DFCO arrests the engine quite quickly, it is common to keep the drive train engaged during DFCO, which means that the engine tends to slow with the vehicle and the pumping losses associated with DFCO contribute to engine braking. In contrast, when DCCO is used, the engine can be disengaged from the transmission to the extent permitted by the drive train components (e.g., a torque converter clutch (TCC), a dual-clutch transmission, etc.). In practice, this allows DCCO to be used for much longer periods than DFCO in certain operating conditions.
An advantage of using DCCO operation is that large amounts of air are not pumped through the engine, increasing an exhaust gas temperature. Diesel engines are particularly sensitive to excessive amounts of air passing through their aftertreatment system, which can lower aftertreatment element temperatures resulting in excess noxious emissions. The control logic depicted in
The engine may remain in the DCCO or skip cylinder compression braking mode until the engine controller determines that it is time to exit either of these modes. The two most common triggers for exiting tend to be either when a positive torque request is received or when the engine slows to a speed at which idle operation is deemed appropriate. Further reduction in engine speed may result in an undesired engine stall, so the engine is placed in idle operation to avoid stalling. Often, a positive torque request is caused by the accelerator pedal being depressed (sometimes referred to herein as accelerator tip-in). However, there may be a variety of other scenarios that require torque that are independent of accelerator pedal tip-in, such a control signal from a cruise control system or autonomous vehicle control system. For example, these types of scenario may occur when accessories such as an air conditioner, etc. require torque. Many vehicle air conditioners are activated by engagement of an air conditioner clutch to the vehicle powertrain, placing an additional torque load on the engine.
The acoustic response characteristics of the exhaust system are known when a vehicle or truck is assembled. Characteristics of the manufactured exhaust system may be pre-programmed into the engine controller in order to allow it to select the appropriate frequencies and frequency ranges to avoid when operating in a skip cylinder compression braking mode. If the original exhaust system is modified; for example, to add emissions control components or replace degraded components with new components that have different acoustic characteristics, the overall acoustic response of the exhaust system may be altered. In this case the original calibrations for the acoustic control algorithms may be in error, possibly resulting in unacceptable or illegal noise levels when operating in a skip cylinder braking mode.
In this case, a recalibration of the control algorithms may be done in a “training mode” that monitors acoustic characteristics under various skip cylinder compression braking conditions. This can take the form of onboard software that uses microphones existing in the vehicle cabin; for example, for handsfree phone use, voice recognition, or active noise control. It could also take the form of offboard software and microphones; for example, in the form of a software application that runs on a tester tablet or mobile phone and uses its microphone(s). By recalibrating the control algorithms, the vehicle can be made to operate at an acceptable noise level.
A certification process can be developed that satisfies mandated noise criteria. This would allow skip cylinder compression braking to be used without operator intervention. Automatic system operation would be transparent to the operator, eliminating concerns about prohibitions against use of manual compression release braking systems. This maximizes the benefits of reduction of wear and tear on friction brakes as well as reducing driver distraction.
In a manner analogous to the previously described situation where an engine is producing torque, a decision whether to enter DCCO mode or skip cylinder braking mode may be based at least in part on the vehicle weight. If the engine is operating in skip cylinder compression braking mode, the skip braking fraction or pattern may depend at least in part on the vehicle weight. For a lightly loaded vehicle a skip cylinder braking fraction or pattern will generally produce more NVH than if the vehicle is more heavily loaded. As such, more skip cylinder braking fractions or patterns will be available for use if the vehicle is more heavily loaded. Of course, the required engine torque to slow the vehicle will also be greater for a more heavily loaded vehicle.
In some embodiments, the internal combustion engine may be part of a hybrid powertrain that includes an electric motor/generator in addition to the internal combustion engine. The electric motor/generator can add or subtract torque from the powertrain. If the electric motor/generator is subtracting torque from the powertrain the energy taken from the powertrain may be stored in a battery. The stored energy may then be added back to the powertrain in the form of positive torque when desired.
The electric/motor generator may be used to subtracted torque from the powertrain instead of, or in addition to, using skip cylinder compression braking. Use of the battery to store powertrain energy depends on the battery state of charge and battery temperature. If the battery is fully charged or almost fully charged, little or no torque may be removed from the powertrain by the electric motor/generator, so skip cylinder braking must be used primarily or exclusively. Conversely, if the battery is depleted of charge, significant amounts of torque may be removed from the powertrain by the electric motor/generator, so skip cylinder braking may be used lightly or not at all. The rate of charging and discharging the battery is dependent on the battery's temperature, so this also may influence the extent to which skip cylinder compression braking is used. In a hybrid system, the engine may operate in a stop/start mode where the engine automatically turns itself off during a drive cycle when there is a request for zero or negative torque. By using the electric motor/generator to add and remove torque, the overall powertrain fuel efficiency may be improved, since torque subtracted from the powertrain by skip cylinder compression braking represents lost energy which cannot be recovered.
It should be appreciated that the engine controller 130 is not limited to the specific arrangement shown in
The invention has been described primarily in the context of operating a 4-stroke, internal combustion piston engines suitable for use in motor vehicles. The internal combustion engine may be a spark ignition engine or a compression ignition engine. However, it should be appreciated that the described applications are very well suited for use in a wide variety of internal combustion engines. These include engines for virtually any type of vehicle or platform—including cars, trucks, boats, aircraft, motorcycles, scooters, locomotives, ships, aircraft etc.; and virtually any other application that involves the firing of working chambers and utilizes an internal combustion engine. The various described approaches work with engines that operate under a wide variety of different thermodynamic cycles—including virtually any type of two stroke piston engines, diesel engines, Otto cycle engines, Dual cycle engines, Miller cycle engines, Atkinson cycle engines, Wankel engines and other types of rotary engines, mixed cycle engines (such as dual Otto and diesel engines), hybrid engines, radial engines, etc. It is also believed that the described approaches will work well with newly developed internal combustion engines regardless of whether they operate utilizing currently known, or later developed thermodynamic cycles. The engine may be naturally aspirated or boosted with a turbocharger, supercharger, or a twin charger. In the case of a boosted engine, the maximum cylinder load may correspond to the maximum cylinder air charge obtained by boosting the air intake.
Although only a few embodiments of the invention have been described in detail, it should be appreciated that the invention may be implemented in many other forms without departing from the spirit or scope of the invention. There are several references to the term, firing fraction. It should be appreciated that a firing fraction may be conveyed or represented in a wide variety of ways. For example, the firing fraction may take the form of a firing pattern, sequence or any other firing characteristic that involves or inherently conveys the aforementioned density or percentage of firings. There are also several references to the term, “cylinder.” It should be understood that the term cylinder should be understood as broadly encompassing any suitable type of working chamber. Therefore, the present embodiments should be considered illustrative and not restrictive and the invention is not to be limited to the details given herein.
This application claims priority of U.S. Provisional Application Nos. 62/830,763, filed Apr. 8, 2019 and 62/860,591, filed Jun. 12, 2019, both of which are incorporated by reference in their entirety.
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