The present description relates generally to methods and systems for a secondary air introduction system for an internal combustion engine.
Exhaust emission control devices, such as catalytic converters (also referred to herein as “catalysts”), are included in an exhaust system of a vehicle to treat exhaust gas components, such as hydrocarbons from unburnt fuel, prior to emission from the vehicle via a tail pipe. However, the exhaust emission control devices achieve higher emission reduction after reaching a predetermined operating temperature (e.g., a light-off temperature). Thus, undesirable vehicle emissions may be the greatest prior to the emission control devices reaching the predetermined operating temperature. To lower such vehicle emissions, various methods attempt to raise a temperature of the emission control device as fast as possible. For example, catalysts may be placed in a close-coupled position to the engine to minimize heat losses and catalyst warm-up time after an engine cold start. Other solutions aim to reduce an amount of hydrocarbons in the exhaust gas provided to the emission control device during the cold start.
One such method for reducing hydrocarbon emissions during warm-up includes introducing secondary air into the exhaust gas upstream of the emission control device. One example approach is shown by Zhang et al. in U.S. Pat. No. 8,955,473 B2. Therein, a port electric thermactor air (PETA) system is used to provide oxygen-rich air from an intake passage of an engine to an exhaust passage upstream of an emission control device. A vane pump or other air induction device may be used to draw the air from the intake passage and deliver it to the exhaust passage. The oxygen-rich air may react with unburnt hydrocarbons in the exhaust passage prior to reaching the emission control device.
However, the inventors herein have recognized potential issues with such systems. As one example, PETA systems are typically expensive and add to a cost and complexity of the vehicle system. Further, the inventors herein have advantageously recognized that some vehicle systems already include components that may be used to generate and supply air to the exhaust system. In particular, an engine may be equipped with a turbulent jet ignition (TJI) system that ignites an air-fuel mixture within a cylinder via combustion in a pre-combustion chamber, referred to herein as a “pre-chamber.” The pre-chamber may be a walled chamber located in a clearance volume of the cylinder (also referred to herein as a “main chamber” or “main combustion chamber”) and may include a spark plug. High pressure air and fuel are introduced into the pre-chamber via the TJI system, and when ignition is requested, the spark plug in the pre-chamber is actuated, igniting the air and fuel in the pre-chamber. Jets of flame and hot gas exit the pre-chamber and enter the cylinder via one or more small orifices in the pre-chamber walls. These jets ignite the air-fuel mixture in the cylinder to produce torque. As such, the inventors herein have identified that the TJI system may be used as either a thermactor or for ignition by adjusting operation of the TJI system, including fuel and spark delivery, based on a temperature of a catalyst, without using an external thermactor system.
In one example, the issues described above may be addressed by a method, comprising: during heating of a catalyst of an exhaust system coupled to an engine, initiating combustion in a cylinder via a spark plug directly coupled to the cylinder and providing secondary air via a turbulent jet system having an igniter. In this way, the air provided by the turbulent jet system may react with unburnt hydrocarbons following combustion, thereby reducing an amount of unburnt hydrocarbons that are delivered to the catalyst during warm-up.
As one example, the turbulent jet system may include a compressor positioned in an air delivery passage, a pre-chamber coupled to the cylinder, and a pre-chamber injector coupled to the pre-chamber and to the air delivery passage, downstream of the compressor, via a first port. As such, providing the secondary air via the turbulent jet system may include pressurizing the secondary air via the compressor. Further, in some examples, the secondary air, pressurized by the compressor, may be delivered to the pre-chamber via the injector. The secondary air may flow out of the pre-chamber to the cylinder, for example. In order to oxidize hydrocarbons after combustion in the cylinder, the secondary air may be injected near an end of an expansion stroke of the cylinder, such as close to bottom dead center (BDC) of the expansion stroke, and/or during an exhaust stroke of the cylinder. In some examples, the air delivery passage of the turbulent jet system may be coupled to an exhaust runner of the cylinder via a second port, and a valve may be disposed in the air delivery passage downstream of the first port and upstream of a second port. In such examples, providing the secondary air via the turbulent jet system may include adjusting a position of the valve. For example, the valve may be adjusted to a partially open position during a first operating condition, the valve may be adjusted to a fully open position during a second operating condition, and the valve may be adjusted to a fully closed position during a third operating condition. Further, the secondary air may be injected into the pre-chamber via the pre-chamber injector during each of the first operating condition and the third operating condition and not during the second operating condition. In this way, the secondary air may be provided to the exhaust runner and provided to the cylinder via the pre-chamber during the first operating condition, the secondary air may be provided to only the exhaust runner during the second operating condition, and the secondary air may be provided only to the cylinder via the pre-chamber during the third operating condition. The first operating condition may include a hydrocarbon output of the engine being greater than an upper threshold, the second operating condition may include the hydrocarbon output of the engine being less than the upper threshold and greater than a lower threshold, and the third operating condition may include the hydrocarbon output of the engine being less than the lower threshold. However, a hydrocarbon output of the vehicle may remain less than a threshold vehicle hydrocarbon output during each of the first, second, and third operating conditions. Additionally or alternatively, the first operating condition may include a duration since engine start being less than a first threshold duration, the second operating condition may include the duration since the engine start being greater than the first threshold duration and less than a second threshold duration, and the third operating condition may include the duration since the engine start being greater than the second threshold duration.
As another example, the heating of the catalyst may be responsive to a temperature of the catalyst being less than a threshold temperature, and the method may further comprise initiating combustion in the cylinder via the turbulent jet system after the temperature of the catalyst reaches or exceeds the threshold temperature. For example, initiating combustion in the cylinder via the turbulent jet system may include injecting fuel into the air delivery passage upstream of the first port to generate an air-fuel mixture, injecting the air-fuel mixture into the pre-chamber during a compression stroke of the cylinder via the pre-chamber injector, and actuating the igniter of the turbulent jet system at a desired ignition timing. For example, the igniter may be coupled to the pre-chamber. Further, initiating combustion in the cylinder via the turbulent jet system may include not actuating the spark plug directly coupled to the cylinder. Thus, the spark plug directly coupled to the cylinder may be used to provide ignition when the turbulent jet system is operated to provide secondary air while heating the catalyst, and the pre-chamber of the turbulent jet system may be used to provide ignition by actuating the igniter while heating the catalyst is not requested.
In an alternative configuration, the pre-chamber may include separate fuel and air injectors (instead of a common injector for both). For example, during a compression stroke, air may be injected via a pre-chamber air injector, and fuel may be injected via a pre-chamber fuel injector. The injected air and fuel may be ignited via the igniter of the turbulent jet system after the injections. Then, late in an expansion stroke or during an exhaust stroke of the same engine cycle, only air may be injected via the pre-chamber air injector (e.g., fuel is not injected via the pre-chamber fuel injector) to provide secondary air to the cylinder via the pre-chamber. In this way, the pre-chamber may be used during cold start to both provide ignition and secondary air into the cylinder.
By introducing secondary air at one or more locations coupled to the cylinder (e.g., the pre-chamber and the exhaust runner), late cycle hydrocarbons that were not burned during combustion in the cylinder may react with oxygen in the secondary air. As a result, the amount of hydrocarbons provided to the catalyst prior to the catalyst reaching its light-off temperature may be reduced. Further, the hydrocarbon oxidation may be enhanced due to the higher in-cylinder temperatures relative to providing secondary air to an exhaust manifold, for example. Vehicle costs and complexity may be reduced by providing the secondary air via the turbulent jet system compared with including an external thermactor pump and delivery lines. Overall, vehicle emissions prior to the catalyst reaching its light-off temperature may be reduced while the engine may operate with increased efficiency and reduced fuel consumption after the catalyst reaches its light-off temperature due to the turbulent jet system providing ignition.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
The following description relates to systems and methods for reducing exhaust emissions during an engine start. The engine may be the engine schematically shown in
Turning now to the figures,
Engine 10 may be controlled at least partially by a controller 12 and by input from a vehicle operator 113 via an accelerator pedal 116 and an accelerator pedal position sensor 118 and via a brake pedal 117 and a brake pedal position sensor 119. Accelerator pedal position sensor 118 may send a pedal position signal (PP) to controller 12 corresponding to a position of accelerator pedal 116, and brake pedal position sensor 119 may send a brake pedal position (BPP) signal to controller 12 corresponding to a position of brake pedal 117.
In some examples, vehicle 5 may be a hybrid vehicle with multiple sources of torque available to one or more vehicle wheels 160. In other examples, vehicle 5 is a conventional vehicle with only an engine. In the example shown in
Crankshaft 140 of engine 10 and electric machine 161 are connected in a powertrain via a transmission 167 to vehicle wheels 160 when one or more clutches 166 are engaged. In the depicted example, a first clutch 166 is provided between crankshaft 140 and electric machine 161, and a second clutch 166 is provided between electric machine 161 and transmission 167. Controller 12 may send a signal to an actuator of each clutch 166 to engage or disengage the clutch, so as to connect or disconnect crankshaft 140 from electric machine 161 and the components connected thereto, and/or connect or disconnect electric machine 161 from transmission 167 and the components connected thereto. Transmission 167 may be a gearbox, a planetary gear system, or another type of transmission. The powertrain may be configured in various manners including as a parallel, a series, or a series-parallel hybrid vehicle.
An exhaust passage 135 can receive exhaust gases from other cylinders of engine 10 in addition to cylinder 130. An exhaust gas sensor 128 is shown coupled to exhaust passage 135 upstream of an emission control device 178. Exhaust gas sensor 128 may be selected from among various suitable sensors for providing an indication of an exhaust gas air-fuel ratio (AFR), such as a linear oxygen sensor or UEGO (universal or wide-range exhaust gas oxygen), a two-state oxygen sensor or EGO (as depicted), a HEGO (heated EGO), a NOx sensor, a HC sensor, or a CO sensor, for example. Emission control device 178 may be a three-way catalyst, a NOx trap, various other emission control devices, or combinations thereof.
In the depicted view, intake valve 4 and exhaust valve 8 are located at an upper region of combustion chamber 130. Intake valve 4 and exhaust valve 8 may be controlled by controller 12 using respective cam actuation systems including one or more cams. The cam actuation systems may utilize one or more of variable displacement engine (VDE), cam profile switching (CPS), variable cam timing (VCT), variable valve timing (VVT), and/or variable valve lift (VVL) systems to vary valve operation. In the depicted example, intake valve 4 is controlled by an intake cam 151, and exhaust valve 8 is controlled by an exhaust cam 153. The intake cam 151 may be actuated via an intake valve timing actuator 101 and the exhaust cam 153 may be actuated via an exhaust valve timing actuator 103 according to set intake and exhaust valve timings, respectively. In some examples, the intake valves and exhaust valves may be deactivated via the intake valve timing actuator 101 and exhaust valve timing actuator 103, respectively. The position of intake cam 151 and exhaust cam 153 may be determined by camshaft position sensors 155 and 157, respectively.
In some examples, the intake and/or exhaust valve may be controlled by electric valve actuation. For example, cylinder 130 may alternatively include an intake valve controlled via electric valve actuation and an exhaust valve controlled via cam actuation, including CPS and/or VCT systems. In still other examples, the intake and exhaust valves may be controlled by a common valve actuator or actuation system or a variable valve timing actuator or actuation system. The various valve control systems may be used to vary a timing, open duration, and lift of intake valve 4 and exhaust valve 8.
Cylinder 130 can have a compression ratio, which is a ratio of volumes when piston 136 is at bottom dead center to top dead center. Conventionally, the compression ratio is in a range of 9:1 to 10:1. However, in some examples where different fuels are used, the compression ratio may be increased. This may happen, for example, when higher octane fuels or fuels with higher latent enthalpy of vaporization are used. The compression ratio may also be increased if direct injection is used due to its effect on engine knock.
As a non-limiting example, cylinder 130 is shown including a cylinder fuel injector 66. Fuel injector 66 is shown coupled directly to combustion chamber 130 for injecting fuel directly therein in proportion to a pulse-width of a signal FPW1 received from controller 12 via an electronic driver 168. In this manner, fuel injector 66 provides what is known as direct injection (hereafter also referred to as “DI”) of fuel into cylinder 130. In another example, fuel injector 66 may be a port injector providing fuel into the intake port upstream of cylinder 130. Further, while
Fuel may be delivered to fuel injector 66 from a high-pressure fuel system 180 including one or more fuel tanks, fuel pumps, and a fuel rail. Alternatively, fuel may be delivered by a single stage fuel pump at a lower pressure. Further, while not shown, the fuel tanks may include a pressure transducer providing a signal to controller 12. Fuel tanks in fuel system 180 may hold fuel with different fuel qualities, such as different fuel compositions. These differences may include different alcohol content, different octane, different heats of vaporization, different fuel blends, and/or combinations thereof, etc. One example of fuels with different heats of vaporization includes gasoline as a first fuel type with a lower heat of vaporization and ethanol as a second fuel type with a greater heat of vaporization. In another example, the engine may use gasoline as a first fuel type and an alcohol-containing fuel blend, such as E85 (which is approximately 85% ethanol and 15% gasoline) or M85 (which is approximately 85% methanol and 15% gasoline), as a second fuel type. Other feasible substances include water, methanol, a mixture of ethanol and water, a mixture of water and methanol, a mixture of alcohols, etc. In this way, air and fuel are delivered to cylinder 130, which may produce a combustible air-fuel mixture.
Fuel may be delivered by fuel injector 66 to cylinder 130 during a single cycle of the cylinder. Further, the distribution and/or relative amount of fuel delivered from cylinder fuel injector 66 may vary with operating conditions. Furthermore, for a single combustion event, multiple injections of the delivered fuel may be performed per cycle. The multiple injections may be performed during the compression stroke, intake stroke, or any appropriate combination thereof.
In the example shown in
Air may be delivered to pre-chamber injector 94 from a compressor 190. Note that in relation to the pre-chamber air system, the term “air” may refer herein to ambient air, oxygen (e.g., O2), hydrogen (e.g., H2), another combustible gas, or a mixture of such gases. Compressor 190 may be driven by an electric motor via electrical power received from battery 170, for example. In some examples, compressor 190 may be driven at a constant speed to provide a desired pressure upstream of compressor 190. In other examples, the speed of compressor 190 may be varied in order to adjust the pressure upstream of compressor 190. Further, a pre-chamber fuel injector 196 is shown coupled upstream of compressor 190. However, in other examples, pre-chamber fuel injector 196 may be positioned downstream of compressor 190. Pre-chamber fuel injector 196 may directly inject fuel into an air delivery passage coupled to pre-chamber injector 94 in proportion to a pulse-width of a signal FPW2 received from controller 12 via an electronic driver 172. Fuel may be provided to pre-chamber fuel injector 196 by high-pressure fuel system 180, described above. Alternatively, fuel may be provided to pre-chamber fuel injector 196 from a dedicated pre-chamber fuel system that may be included within or distinct from high-pressure fuel system 180. The fuel provided by pre-chamber fuel injector 196 may mix with the air provided by compressor 190 before being delivered to pre-chamber injector 94. Pre-chamber injector 94 may inject the received air and/or fuel into pre-chamber 138 in proportion to a pulse-width of a signal IPW received from controller 12. Thus, both air and fuel are delivered to pre-chamber 138, which may produce an air-fuel mixture with an air/fuel ratio (AFR) that may differ from an AFR in cylinder 130. In one example, the AFR in pre-chamber 138 may be richer (e.g., have a higher proportion of fuel relative to air) than the AFR in cylinder 130. In another example, the AFR in the pre-chamber may be the same as the AFR in the cylinder. In yet another example, the AFR in pre-chamber 138 may be leaner (e.g., have a higher proportion of air relative to fuel) than the AFR in cylinder 130.
Note that compressor 190 and pre-chamber fuel injector 196 may provide air and fuel to the pre-chamber of every cylinder of engine 10. Further, during some operating conditions, pre-chamber fuel injector 196 may be disabled so that no fuel is injected via pre-chamber injector 94, as will be elaborated herein. For example, pre-chamber fuel injector 196 may be disabled when TJI system 195 is operated to provide secondary air injection to cylinder 130 instead of providing ignition to cylinder 130.
However, in an alternative configuration, pre-chamber 138 may include separate air and fuel injectors instead of a combined air and fuel injector. For example, instead of providing fuel to every pre-chamber of the engine via pre-chamber fuel injector 196 by including pre-chamber fuel injector 196 coupled to air delivery passage upstream of pre-chamber injector 94, pre-chamber fuel injector 196 may be directly coupled to pre-chamber 138 for directly injecting fuel therein. In such a configuration, pre-chamber injector 94 may inject only air (instead of air and/or fuel). Such a configuration may enable additional operating flexibility of TJI system 195 by separately controlling whether air, fuel, or both are injected into pre-chamber 138.
Further, pre-chamber walls 139 include a plurality of openings 142. The plurality of openings 142 provide orifices between pre-chamber 138 and cylinder 130, fluidically coupling an interior of pre-chamber 138 to an interior of cylinder 130. As such, during some conditions, gases may flow between the interior of pre-chamber 138 and the interior of cylinder 130. For example, the gases (e.g., air, fuel, and/or residual combustion gases) may flow through each of the plurality of openings 142 with a directionality and rate based on a pressure difference across each of the plurality of openings 142 (e.g., between the interior of pre-chamber 138 and the interior of cylinder 130). The plurality of openings 142 may also provide an ignition flame from pre-chamber 138 to cylinder 130, as will be elaborated below.
An ignition system 88 may provide an ignition spark to pre-chamber 138 via pre-chamber spark plug 92 in response to a spark advance signal SA from controller 12, under select operating modes. Thus, pre-chamber spark plug 92 comprises an igniter of TJI system 195. A timing of signal SA may be adjusted based on engine operating conditions and a driver torque demand. For example, spark may be provided at maximum brake torque (MBT) timing to maximize engine power and efficiency. Controller 12 may input engine operating conditions, including an engine speed, an engine load, and an exhaust gas AFR, into a look-up table, which may output the corresponding MBT timing for the input engine operating conditions. In other examples, spark may be retarded from MBT to prevent an occurrence of knock. In still other examples, spark may be retarded from MBT to reduce engine torque, such as due to a decrease in the driver-demanded torque or a transmission gear shift event. When pre-chamber spark plug 92 provides the ignition spark to pre-chamber 138, the air-fuel mixture within the pre-chamber may combust, with the increased pressure of combustion sending jets of flame and hot gases into cylinder 130 via the plurality of openings 142. The plurality of openings 142 may be arranged such that the jets of flame are evenly distributed in cylinder 130. The jets of flame may ignite the air-fuel mixture in cylinder 130, causing combustion. After combustion, a mixture of exhaust gases from both pre-chamber 138 and cylinder 130 may be exhausted from cylinder 130 to exhaust manifold 48 via opening of exhaust valve 8.
In the example shown in
External exhaust gas recirculation (EGR) may be provided to the engine via a high pressure EGR system 83, delivering exhaust gas from a zone of higher pressure in exhaust passage 135 to a zone of lower pressure in intake manifold 44, downstream of throttle 62, via an EGR passage 81. An amount EGR provided to intake manifold 44 may be varied by controller 12 via an EGR valve 80. For example, controller 12 may be configured to actuate and adjust a position of EGR valve 80 to adjust the amount of exhaust gas flowing through EGR passage 81. EGR valve 80 may be adjusted between a fully closed position, in which exhaust gas flow through EGR passage 81 is blocked, and a fully open position, in which exhaust gas flow through the EGR passage is maximally enabled. As an example, EGR valve 80 may be continuously variable between the fully closed position and the fully open position. As such, the controller may increase a degree of opening of EGR valve 80 to increase an amount of EGR provided to intake manifold 44 and decrease the degree of opening of EGR valve 80 to decrease the amount of EGR provided to intake manifold 44. As an example, EGR valve 80 may be an electronically activated solenoid valve. In other examples, EGR valve 80 may be positioned by an incorporated stepper motor, which may be actuated by controller 12 to adjust the position of EGR valve 80 through a range of discreet steps (e.g., 52 steps), or EGR valve 80 may be another type of flow control valve. Further, EGR may be cooled via passing through an EGR cooler 85 within EGR passage 81. EGR cooler 85 may reject heat from the EGR gases to engine coolant, for example.
Under some conditions, EGR system 83 may be used to regulate a temperature of the air and fuel mixture within the combustion chamber. Further, EGR may be desired to attain a desired engine dilution, thereby increasing fuel efficiency and emissions quality, such as emissions of nitrogen oxides. As an example, EGR may be requested at low-to-mid engine loads. Thus, it may be desirable to measure or estimate an EGR mass flow. EGR sensors may be arranged within EGR passage 81 and may provide an indication of one or more of mass flow, pressure, and temperature of the exhaust gas, for example. An amount of EGR requested may be based on engine operating conditions, including engine load (as estimated via accelerator pedal position sensor 118), engine speed (as estimated via a crankshaft acceleration sensor), engine temperature (as estimated via an engine coolant temperature sensor 112), etc. For example, controller 12 may refer to a look-up table having the engine speed and load as the input and output a desired amount of EGR corresponding to the input engine speed-load. In another example, controller 12 may determine the desired amount of EGR (e.g., desired EGR flow rate) through logic rules that directly take into account parameters such as engine load, engine speed, engine temperature, etc. In still other examples, controller 12 may rely on a model that correlates a change in engine load with a change in a dilution request, and further correlates the change in the dilution request with a change in the amount of EGR requested. For example, as the engine load increases from a low load to a mid load, the amount of EGR requested may increase, and then as the engine load increases from a mid load to a high load, the amount of EGR requested may decrease. Controller 12 may further determine the amount of EGR requested by taking into account a best fuel economy mapping for a desired dilution rate. After determining the amount of EGR requested, controller 12 may refer to a look-up table having the requested amount of EGR as the input and a signal corresponding to a degree of opening to apply to EGR valve 80 (e.g., as sent to the stepper motor or other valve actuation device) as the output.
Controller 12 is shown in
Controller 12 may receive various signals from sensors coupled to engine 10, in addition to those signals previously discussed, including a measurement of inducted mass air flow (MAF) from a mass air flow sensor 123, an engine coolant temperature signal (ECT) from engine coolant temperature sensor 112 coupled to coolant sleeve 114, signal EGO from exhaust gas sensor 128, which may be used by controller 12 to determine the AFR of the exhaust gas, an exhaust gas temperature signal (EGT) from a temperature sensor 158 coupled to exhaust passage 135, a profile ignition pickup signal (PIP) from a Hall effect sensor 120 (or other type) coupled to crankshaft 140, a throttle position (TP) from a throttle position sensor coupled to throttle 62, and an absolute manifold pressure signal (MAP) from a MAP sensor 122 coupled to intake manifold 44. An engine speed signal, RPM, may be generated by controller 12 from signal PIP. The manifold pressure signal MAP from the manifold pressure sensor may be used to provide an indication of vacuum or pressure in the intake manifold.
Based on input from one or more of the above-mentioned sensors, controller 12 may adjust one or more actuators, such as cylinder fuel injector 66, throttle 62, pre-chamber spark plug 92, main chamber spark plug 93, pre-chamber fuel injector 196, pre-chamber injector 94, the intake/exhaust valves and cams, etc. The controller may receive input data from the various sensors, process the input data, and trigger the actuators in response to the processed input data based on instruction or code programmed therein corresponding to one or more routines, an example of which is described with respect to
A greatest occurrence of hydrocarbon emissions may occur in the first few firing events after engine 10 is started. For example, an output of unburnt hydrocarbons from the engine may peak before emission control device 178 reaches its light-off temperature. As such, emission control device 178 may not be maximally effective at neutralizing (e.g., oxidizing) the hydrocarbons output by the engine when the hydrocarbon output is the highest, resulting in higher hydrocarbon tailpipe emissions. Therefore, TJI system 195 may be used to deliver additional (e.g., secondary) air to cylinder 130, as will be elaborated below with respect to
Continuing to
Air is provided to compressor 190 via an air intake passage 202. In the example shown, pre-chamber fuel injector 196 is coupled to air intake passage 202 upstream of compressor 190. However, as noted above with respect to
Reference will now be made to different operating modes of extended TJI system 200 illustrated in
Referring now to
Turning now to
At 302, method 300 includes estimating and/or measuring operating conditions. The operating conditions may include, for example, an engine speed, an intake manifold pressure (e.g., MAP), a mass air flow of intake air provided to the engine (e.g., MAF), an engine temperature, an engine torque demand, an exhaust gas temperature, a commanded engine AFR, a measured engine AFR, an engine dilution, an accelerator pedal position, a brake pedal position, etc. As one example, the exhaust gas temperature may be measured by the exhaust gas temperature sensor, such as temperature sensor 158 of
At 304, it is determined if a cold start condition is present. As an example, the cold start may be confirmed when the engine temperature is less than a first threshold temperature. The first threshold temperature may correspond to a non-zero, positive temperature value stored in a memory of the controller, above which the engine is considered to be warm and at a steady state operating temperature. As another example, the cold start may be confirmed when the engine temperature is substantially equal to ambient temperature (e.g., within a threshold of the ambient temperature, such as within 10° C.) at engine start (e.g., when the engine cranked from zero speed to a non-zero speed, with fuel and spark provided to initiated combustion). As still another example, the cold start may be confirmed when the engine has been inactive for greater than a threshold duration, which may correspond to a non-zero amount of time (e.g., minutes, hours, or days) over which the engine is expected to cool to approximately ambient temperature.
Additionally or alternatively, the cold start condition may be confirmed when the temperature of the catalyst is less than a desired operating temperature. As one example, the desired operating temperature may be a light-off temperature of the catalyst. The light-off temperature of the catalyst may be a predetermined, second threshold temperature stored in the memory of the controller at or above which a high catalytic efficiency is achieved, enabling the catalyst to effectively decrease vehicle emissions, for example. The catalyst may be below its light-off temperature when the engine temperature is less than the first threshold temperature, for example, and thus, heating of the catalyst may be requested during the cold start condition.
If the cold start condition is not present, method 300 proceeds to 306 and includes disabling an in-cylinder spark plug. For example, the in-cylinder spark plug may be main chamber spark plug 93 of
At 308, method 300 includes injecting fuel into the cylinder for combustion. Fuel may be injected, for example, by a fuel injector (e.g., fuel injector 66 of
The controller may determine a total amount of fuel to inject into the cylinder during an engine cycle based on an amount (e.g., mass) of primary air inducted into the cylinder, also referred to herein as a cylinder air charge, and a desired AFR. As one example, the desired AFR may be stoichiometry. The controller may input the cylinder air charge and the desired AFR into a look-up table, algorithm, or map stored in a memory of the controller, which may output the total amount of fuel to inject into the cylinder. Further, the controller may determine the timing of the fuel injection(s) based on a plurality of engine operating conditions, such as the engine speed, the engine temperature, and the engine load. The controller may input the plurality of engine operating conditions (e.g., the engine speed, the engine temperature, and the engine load) into another look-up table, algorithm, or map stored in the memory of the controller, which may output the timing (e.g., a start of injection timing) for each of the fuel injection(s). When multiple injections are used, the output may further include a fraction of the total amount of fuel to deliver via each injection. The controller may then adjust and transmit the fuel pulse-width signal to the cylinder fuel injector to inject the determined amount of fuel at the determined timing(s).
At 310, method 300 includes operating the TJI system in an ignition mode. An example of operating TJI system in the ignition mode is shown in
Operating the TJI system in the ignition mode includes enabling a pre-chamber fuel supply, as indicated at 312. For example, the controller operates a pre-chamber fuel injector (e.g., pre-chamber fuel injector 196 of
Operating the TJI system in the ignition mode further includes injecting the air-fuel mixture into the pre-chamber during the compression stroke, as indicated at 314. For example, the pre-chamber injector receives the air-fuel mixture from the common delivery passage via a port and is actuated open by the controller during the compression stroke of the cylinder to inject the air-fuel mixture into the pre-chamber. For example, the pre-chamber injector may be opened according to an injector pulse-width signal received from the controller (e.g., signal IPW shown in
Operating the TJI system in the ignition mode further includes actuating a pre-chamber spark plug at a desired ignition timing, as indicated at 316. For example, the pre-chamber spark plug may be pre-chamber spark plug 92 shown in
To generate the ignition spark in the pre-chamber at the desired ignition timing, the controller may generate a control signal (e.g., signal SA) that is sent to an ignition system (e.g., ignition system 88 of
In some examples, operating the TJI system in the ignition mode includes closing or maintaining closed an exhaust runner supply valve, as optionally indicated at 317. When included, the exhaust runner supply valve (e.g., valve 212 of
Method 300 may then end. For example, method 300 may be repeated at a pre-determined frequency during engine operation to provide robust pre-chamber ignition to the cylinder across a variety of operating conditions.
Returning to 304, if the cold start condition is present, method 300 proceeds to 318 and includes disabling the pre-chamber fuel supply, such as by disabling or deactivating the pre-chamber fuel injector. When the pre-chamber fuel injector is disabled, the pre-chamber fuel injector stops receiving the fuel pulse-width signal from the controller. As such, the pre-chamber fuel injector will not open and will not inject fuel into the air intake passage upstream of the compressor. As a result, the compressor will supply air to the common delivery passage and not an air-fuel mixture.
At 320, method 300 includes disabling the pre-chamber spark plug. Since the pre-chamber is not being supplied with fuel, the pre-chamber spark plug will not have an air-fuel mixture to ignite with a spark. To disable the pre-chamber spark plug, the controller may not send the spark advance signal to the pre-chamber spark plug, for example. As a result, the pre-chamber spark plug does not generate a spark in the pre-chamber, and combustion does not occur within the pre-chamber. Thus, the pre-chamber (and the TR system) is not used for ignition.
At 322, method 300 includes injecting fuel into the cylinder for combustion. Fuel may be injected, for example by the fuel injector coupled to the cylinder in response to the fuel pulse-width signal received from the controller. Similar to method 300 at 308, the fuel may be injected into the cylinder during the intake stroke and/or the compression stroke via one or more injections. In some examples, the desired AFR of the cylinder may be different than when the cold start condition is not present (e.g., at 308). As one example, the AFR may be richer during the cold start condition.
At 324, method 300 includes actuating the in-cylinder spark plug at the desired ignition timing. The in-cylinder spark plug may provide a spark to the cylinder in response to the spark advance signal from the controller. The controller may determine the desired ignition timing similar to the manner described above at 316, for example, and actuate the in-cylinder spark plug at the desired ignition timing. However, the desired ignition timing may be different during the cold start compared to when the cold start condition is not present. For example, combustion phasing may be very late (e.g., compared to when the cold start condition is not present, as at 316) to provide more heat to the catalyst as exhaust waste heat. The late combustion phasing means that flame propagation within the cylinder may occur while the cylinder is expanding. As one example, the desired ignition timing may be during an expansion stroke. Further, the desired ignition timing may be different when the in-cylinder spark plug is used relative to when the pre-chamber spark plug is used for a same combustion phasing. For example, the in-cylinder spark plug may be actuated earlier than the pre-chamber spark plug would be for the same combustion phasing due to the slower burn rate produced via the direct in-cylinder spark ignition. As one non-limiting example, the spark timing for the in-cylinder spark plug may occur further before TDC during the compression stroke while the spark timing for the pre-chamber spark plug may occur closer to TDC during the compression stroke for the same combustion phasing.
At 326, method 300 includes estimating a hydrocarbon output of the engine. As one example, the exhaust gas sensor may be used to estimate the hydrocarbon output of the engine. For example, the controller may input measurements received from the exhaust gas sensor into a look-up table, algorithm, or map stored in memory, which may output the estimated hydrocarbon output of the engine. The hydrocarbon output may be a concentration or mass, for example. Additionally or alternatively, the controller may estimate the hydrocarbon output of the engine based on one or more engine operating conditions, such as the engine temperature, a number of engine cycles or a duration since engine start, a fuel injection timing and amount, etc. For example, the controller may input the one or more engine operating conditions (e.g., the engine temperature, the number of engine cycles since engine start or the duration since the engine start, the fuel injection timing and amount) into a look-up table, algorithm, or map stored in memory, which may output the estimated hydrocarbon output of the engine. In particular, the hydrocarbon output of the engine may peak during the first several firing events of the engine and then begin to decrease. In still other examples, the controller may determine the hydrocarbon output of the engine from an output of a hydrocarbon sensor positioned, for example, in an exhaust manifold of the engine.
At 328, method 300 includes selecting a thermactor mode based on the TJI system configuration and an operating condition. In particular, the controller may determine if the TJI system is the extended configuration that includes additional plumbing to the exhaust runner or the non-extended configuration that only provides air or air and fuel to the pre-chamber. In one example, the controller may automatically determine the TJI system configuration based on known TJI system components and/or pre-programmed instructions stored into the memory of the controller. Further, the extended configuration may enable the controller to select between an in-cylinder thermactor mode, an exhaust runner thermactor mode, and a combined thermactor mode, whereas the non-extended configuration may enable the controller to only select the in-cylinder thermactor mode.
Therefore, if the TJI system is in the extended configuration, the controller may select between the in-cylinder thermactor mode, the exhaust runner thermactor mode, and the combined thermactor mode based on the operating condition. In some examples, the operating condition may include the estimated hydrocarbon output of the engine. Further, the operating condition may be one of a first operating condition, a second operating condition, and a third operating condition. The first operating condition may include the hydrocarbon output of the engine being greater than a first, upper threshold. The second operating condition may include the hydrocarbon output of the engine being less than the upper threshold and greater than a second, lower threshold. The third operating condition may include the hydrocarbon output of the engine being less than the lower threshold. The first, upper threshold may be a non-zero, positive hydrocarbon amount (e.g., concentration or mass) above which supplying secondary air injection to one location (e.g., either the cylinder or the exhaust runner) may not efficiently neutralize the hydrocarbons in the feedgas provided to the catalyst. The second threshold may be a non-zero, positive hydrocarbon amount (e.g., concentration or mass) that is less than the first threshold and above which supplying secondary air injection to the exhaust runner may be more efficient for oxidizing hydrocarbons than air injection via the pre-chamber and below which the air injection may more precisely deliver a desired amount of air for oxidizing the hydrocarbons. For example, when the hydrocarbon output is less than the second threshold, supplying secondary air to the exhaust runner may result in excess oxygen in the exhaust gas.
As one example, the combined thermactor mode may be the most efficient at oxidizing unburnt hydrocarbons because secondary air is provided to two locations (the cylinder via the pre-chamber and the exhaust runner). Therefore, if the estimated hydrocarbon output is high (e.g., higher than the first, upper threshold), the first operating condition may be present, and the controller may select the combined thermactor mode responsive to the first operating condition. As another example, if the estimated hydrocarbon output is lower than the first threshold and greater than the second, lower threshold, the second operating condition may be present. Responsive to the second operating condition, the controller may select the exhaust runner thermactor mode. If the estimated hydrocarbon output is less that the second threshold, the third operating condition may be present. In response to the third operating condition, the controller may select the in-cylinder thermactor mode.
Additionally or alternatively, the operating condition may include the number of engine cycles since the engine start or the duration since the engine start. As such, the first operating condition may additionally or alternatively include the duration since the engine start being less than a first threshold duration (or the number of engine cycles since the engine start being less than a first threshold number of engine cycles), the second operating condition may additionally or alternatively include the duration since the engine start being greater than the first threshold duration and less than a second threshold duration (or the number of engine cycles since the engine start being greater than the first threshold number of engine cycles and less than a second number of engine cycles), and the third operating condition may additionally or alternatively include the duration since the engine start being greater than the second threshold duration (or the number of engine cycles since the engine start being greater than the second threshold number of engine cycles). As an example, the first threshold duration or the first threshold number of engine cycles may correspond to a period over which the hydrocarbon output of the engine peaks, after which providing secondary air to two locations (e.g., via the combined thermactor mode) may promote cooling of the exhaust gas while not increasing hydrocarbon oxidation efficiency. Similarly, the second threshold duration or the second threshold number of engine cycles may correspond to a period after which in-cylinder air injection is the most efficient for oxidizing unburnt hydrocarbons while reducing (e.g., minimizing) unreacted oxygen in the exhaust gas.
As noted above, the hydrocarbon output of the engine may peak during the first several firing events. Therefore, in anticipation of the high hydrocarbon output of the engine in the first several firing events, the controller may be programmed to initially select the combined thermactor mode responsive to the cold start condition being confirmed at engine start (e.g., when the engine is cranked to a non-zero speed from rest and combustion is commenced), which occurs while or during the first operating condition. Then, after operating in the combined thermactor mode for the first threshold number of engine cycles or the first threshold duration, the second operating condition is present, and the controller may select the exhaust runner thermactor mode in response thereto. After operating in the exhaust runner thermactor mode for the second threshold duration or the second threshold number of engine cycles, the third operating condition is present, and the controller may select the in-cylinder thermactor mode in response thereto. Alternatively, the controller may more gradually adjust the TJI system between the three thermactor operating modes, as will be elaborated below.
At 330, method 300 includes determining if the in-cylinder thermactor mode is selected, such as when only the in-cylinder thermactor mode is available and/or when the third operating condition is present. If the in-cylinder thermactor mode is selected, method 300 proceeds to 332 and includes operating the TJI system in the in-cylinder thermactor mode.
In some examples, operating the TJI system in the in-cylinder thermactor mode includes closing or maintaining closed the exhaust runner supply valve, as optionally indicated at 334. When included, the exhaust runner supply valve is actuated closed if the exhaust runner supply valve is open. If the exhaust runner supply valve is already closed, then the exhaust runner supply valve is maintained fully closed. When the exhaust runner supply valve is maintained fully closed, air from the TJI system is not provided to the exhaust runner of the cylinder. In examples where the TJI system does not include the exhaust runner supply valve, 334 may be omitted.
Operating the TJI system in the in-cylinder thermactor mode further includes injecting air into the pre-chamber during an expansion and/or exhaust stroke of the cylinder, as indicated at 336. The pre-chamber injector is actuated open by the controller to inject air into the pre-chamber at a timing determined based on a temperature in the cylinder, for example. The temperature of the cylinder may fluctuate throughout the engine cycle, with peak combustion temperatures occurring following ignition as the flame propagates through the cylinder. Therefore, the air is injected late in the expansion and/or exhaust stroke because the temperature in the cylinder is high enough for hydrocarbon oxidation, but the temperature is not excessively high for NOx formation. As one example, the temperature in the cylinder may be inferred based on the ignition timing, and the controller may input the ignition timing into a look-up table, algorithm, or map stored in memory, which may output an air injection timing for injecting the secondary air into the pre-chamber. The air injection timing may be further adjusted based on an in-cylinder pressure and a pressure of the air delivery passage, particularly when the injection is performed in the expansion stroke. For example, the in-cylinder pressure fluctuates throughout an engine cycle and may be higher earlier in the expansion stroke and lower later in the expansion stroke. The air injection timing may be programmed to occur while the pressure in the air delivery passage is at least a threshold amount higher than the in-cylinder pressure, with the threshold amount corresponding to a non-zero, positive amount of pressure that is calibrated to prevent back flow and to provide desired mixing characteristics. Thus, the air injection timing may only occur while the pressure in the air delivery passage is at least the threshold amount greater than the in-cylinder pressure, at least in some examples.
Further, the controller may adjust the amount of air injected based on the estimated hydrocarbon output of the engine, such as by increasing the amount of air injected as the estimated hydrocarbon output of the engine increases and decreasing the amount of air injected as the estimated hydrocarbon output of the engine decreases. The controller may adjust the pulse-width of the IPW signal accordingly and transmit the injector pulse-width signal to the pre-chamber injector at the determined air injection timing. The injected air oxidizes unburned hydrocarbons within the corresponding cylinder, thus lowering the hydrocarbon output, and generating additional heat through the exothermic reaction.
Method 300 may then end. For example, method 300 may be repeated at a pre-determined frequency during engine operation to adjust the TJI system operating mode as the operating conditions change in order to effectively reduce hydrocarbon emissions during catalyst heating.
Returning to 330, if the in-cylinder thermactor mode is not selected, method 300 proceeds to 338 and includes determining if the exhaust runner thermactor mode is selected. The exhaust runner thermactor mode may be selected during the second operating condition described above at 328, for example.
If the exhaust runner thermactor mode is selected, method 300 proceeds to 340 and includes operating the TJI system in the exhaust runner thermactor mode. Operating the TJI system in the exhaust runner thermactor mode includes fully (or nearly fully) opening the exhaust runner supply valve, as indicated at 342. For example, the exhaust runner supply valve may be opened to a first, larger degree when the exhaust runner thermactor mode is selected relative to when the combined thermactor mode is selected, as will be described below. To open the exhaust runner supply valve, the valve is energized via a control signal from the controller. When fully open, air is delivered to the exhaust runner of the cylinder via the common delivery passage of the TJI system. By supplying additional, secondary air to the exhaust runner, unburnt hydrocarbons in the exhaust runner may be oxidized to reduce the amount of hydrocarbons in the exhaust gas supplied to the catalyst.
Operating the TJI system in the exhaust runner thermactor mode further includes disabling the pre-chamber injector, as indicated at 344. To disable the pre-chamber injector, the controller discontinues sending the signal IPW. As a result, the pre-chamber injector no longer delivers air to the pre-chamber. Method 300 may then end.
Returning to 338, if the exhaust runner thermactor mode is not selected, it may be determined that the combined thermactor mode is selected, and method 300 proceeds to 346 and includes operating the TJI system in the combined thermactor mode. Operating the TJI system in the combined thermactor mode includes partially opening the exhaust runner supply valve, as indicated at 348. As an example where the exhaust runner supply valve is a solenoid valve, the controller may adjust the exhaust runner supply valve to the partially open position by providing current to solenoid coils of the exhaust runner supply valve. However, an amount of current provided may be less than when the TJI system is operated in the exhaust runner thermactor mode (e.g., as at 342). Thus, the exhaust runner supply valve may be opened to a second, smaller degree when the TJI system is operated in the combined thermactor mode. With the exhaust runner supply valve partially open, pressurized air from the compressor may flow to the exhaust runner. Thus, any unburnt hydrocarbons within the exhaust runner may then be oxidized by the air provided by the TJI system to the exhaust runner via the partially open exhaust runner supply valve.
Operating the TJI system in the combined thermactor mode further includes injecting air into the pre-chamber during the expansion and/or exhaust stroke, as indicated at 350. The pre-chamber injector is actuated open by the controller to inject air in a manner similar to that described above at 336. However, the amount of air injected may be less than when operating in the in-cylinder thermactor mode since secondary air is provided at two secondary air introduction locations (e.g., the cylinder via the pre-chamber and the exhaust runner), at least in some examples. The injected air oxidizes unburned hydrocarbons within the cylinder, while the air delivered to each exhaust runner reacts with additional unburnt hydrocarbons within the exhaust runner.
Additionally or alternatively, the controller may gradually adjust the TJI system between the different operating modes. For example, the TJI system may be initially operated in the combined thermactor mode (e.g., responsive to the first operating condition) and gradually shifted to operating in the in-cylinder thermactor mode by the controller gradually closing the exhaust runner supply valve. In such an example, the controller may adjust the opening of the exhaust runner supply valve as a function of the number of engine cycles (or duration) since the engine start, the estimated or measured hydrocarbon output of the engine, and/or the temperature of the catalyst. For example, the opening (e.g., amount or degree of opening) of the exhaust runner supply valve may generally decrease as one or more of the number of engine cycles, the hydrocarbon output of the engine, and the temperature of the catalyst increases. As another example, the TJI system may be initially operated in the combined thermactor mode and gradually shifted to operating in the exhaust runner thermactor mode by gradually reducing the pre-chamber injector pulse-width. In such an example, the pre-chamber injector pulse-width may be adjusted as a function of the number of engine cycles since the engine start, the estimated or measured hydrocarbon output of the engine, and/or the temperature of the catalyst. For example, the pulse-width of the control signal transmitted to the pre-chamber injector may generally decrease as one or more of the number of engine cycles, the hydrocarbon output of the engine, and the temperature of the catalyst increases.
In yet another example, the TJI system may be initially operated in the exhaust runner thermactor mode and gradually switch to operating in the in-cylinder thermactor mode with the combined thermactor mode serving as an intermediate mode between the exhaust runner thermactor mode and the in-cylinder thermactor mode. In this example, the controller may gradually close the exhaust runner supply valve while simultaneously increasing the pre-chamber injector pulse width. However, in this example, a smaller amount of secondary air may be provided at the engine start compared to when the TJI system is initially operated in the combined thermactor mode at the engine start.
Further, in general, the pre-chamber injector pulse-width and the exhaust runner supply valve opening may follow prescribed profiles (e.g., functions or maps stored in controller memory) that relate the pulse-width or valve opening to the number of engine cycles since start, the hydrocarbon output of the engine, and/or the catalyst temperature, allowing gradual or discrete switches among the three modes. Method 300 may then end.
In this way, the TJI system may be operated to provide ignition or to introduce secondary air based on operating conditions. For example, the TJI system may be operated to provide ignition when a cold start condition is not present in order to provide increased engine efficiency, for example, while the TJI system may be operated to provide secondary air during a cold start condition to reduce an amount of unburnt hydrocarbons provided to the catalyst prior to light-off. Further, when the TJI system is coupled to the exhaust runner, the TJI system may be operated in one of a plurality of different thermactor operating modes in order to more efficiently reduce hydrocarbon emissions. For example, the secondary air may be provided at one or more secondary air introduction locations according to an operating condition (e.g., whether a first, second, or third operating condition is present, as defined above). As a result, vehicle emissions during the cold start may be reduced. For example, a total hydrocarbon output of the vehicle may remain less than a threshold vehicle hydrocarbon output (e.g., a regulatory emissions threshold) during each of the first, second, and third operating conditions due to the oxidation of the hydrocarbons prior to the hydrocarbons reaching the catalyst prior to light-off.
In an alternative example of the method, such as where each pre-chamber has a separate fuel injector coupled thereto, the TJI system may be operated to provide ignition during the compression stroke, as described at 310, and also to provide secondary air during the expansion and/or exhaust strokes, such as described at 332, 340, and 346. Thus, during a single combustion cycle of the cylinder, the TJI system may provide ignition at a first timing during the combustion cycle (e.g., during the compression stroke) and may provide secondary air at a second timing during the combustion cycle (e.g., during the expansion stroke and/or the exhaust stroke). In such example, the in-cylinder spark plug may not be used. Further, the in-cylinder spark plug may be optionally omitted from the engine.
Next,
For all of the above, the horizontal axis represents engine position (in crank angle degrees, CAD), with the engine position increasing along the horizontal axis from left to right. For example, as mentioned above, one four-stroke engine cycle is shown, which occurs from 0 to 720 CAD (e.g., two full rotations of an engine crankshaft). In the example timing charts, the intake stroke corresponds to an interval from 0 CAD to 180 CAD, the compression stroke corresponds to an interval from 180 CAD to 360 CAD, the expansion (or power) stroke corresponds to an interval from 360 CAD to 540 CAD, and the exhaust stroke corresponds to an interval from 540 CAD to 720 CAD. The vertical axis of each plot represents the labeled parameter. For plot 402, the vertical axis shows piston position relative to TDC and BDC. For plots 404 and 406, the vertical axis shows the valve position (plot 404) and the pre-chamber injector (plot 406) ranging from “closed,” which refers to a fully closed position, and “open,” which refers to a fully open position. For plot 408, the vertical axis shows the pre-chamber fuel injection as “active,” in which fuel is provided to the TJI system, or “inactive,” in which fuel is not provided to the TJI system. For plots 410 and 412, the vertical axis indicates whether the corresponding spark plug is on (e.g., the corresponding spark plug is actuated) or off (e.g., the corresponding spark plug is not actuated), as labeled.
Turning first to
Continuing to
Within the third example timing chart 600 of
Turning now to
Turning now to
For all of the above, the horizontal axis represents time, with time increasing along the horizontal axis from left to right. The vertical axis represents each labeled parameter. For plots 802 and 804, the catalyst temperature and hydrocarbon output, respectively, increase up the vertical axis from bottom to top. For plot 806, the valve position may range from a fully open position to a fully closed position. For example, decreasing along the vertical axis causes the valve position to further close while increasing along the vertical axis causes the valve position to further open. For plot 808, the vertical axis indicates whether the pre-chamber injector is in an active or a disabled state. As an example, while in the active state the pre-chamber injector may inject air and/or fuel into a pre-chamber during specific times in a four-stroke engine cycle depending on which TJI system mode is selected. While in the disabled state, the pre-chamber injector does not inject air and/or fuel into the pre-chamber. For plot 810, the vertical axis indicates whether the pre-chamber fuel injection is on (e.g., a pre-chamber fuel injector may deliver fuel to the TJI system) or off (e.g., the pre-chamber fuel injector may not deliver fuel to the TJI system), as labeled. For plot 812, the vertical axis represents the spark location, which may either be in a cylinder (e.g., cylinder 130 of
Further, a threshold catalyst temperature is represented by a dashed line 803 and corresponds to a light-off temperature of the catalyst. The threshold catalyst temperature corresponds to a non-zero, positive temperature value stored in a memory of a controller (e.g., controller 12 of
From time t0 to time t1, the engine is off and the catalyst temperature (plot 802) reflects the ambient temperature of the environment in which the catalyst is located. At time t1, the engine is turned on. For example, the engine may be turned on responsive to input of a key turning, push of a start button, etc. by a vehicle operator (e.g., vehicle operator 113 shown in
To operate in the combined thermactor mode, the pre-chamber injector (plot 808) is active and the valve is adjusted to a partially open position (plot 806). Near BDC in the expansion stroke and/or near TDC of the exhaust stroke, the pre-chamber injector injects air into the pre-chamber (e.g., a first secondary air introduction location), providing air that may oxidize any unburnt hydrocarbons in the cylinder. Further, additional air is provided to exhaust runners (e.g., exhaust runners 86a, 86b, and 86n from
From time t1 to time t2, as the TJI system operates in the combined thermactor mode, the temperature of the catalyst (plot 802) increases and the hydrocarbon output (plot 804) decreases due to the combined thermactor mode oxidizing unburnt hydrocarbons. However, the catalyst temperature (plot 802) remains below the threshold catalyst temperature (dashed line 803), and as such, the catalyst remains inefficient at treating hydrocarbon emissions. At time t2, the hydrocarbon output decreases below the upper hydrocarbon threshold (dashed line 805) and remains above the lower hydrocarbon threshold (dashed line 807). In response, the TJI system mode is adjusted to the exhaust runner thermactor mode (TJI system mode 3 shown by plot 814).
The exhaust runner thermactor mode provides secondary air to the exhaust runners, and not the pre-chamber, to oxidize unburnt hydrocarbons. In response to the exhaust runner thermactor mode being selected at time t2, the valve position (plot 806) is adjusted to a fully open position, enabling more air to flow to the exhaust runners. The pre-chamber injector (plot 808) is disabled, stopping the pre-chamber injector from injecting air into the pre-chamber. Similar to the combined thermactor mode, the spark location (plot 812) is in the cylinder, and the pre-chamber fuel injection (plot 810) is turned off. Thus, combustion occurs in the cylinder without combustion in the pre-chamber initiating the combustion in the cylinder.
By time t3, the catalyst temperature (plot 802), although increasing, is still below the threshold catalyst temperature (dashed line 803). Since the catalyst temperature is below the threshold temperature, the catalyst is still inefficient in burning hydrocarbons that were not burned during combustion within the cylinder. Also at time t3, the hydrocarbon output (plot 804) decreases below the lower hydrocarbon threshold (dashed line 807) due in part to the hydrocarbon oxidation provided by operating the TJI system in the exhaust runner thermactor mode. In response to the hydrocarbon output decreasing below the lower hydrocarbon threshold at time t3, the TJI mode is transitioned to operating in the in-cylinder thermactor mode (TJI system mode 2 shown in plot 814).
To transition the TJI system to operating in the in-cylinder thermactor mode at time t3, the valve is adjusted from the fully open position to the fully closed position (plot 806). With the valve closed, air is no longer provided to the exhaust runners. Instead, the pre-chamber injector (plot 808) is activated to inject air into the pre-chamber late in the expansion stroke and/or during the exhaust stroke, and the injected air flows into the cylinder. The addition of air to cylinder by the pre-chamber injector may oxidize unburnt hydrocarbons that are not consumed during combustion in the cylinder. Similar to both the combined thermactor mode and the exhaust runner thermactor mode, the spark location (plot 812) is within the cylinder, and the pre-chamber fuel injection (plot 810) is turned off due to combustion being initiated directly within the cylinder by the cylinder spark plug.
At time t4, the catalyst temperature (plot 802) increases above the threshold catalyst temperature (dashed line 803). As such, the catalyst has reached its light-off temperature and is maximally effective at oxidizing hydrocarbons output by the engine. Additionally, the catalyst temperature increasing above the threshold catalyst temperature indicates that the cold start condition is no longer present in the engine. As a result, the TJI system is adjusted to the pre-chamber ignition mode (TJI system mode 1 shown in plot 814). In the pre-chamber ignition mode, the TJI system provides ignition to the cylinder via combustion within the pre-chamber, and the TJI system is no longer operated to provide secondary air injection for reducing hydrocarbon emissions. The valve position (plot 806) is kept in a fully closed position, preventing air from flowing through the valve to the exhaust runners. Pre-chamber fuel injection (plot 810) is turned on, allowing fuel to be injected into a common delivery passage (e.g., common delivery passage 208 shown in
In this way, by providing secondary air at one or more introduction locations, a quantity of unburned hydrocarbons that are delivered to the catalyst prior to the catalyst reaching its light-off temperature are reduced. Further, the exothermic reaction between the secondary air and the hydrocarbons may help the catalyst may reach its light-off temperature more quickly, after which it may more efficiently reduce exhaust emissions (e.g., by oxidizing the unburned hydrocarbons). As a result, overall vehicle emissions are reduced. Further, vehicle costs and complexity may be reduced by providing the secondary air via the turbulent jet ignition system compared with including an external thermactor pump and delivery lines.
The technical effect of providing secondary air to a pre-chamber and/or an exhaust runner of a cylinder and via a turbulent jet ignition system during a cold start is that the secondary air may provide additional oxidation of hydrocarbons prior to a catalyst reaching its light-off temperature.
As one example, a method comprises: during heating of a catalyst of an exhaust system coupled to an engine, initiating combustion in a cylinder via a spark plug directly coupled to the cylinder and providing secondary air via a turbulent jet system having an igniter. In a first example of the method, the turbulent jet system includes a compressor positioned in an air delivery passage, a pre-chamber coupled to the cylinder, and a pre-chamber injector coupled to the pre-chamber and to the air delivery passage, downstream of the compressor, via a first port, and wherein providing the secondary air via the turbulent jet system comprises pressurizing the secondary air via the compressor. In a second example of the method, optionally including the first example, providing the secondary air via the turbulent jet system further comprises injecting the secondary air into the pre-chamber via the pre-chamber injector during at least one of an expansion stroke and an exhaust stroke of the cylinder. In a third example of the method, optionally including one or both of the first and second examples, the turbulent jet system further includes a valve disposed in the air delivery passage downstream of the first port and upstream of a second port coupling the air delivery passage to an exhaust runner of the cylinder, and wherein providing the secondary air via the turbulent jet system further comprises adjusting a position of the valve. In a fourth example of the method, optionally including any or all of the first through third examples, adjusting the position of the valve comprises: adjusting the position of the valve to a first open position responsive to a first operating condition, adjusting the position of the valve to a second open position, greater than the first open position, responsive to a second operating condition, and adjusting the position of the valve to a fully closed position responsive to a third operating condition. In a fifth example of the method, optionally including any or all of the first through fourth examples, the first operating condition includes a hydrocarbon output of the engine being greater than a first, higher threshold, the second operating condition includes the hydrocarbon output of the engine being both less than the first, higher threshold and greater than a second, lower threshold, and the third operating condition includes the hydrocarbon output of the engine being less than the second, lower threshold. In a sixth example of the method, optionally including any or all of the first through fifth examples, the first operating condition includes a duration of operating the engine being less than a first threshold duration, the second operating condition includes the duration of operating the engine being both greater than the first threshold duration and less than a second threshold duration, the second threshold duration being greater than the first threshold duration, and the third operating condition includes the duration of operating the engine being greater than the second threshold duration. In a seventh example of the method, optionally including any or all of the first through sixth examples, providing the secondary air via the turbulent jet system further comprises injecting the secondary air into the pre-chamber via the pre-chamber injector during at least one of an expansion stroke and an exhaust stroke of the cylinder during the first operating condition and the third operating condition and not during the second operating condition. In an eighth example of the method, optionally including any or all of the first through seventh examples, the heating of the catalyst is responsive to a temperature of the catalyst being less than a threshold temperature, and the method further comprises: in response to the temperature of the catalyst reaching the threshold temperature, initiating combustion in the cylinder via the igniter of the turbulent jet system and not via the spark plug directly coupled to the cylinder. In a ninth example of the method, optionally including any or all of the first through eighth examples, the igniter of the turbulent jet system is coupled to the pre-chamber, and initiating combustion in the cylinder via the turbulent jet system comprises: injecting fuel into the air delivery passage via a fuel injector coupled to the air delivery passage upstream of the first port to generate an air-fuel mixture, injecting the air-fuel mixture into the pre-chamber via the pre-chamber injector during a compression stroke of the cylinder, and after injecting the air-fuel mixture into the pre-chamber, actuating the igniter at a desired ignition timing.
As another example, a method comprises: during a cold start of an engine: disabling fuel supply to a turbulent jet system having an igniter, and providing air to at least one secondary air introduction location coupled to a cylinder of the engine via the turbulent jet system. In a first example of the method, the turbulent jet system includes a pre-chamber fluidically coupled to the cylinder via a plurality of openings in pre-chamber walls dividing an internal volume of the pre-chamber from an internal volume of the cylinder, wherein the igniter is positioned in the pre-chamber, and wherein the at least one secondary air introduction location includes the pre-chamber. In a second example of the method, optionally including the first example, providing the air to the at least one secondary air introduction location comprises injecting air into the pre-chamber during at least one of an expansion stroke of the cylinder and an exhaust stroke of the cylinder. In a third example of the method, optionally including one or both of the first and second examples, the turbulent jet system is fluidically coupled to an exhaust runner of the cylinder, and wherein the at least one secondary air introduction location includes the exhaust runner. In a fourth example of the method, optionally including any or all of the first through third examples, providing the air to the at least one secondary air introduction location comprises at least partially opening a valve positioned to regulate a flow of the air to the exhaust runner. In a fifth example of the method, optionally including any or all of the first through fourth examples, providing the air to the at least one secondary air introduction location comprises selecting between providing the air to the pre-chamber, providing air to the exhaust runner, and providing the air to both of the pre-chamber and the exhaust runner based on an estimated hydrocarbon output of the engine.
In yet another example, a system comprises: an engine including a plurality of cylinders, each of the plurality of cylinders including a pre-chamber of a turbulent jet ignition (TJI) system, the pre-chamber including a first spark plug coupled thereto, and a controller storing including executable instructions stored in non-transitory memory that, when executed, cause the controller to: operate the TJI system in a thermactor mode responsive to a cold start condition of the engine, and operate the TJI system in an ignition mode responsive to the cold start condition of the engine not being present. In a first example of the system, the TJI system comprises a compressor positioned in an air delivery passage fluidically coupled to an injector of the pre-chamber of each of the plurality of cylinders, downstream of the compressor, and a pre-chamber fuel injector coupled to the air delivery passage upstream of the compressor, and wherein to operate the TJI system in the thermactor mode, the controller includes further instructions stored in non-transitory memory that, when executed, cause the controller to: disable the pre-chamber fuel injector, and operate the compressor. In a second example of the system, optionally including the first example, the air delivery passage is further coupled to an exhaust runner of each of the plurality of cylinders and includes a valve disposed upstream of the exhaust runner of each of the plurality of cylinders and downstream of the injector of the pre-chamber of each of the plurality of cylinders, and wherein to operate the TJI system in the thermactor mode, the controller includes further instructions stored in non-transitory memory that, when executed, cause the controller to: partially open the valve to deliver air from the air delivery passage to the exhaust runner and also deliver air from the air delivery passage to the pre-chamber via the injector responsive to a first condition, the first condition including at least one of a hydrocarbon output of the engine being greater than a first threshold and a duration of operating the engine being less than a first threshold duration, fully open the valve to deliver air from the air delivery passage to the exhaust runner and maintain the injector fully closed responsive to a second condition, the second condition including at least one of the hydrocarbon output of the engine being both less than the first threshold and greater than a second threshold and the duration of operating the engine being both greater than the first threshold duration and less than a second threshold duration, and deliver air from the air delivery passage to the pre-chamber via the injector while maintaining the valve fully closed responsive to a third condition, the third condition including at least one of the hydrocarbon output of the engine being less than the second threshold and the duration of operating the engine being greater than the second threshold duration. In a third example of the system, optionally including one or both of the first and second examples, each of the plurality of cylinders further includes a second spark plug directly coupled thereto, and the controller includes further instructions stored in non-transitory memory that, when executed, cause the controller to: actuate the second spark plug at a desired ignition timing while operating the TJI system in the thermactor mode, and actuate the first spark plug at the desired ignition timing while operating the TJI system in the ignition mode.
In another representation, a method comprises: during heating of a catalyst of an exhaust system coupled to an engine, initiating combustion in a cylinder via a turbulent jet ignition system at a first timing during a combustion cycle of the cylinder and providing secondary air via the turbulent jet ignition system during a second timing during the combustion cycle. In the preceding example, additionally or optionally, the first timing is during a compression stroke of the cylinder, and the second timing is during an expansion stroke of the cylinder. In one or both of the preceding examples, additionally or optionally, the first timing is during a compression stroke of the cylinder, and the second timing is during an exhaust stroke of the cylinder. In any or all of the preceding examples, additionally or optionally, initiating combustion in the cylinder via the turbulent jet ignition system comprises: injecting air and fuel into a pre-chamber of the turbulent jet ignition system; and actuating a spark plug coupled in the pre-chamber after injecting the air and the fuel. In any or all of the preceding examples, additionally or optionally, providing secondary air via the turbulent jet ignition system comprises injecting air and not injecting fuel into the pre-chamber. In any or all of the preceding examples, additionally or optionally, injecting air and fuel into the pre-chamber of the turbulent jet ignition system comprises: injecting air via an air injector directly coupled to the pre-chamber and injecting fuel via a fuel injector directly coupled to the pre-chamber. In any or all of the preceding examples, additionally or optionally, the air injector directly coupled to the pre-chamber is coupled to an air compressor via an air delivery passage, and wherein injecting air via the air injector directly coupled to the pre-chamber further comprises operating the air compressor at a non-zero speed. In any or all of the preceding examples, additionally or optionally, a pressure in the air delivery passage is greater than a pressure in the cylinder at both of the first timing and the second timing. In any or all of the preceding examples, additionally or optionally, after the heating of the catalyst, initiating combustion in the cylinder via the turbulent jet ignition system and not providing the secondary air via the turbulent jet ignition system.
Note that the example control and estimation routines included herein can be used with various engine and/or vehicle system configurations. The control methods and routines disclosed herein may be stored as executable instructions in non-transitory memory and may be carried out by the control system including the controller in combination with the various sensors, actuators, and other engine hardware. The specific routines described herein may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various actions, operations, and/or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the features and advantages of the example embodiments described herein, but is provided for ease of illustration and description. One or more of the illustrated actions, operations, and/or functions may be repeatedly performed depending on the particular strategy being used. Further, the described actions, operations, and/or functions may graphically represent code to be programmed into non-transitory memory of the computer readable storage medium in the engine control system, where the described actions are carried out by executing the instructions in a system including the various engine hardware components in combination with the electronic controller.
It will be appreciated that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not to be considered in a limiting sense, because numerous variations are possible. For example, the above technology can be applied to V-6, I-4, I-6, V-12, opposed 4, and other engine types. Moreover, unless explicitly stated to the contrary, the terms “first,” “second,” “third,” and the like are not intended to denote any order, position, quantity, or importance, but rather are used merely as labels to distinguish one element from another. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.
As used herein, the term “approximately” is construed to mean plus or minus five percent of the range unless otherwise specified.
The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.
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