Method and system for leak detection at a particulate filter
阅读说明：本技术 用于微粒过滤器处的泄漏检测的方法和系统 (Method and system for leak detection at a particulate filter ) 是由 埃里克·比瑟姆 米希尔·J·范尼乌斯塔特 艾伦·莱曼 道格拉斯·马丁 雷蒙德·亨利·伯格 于 2020-03-16 设计创作，主要内容包括：本公开提供了“用于微粒过滤器处的泄漏检测的方法和系统”。提供了用于诊断发动机排气道中的汽油微粒过滤器的方法和系统。在低发动机转速和高发动机转速范围内学习所述过滤器的压力-流量关系。基于在所述高速和低速范围的曲线拟合之间的实质分离来识别所述过滤器的劣化。(The present disclosure provides "methods and systems for leak detection at a particulate filter. Methods and systems for diagnosing a gasoline particulate filter in an exhaust passage of an engine are provided. The pressure-flow relationship of the filter is learned in a low engine speed and a high engine speed range. Identifying degradation of the filter based on a substantial separation between curve fits of the high and low speed ranges.)
1. A method for engine exhaust, comprising:
comparing a first relationship between an exhaust flow rate and a pressure differential across an exhaust particulate filter in a first engine speed range with a second relationship between an exhaust flow rate and a pressure differential across the exhaust particulate filter in a second engine speed range; and
based on the comparison, exhaust particulate filter degradation is indicated.
2. The method of claim 1, wherein the indication comprises illuminating a warning light.
3. The method of claim 1, wherein the comparing is performed when an exhaust flow rate is above a threshold flow rate.
4. The method of claim 1, wherein the first engine speed range includes engine speeds below a threshold speed and the second engine speed range includes engine speeds above the threshold speed, and wherein the first engine speed range and the second engine speed range do not overlap.
5. The method of claim 4, wherein the comparing comprises comparing the first relationship within a first flow and pressure range to the second relationship within the same first flow and pressure range, and wherein the indicating based on the comparing comprises indicating no degradation when the first relationship and the second relationship are aligned with each other within a threshold, and comprises indicating degradation when the first relationship and the second relationship are misaligned with each other by more than the threshold.
6. The method of claim 1, wherein the pressure differential is estimated by one of: a single gauge pressure sensor coupled upstream of the exhaust particulate filter in the engine exhaust, a differential pressure sensor coupled across the exhaust particulate filter, and a pair of gauge pressure sensors coupled upstream and downstream of the exhaust particulate filter in the engine exhaust.
7. The method of claim 1, wherein the indicating comprises indicating degradation in response to being above a threshold difference between the first relationship and the second relationship, the threshold difference adjusted according to atmospheric pressure.
8. The method of claim 1, wherein the first relationship comprises a first curve fit of the exhaust flow rate and the pressure differential measured over the first engine speed range, and the second relationship comprises a second curve fit of the exhaust flow rate and the pressure differential measured over the second engine speed range.
9. The method of claim 1, wherein the indicating includes indicating degradation in response to a threshold pressure differential across the exhaust particulate filter being above in the first engine speed range and below in the second engine speed range for a given exhaust flow rate.
10. The method of claim 1, wherein the indicating degradation comprises indicating a leak or a loss of the exhaust particulate filter, and wherein the exhaust particulate filter is a gasoline particulate filter.
11. An engine system, comprising:
an engine including an exhaust passage;
a gasoline particulate filter coupled in the exhaust passage;
one or more gauge pressure sensors coupled to the gasoline particulate filter for estimating a pressure differential across the gasoline particulate filter;
a flow sensor coupled in the exhaust passageway upstream of the gasoline particulate filter for estimating an exhaust flow rate through the gasoline particulate filter; and
a controller having computer-readable instructions stored on a non-transitory memory that, when executed, cause the controller to:
measuring pressure data via the one or more pressure sensors when the exhaust flow rate is above a threshold rate; and is
Indicating degradation of the gasoline particulate filter in response to a curve fit of the pressure data being below a threshold value, the threshold value based on the exhaust flow rate and engine speed.
12. The engine system of claim 11, wherein the engine further comprises an engine intake, the engine intake comprising an intake throttle, and wherein the controller includes further instructions to limit an opening of the intake throttle to limit engine output torque in response to the indicated degradation.
13. The engine system of claim 11, wherein the indication of degradation comprises:
incrementing a counter stored in the memory of the controller in response to the curve fit of the pressure data being below the threshold; and is
Indicating degradation of the gasoline particulate filter in response to an output of the counter retrieved after measuring the duration of the pressure data being above a threshold.
14. The engine system of claim 11, wherein the pressure data is measured at engine speeds above idle speed.
Technical Field
The present disclosure relates to systems and methods for leak detection at a coupled particulate filter in an internal combustion engine, such as a gasoline-fueled engine.
Background
Particulates (e.g., soot) may be formed in internal combustion engines as a by-product of certain combustion processes. For example, at high engine speeds or high engine loads, particulates may form in the exhaust. Particulate formation may also be associated with the direct injection of fuel into the engine cylinder. A particulate filter in the exhaust line may be used to retain particulates and reduce soot emissions. Over time, particulates accumulate within the filter, thereby reducing the exhaust flow rate through the exhaust system and creating engine backpressure, which may reduce engine efficiency and fuel economy. To reduce the back pressure, the filter may be intermittently regenerated to burn off the accumulated soot. However, even with intermittent regeneration, the particulate filter may deteriorate and leak particulates into the atmosphere through the tailpipe.
One method of determining whether a particulate filter is leaking is through the use of a pressure sensor, as shown in US 9,664,095 to Nieuwstadt et al. Wherein the pressure drop is measured across the exhaust particulate filter by upstream and downstream exhaust oxygen sensors. This pressure drop is then used to infer a filter leak during conditions when the exhaust gas oxygen concentration across the filter is substantially constant.
However, the inventors herein have recognized potential problems with this approach. As one example, while there is a substantial change in the pressure-flow relationship for a normally operating Gasoline Particulate Filter (GPF) versus a leaking (or missing) GPF at high exhaust flow rates, at low exhaust flow rates (such as below 300 m)3H) there may be significant overlap between the pressure-flow relationships of the normal operating condition and the fault condition. Specifically, lower nominal pressure drop confounding effects of ash loading may result in lower separations in GPF diagnostics compared to Diesel Particulate Filter (DPF) diagnostics. Therefore, it may be difficult to accurately and reliably diagnose GPF leaks. Furthermore, due to the pressure created by the sharp exhaust pipe bends after the GPF and the resonance in the cavity, in some cases it may be difficult to even detect a complete absenceGPF of (3).
Disclosure of Invention
The inventors herein have recognized that the pressure-flow relationship across the GPF may vary with engine speed. Specifically, at low engine speeds, if GPF is missing or leaking, resonance can develop in the exhaust pipe, which can result in a higher pressure drop. At higher speeds, the frequency may be too high to form standing waves and the pressure drop may be lower. Thus, in one example, the above-described problem may be solved by a method for determining Gasoline Particulate Filter (GPF) leakage or degradation in engine exhaust, comprising: comparing a first relationship between an exhaust flow rate and a pressure differential across the exhaust particulate filter in a first engine speed range with a second relationship between the exhaust flow rate and the pressure differential across the particulate filter in a second engine speed range; and indicating particulate filter degradation based on the comparison. In this way, the detectability of a leaking or missing GPF is improved.
As one example, an exhaust system may include a first exhaust gas sensor (e.g., a first oxygen sensor) located upstream of an exhaust gas Gasoline Particulate Filter (GPF) and a second exhaust gas sensor (e.g., a second oxygen sensor) located downstream of the GPF. The controller may generate a first graph plotting a pressure drop across the filter versus exhaust flow rate over a first range of engine speeds, such as when engine speeds are above a threshold speed. The controller may also generate a second graph plotting a pressure drop across the filter versus exhaust flow rate over a second range of engine speeds, such as when the engine speed is below a threshold speed. If the separation between the curve fit of the first graph and the curve fit of the second graph is greater than a threshold difference, then a GPF degradation is indicated. For example, a diagnostic code may be set.
In this manner, existing exhaust gas sensors and pressure-based GPF monitors may be advantageously used to infer particulate filter leaks without the need for other dedicated sensors. By monitoring the output of the exhaust gas oxygen sensor coupled across the GPF at different engine speeds, the relationship between the pressure drop across the GPF at high and low engine speeds and the exhaust flow across the GPF can be correlated to the health of the filter. A technical effect of correlating exhaust pressure versus flow across the GPF captured at higher engine speeds with exhaust pressure versus flow across the GPF captured at lower engine speeds is that a higher curve-fitting separation can be achieved even at lower flow rates. By improving this separation, the confounding effect of ash loading on GPF diagnostics is reduced, thereby improving the reliability of GPF monitor results. By improving monitoring of particulate filter health, vehicle emissions may be improved.
It should be appreciated that the summary above is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This 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.
Drawings
Fig. 1 schematically shows an engine with an exhaust system.
2A-2C schematically illustrate example embodiments of a pressure sensor arrangement coupled to an exhaust particulate filter.
FIG. 3 illustrates an example embodiment of a GPF diagnostic routine based on pressure/flow data and engine speed.
FIG. 4 illustrates another example embodiment of a GPF diagnostic program.
FIG. 5 illustrates yet another example embodiment of a GPF diagnostic program.
FIG. 6 shows an example pressure-flow curve for a GPF diagnostic routine known in the prior art.
FIG. 7 illustrates an example pressure-flow curve for a GPF diagnostic routine according to this disclosure.
Detailed Description
The present description relates to methods and systems for diagnosing degradation of particulate matter from a Gasoline Particulate Filter (GPF) coupled with an engine exhaust system, such as the exhaust systems of fig. 1-2. The engine controller may be configured to execute diagnostic routines (such as those depicted in fig. 3-5) to correlate the pressure drop across the particulate filter with the exhaust flow through the filter over different engine speed ranges. The controller may compare a curve fit of the pressure-flow data captured during high engine speed conditions to another curve fit of the pressure-flow data captured during low engine speed conditions, such as the curve fit of fig. 7. The controller may then correlate the curve-fitting change with changing engine speed to GPF health, thereby enabling improved GPF diagnostics even at low flow rates than methods that do not account for engine speed (such as the method used in FIG. 6). In this manner, filter diagnostics may be improved, thereby improving emissions compliance.
Turning to FIG. 1, a schematic diagram of one cylinder of a multi-cylinder engine 10 is shown that may be included in a propulsion system of a vehicle 5. The vehicle 5 may be configured for on-road propulsion. Engine 10 may be controlled at least partially by a control system including controller 12 and by input from a vehicle operator 132 via an input device 130. In this example, the input device 130 includes an accelerator pedal and a pedal position sensor 134 for generating a proportional pedal position signal PP. Combustion chamber 30 (also referred to as cylinder 30) of engine 10 may include combustion chamber walls 32 with piston 36 positioned therein. Piston 36 may be coupled to crankshaft 40 such that reciprocating motion of the piston is translated into rotational motion of the crankshaft. Crankshaft 40 may be coupled to at least one drive wheel of a vehicle via an intermediate transmission system (not shown). Further, a starter motor may be coupled to crankshaft 40 via a flywheel (not shown) to enable a starting operation of engine 10.
Combustion chamber 30 may receive intake air from intake manifold 44 via intake passage 42 and may exhaust combustion gases via exhaust manifold 48. Intake manifold 44 and exhaust manifold 48 may selectively communicate with combustion chamber 30 via respective intake valve 52 and exhaust valve 54. In some embodiments, combustion chamber 30 may include two or more intake valves and/or two or more exhaust valves.
Fuel injector 66 is shown disposed in intake manifold 44 in a configuration that provides what is known as port injection of fuel into the intake port upstream of combustion chamber 30. Fuel injector 66 injects fuel in proportion to the pulse width of signal FPW received from controller 12 via electronic driver 68. Fuel may be delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail. In some embodiments, combustion chamber 30 may alternatively or additionally include a fuel injector coupled directly to combustion chamber 30 to inject fuel directly therein in a manner referred to as direct injection.
Intake passage 42 may include a throttle 62 having a throttle plate 64. In this particular example, the position of throttle plate 64 may be changed by controller 12 via signals provided to an electric motor or actuator included with throttle 62, a configuration commonly referred to as Electronic Throttle Control (ETC). In this manner, throttle 62 may be operated to vary the intake air provided to combustion chamber 30 as well as other engine cylinders. The position of throttle plate 64 may be provided to controller 12 via throttle position signal TP. Intake passage 42 may include a mass air flow sensor 120 coupled upstream of throttle 62 for measuring a flow rate of an air charge entering the cylinder through throttle 62. Intake passage 42 may also include a manifold air pressure sensor 122 coupled downstream of throttle 62 for measuring manifold air pressure MAP.
In some embodiments, a compression device, such as a turbocharger or supercharger, including at least a compressor (not shown) may be disposed along intake manifold 44. For a turbocharger, the compressor may be at least partially driven by a turbine (not shown), for example via a shaft, disposed along the exhaust manifold 48. For a supercharger, the compressor may be at least partially driven by the engine and/or the electric machine, and may not include a turbine.
Ignition system 88 can provide an ignition spark to combustion chamber 30 via spark plug 92 in response to spark advance signal SA from controller 12, under select operating modes. Although spark ignition components are shown, in some embodiments, combustion chamber 30 or one or more other combustion chambers of engine 10 may be operated in a compression ignition mode with or without an ignition spark.
Exhaust gas sensor 126 is shown coupled to exhaust passage 58 upstream of
In addition, engine 10 may include an Exhaust Gas Recirculation (EGR) system (not shown) to help reduce NOx and other emissions. The EGR system may be configured to recirculate a portion of exhaust gas from engine exhaust to engine intake. In one example, the EGR system may be a low pressure EGR system, wherein exhaust gas is recirculated to the engine intake downstream from the
The first emission control device 71 may, for example, treat engine exhaust to oxidize exhaust constituents. For example, emission control device 71 may be placed in close-coupled position in exhaust passage 58. A Gasoline Particulate Filter (GPF)70 (also referred to herein as a particulate filter or filter 70) is located downstream of first emission control device 71 in engine exhaust 58 and is configured to retain residual ash and other hydrocarbons emitted from engine 10 to reduce particulate emissions. The retained particulates may be oxidized during regeneration performed during engine operation to produce carbon dioxide, thereby reducing the soot loading of the GPF. During regeneration, the temperature of the GPF and the temperature of the exhaust entering the GPF may be increased to burn off the stored soot. In this way, GPF regeneration may be performed at high exhaust temperatures (e.g., 600 ℃ and above) so that retained particulates are burned in a rapid manner and not released into the atmosphere. To accelerate the regeneration process and oxidize soot in an efficient manner, the exhaust gas entering the particulate filter may be temporarily diluted. In some embodiments,
Exhaust passage 58 may include at least two exhaust gas sensors. In the illustrated embodiment, three exhaust gas sensors 126, 72, and 76 are shown coupled in the exhaust gas. Exhaust gas sensor 72 may be located upstream of
The oxygen sensor may be a linear oxygen sensor or a switching oxygen sensor. As one example, the oxygen sensor may be one of a UEGO (universal or wide-range exhaust gas oxygen), a two-state oxygen or EGO sensor, or a HEGO (heated EGO) sensor. Exhaust gas oxygen sensor 126 (and sensors 76, 72, if so configured) may evaluate the concentration of oxygen present in the exhaust and sense the tailpipe exhaust oxygen concentration around
Other sensors, such as a mass air flow (AM) sensor 73 and/or a temperature sensor may be disposed upstream of the first emission control device 71 to monitor the mass flow and temperature of the exhaust gas entering the emission control device. The sensor locations shown in FIG. 1 are merely examples of various possible configurations. For example, an emission control system may include one emission control device in which a portion of the volume is provided with close-coupled catalyst.
The air-fuel ratio of the exhaust gas released from cylinders 30 may be determined by one or more oxygen sensors located in the exhaust stream of the engine. Based on the estimated exhaust air-fuel ratio, fuel injection to the engine cylinders may be adjusted to control the air-fuel ratio of the cylinder combustion. For example, the amount of fuel injected into the cylinder may be adjusted based on a deviation in exhaust air-fuel ratio, estimated based on the output of one or more of exhaust sensors 126, 72, and 76 and a desired air-fuel ratio (such as a deviation from stoichiometry).
To achieve emissions compliance, GPF may be diagnosed intermittently, such as to diagnose leaks or removal. As detailed in fig. 3-5, the controller may measure the pressure change across the GPF at different exhaust flow levels to generate a pressure-flow curve. The inventors herein have recognized that while there is a substantial change in the pressure-flow relationship for a normally operating GPF versus a leaking (or missing) GPF at high exhaust flow rates, at low exhaust flow rates (such as below 300 m)3H) there is a significant overlap between the pressure-flow relationships of the normal operating situation and the fault situation. This is shown in fig. 6. The map 600 shows the pressure-flow data collected for a normally operating GPF (black dots forming a curve fit 602) and compared to the data collected for a leaking or missing GPF (gray dots forming a curve fit 604). The map depicts exhaust flow through the GPF (in m) along the x-axis3In h) and the pressure drop across the GPF along the y-axis (in hPa). As can be seen by comparing the curve fits, at lower flow rates, the separation between the curve fits is smaller. This may be due to the commingling of ash loads in GPFsThe effect results in a lower nominal pressure drop. Specifically, the ash loading has the effect of shifting the curve of the degraded GPF (see curve fit 604 of fig. 6) in the upward direction, thereby reducing separation even in the presence of leakage. Thus, at low flow rates, it may be difficult to accurately and reliably distinguish between a properly functioning GPF and a leaking GPF. Emissions may degrade if the GPF is misdiagnosed as being operable properly when leaking. If the GPF is misdiagnosed as degraded during normal operation, warranty issues may result. Furthermore, it may be difficult in some cases to detect even a completely missing GPF due to the pressure created by the sharp exhaust pipe bends after the GPF and the resonance in the cavity. By generating pressure-flow curves at two different engine speed ranges, as detailed in FIG. 3, such as above and below the threshold speed range, and comparing the curve fits in both cases, the variation between the curve fits is increased, thereby improving the reliability of the diagnostic results.
Returning to fig. 1, the vehicle 5 may be a hybrid vehicle having multiple torque sources available for use by one or more wheels 55. In other examples, the vehicle 5 is a conventional vehicle having only an engine or an electric vehicle having only one or more electric machines. In the illustrated example, the vehicle 5 includes an engine 10 and a motor 53. The electric machine 53 may be a motor or a motor/generator. When the one or more clutches 56 are engaged, the crankshaft 140 of the engine 10 and the motor 53 are connected to the wheels 55 via the transmission 57. In the depicted example, the first clutch 56 is disposed between the crankshaft 140 and the motor 53, and the second clutch 56 is disposed between the motor 53 and the transmission 57. Controller 12 may send a clutch engagement or disengagement signal to an actuator of each clutch 56 to connect or disconnect crankshaft 140 from motor 53 and the components connected thereto, and/or to connect or disconnect motor 53 from transmission 57 and the components connected thereto. The transmission 57 may be a gearbox, a planetary gear system, or another type of transmission. The powertrain may be configured in various ways, including as a parallel, series, or series-parallel hybrid vehicle.
The electric machine 53 receives power from the traction battery 58 to provide torque to the wheels 55. The electric machine 53 may also operate as a generator to provide electrical power to charge the battery 58, for example, during braking operations.
The controller 12 is shown in fig. 1 as a microcomputer including: microprocessor unit 102, input/output ports 104, an electronic storage medium for executable programs and calibration values (shown in this particular example as read only memory 106), random access memory 108, keep alive memory 110 and a data bus. Controller 12 may receive various signals from sensors coupled to engine 10, including a measurement of intake Mass Air Flow (MAF) from mass air flow sensor 120, in addition to those signals previously discussed; engine Coolant Temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114; a surface ignition pickup signal (PIP) from Hall effect sensor 118 (or other type) coupled to crankshaft 40; a Throttle Position (TP) from a throttle position sensor; air quality and/or temperature of exhaust entering the catalyst from sensor 73; GPF rear exhaust pressure from sensor 76; GPF front exhaust pressure from sensor 72; and absolute manifold pressure signal MAP from sensor 122. Engine speed signal, RPM, may be generated by controller 12 from signal PIP. Manifold pressure signal MAP from a manifold pressure sensor may be used to provide an indication of vacuum or pressure in the intake manifold. It should be noted that various combinations of the above sensors may be used, such as using a MAF sensor without a MAP sensor, or vice versa. During stoichiometric operation, the MAP sensor may give an indication of engine torque. Additionally, this sensor, along with the detected engine speed, may provide an estimate of the charge (including air) inducted into the cylinder. In one example, sensor 118 (which also functions as an engine speed sensor) may produce a predetermined number of equally spaced pulses per revolution of the crankshaft. In addition, controller 12 may communicate with an aggregation display device, for example, to alert the driver to a fault in the engine or exhaust aftertreatment system.
Storage medium read-only memory 106 may be programmed with computer readable data representing instructions executable by processor 102 for performing the methods described below as well as other variations that are anticipated but not specifically listed.
The controller 12 receives signals from the various sensors of FIG. 1 and employs the various actuators of FIG. 1 to regulate engine operation based on the received signals and instructions stored on a memory of the controller. For example, adjusting fuel injection may include adjusting pulse width signal FPW to electronic driver 68 to adjust the amount of fuel injected into the cylinder via fuel injector 66.
2A-2C, exemplary configurations and architectures of pressure sensors coupled to an exhaust GPF are shown. These configurations enable the pressure drop across the GPF to be measured at different exhaust flow rates across the GPF. In each of fig. 2A-2C, the GPF is
FIG. 2A illustrates a first embodiment 200 in which a
FIG. 2B illustrates a
FIG. 2C shows a
Turning now to FIG. 3, an example method 300 is shown for diagnosing an exhaust GPF by correlating a pressure-flow relationship of the GPF as measured in a high engine speed range and a low engine speed range. This method improves the separation of the curve fit even at lower flow rates. An additional embodiment of the method of fig. 3 is shown in fig. 4. The instructions for performing the method 300 and the remaining methods included herein may be executed by the controller based on instructions stored on a memory of the controller in conjunction with signals received from sensors of the engine system, such as the sensors described above with reference to fig. 1 and 2A-2C. The controller may employ engine actuators of the engine system to adjust engine operation according to the methods described below.
At 302, the method may determine engine operating parameters. For example, the method may determine an operator torque request, an engine speed-load condition, an engine temperature, an exhaust flow rate, a boost level, and the like.
At 304, it may be confirmed that the exhaust flow rate is above a threshold. For example, it can be confirmed that the exhaust gas flow rate is higher than 200m3And/hr. Since higher exhaust flow rates improve the separation between the curve fits of degraded GPFs and normally operating GPFs, the GPF monitor will be selectively implemented when the exhaust flow rate is above a threshold. If the exhaust flow rate is not above the threshold, at 306, the method includes disabling the GPF monitor and not collecting any GPF related data.
After identifying an exhaust flow rate above the threshold, at 308, the method includes identifying that the engine speed (Ne) is below a first threshold (Thr1), such as below 2000 rpm. Here, the below-threshold engine speed range may be a first engine speed range in which pressure and flow data for the GPF is collected. If the engine speed is not below the first threshold, the method moves to 314 to determine if the engine speed is within a second engine range.
Upon confirming that the engine is operating within the first speed range, at 310, the method includes collecting pressure and flow data for the GPF while the engine is operating within the first speed range. As one example, the exhaust flow rate may be estimated based on engine operating conditions or based on the output of an intake or exhaust flow sensor (e.g., MAF sensor 120 or AM sensor 73 of FIG. 1). As another example, pressure data may be collected by a pressure sensor (such as sensors 72 and/or 76 of fig. 1) or any of the pressure sensor configurations of fig. 2A-2C. The pressure data may include pressure changes or pressure drops sensed across the GPF. The pressure sensor may be a gauge pressure sensor or a differential pressure sensor. After collecting the pressure and flow data, the controller may fit a straight line or a quadratic curve to the collected data. An example of pressure and flow data collected over a lower engine speed range is shown by the gray data points and is correspondingly shown in the map 600 of FIG. 6.
At 312, the method includes estimating a first slope (slope _1) of a curve fit of the collected pressure-flow data for the GPF over a lower engine speed range.
At 314, it may be confirmed that the engine speed (Ne) is above a second threshold (Thr2), which second threshold (Thr2) is above the first threshold (Thr 1). For example, it can be confirmed that the engine speed is higher than 3000 rpm. Here, the below-threshold engine speed range may be a second engine speed range in which pressure and flow data for the GPF is collected. If an engine speed range above the second threshold is not identified, the method returns to 308 to continue collecting data within the first engine speed range. Further, between a first threshold speed and a second threshold speed, such as between 2000rpm and 3000rpm, the controller may wait for the engine speed to rise and then begin collecting data above the second threshold speed.
Upon confirming that the engine is operating within the second speed range, at 316, the method includes collecting pressure and flow data for the GPF while the engine is operating within the second speed range. As one example, the exhaust flow rate may be estimated based on engine operating conditions or based on the output of an intake or exhaust flow sensor (e.g., MAF sensor 120 or AM sensor 73 of FIG. 1). As another example, pressure data may be collected by a pressure sensor (such as sensors 72 and/or 76 of fig. 1) or any of the pressure sensor configurations of fig. 2A-2C. The pressure data may include pressure changes or pressure drops sensed across the GPF. The pressure sensor may be a gauge pressure sensor or a differential pressure sensor. After collecting the pressure and flow data, the controller may fit a straight line or a quadratic curve to the collected data. At 318, the method includes estimating a second slope (slope _2) of a curve fit of the collected pressure-flow data for the GPF over a higher engine speed range.
At 320, it is determined whether the slope of the curve fit of the pressure-flow data collected in the lower speed range is significantly different from the slope of the curve fit of the pressure-flow data collected in the higher speed range. For example, the absolute difference between slope _1 and slope _2 is calculated and compared to a non-zero threshold (e.g., the difference is greater than 5hPa/(m 3/h)). In some examples, the threshold may be further adjusted based on barometric pressure or altitude.
If the curve fit slopes are determined to differ by more than a threshold, then at 322, GPF degradation may be indicated. For example, a GPF leak or a GPF miss may be indicated. For example, the controller may be able to distinguish certain intermediate leak sizes from missing GPFs. Degradation may be indicated by setting a diagnostic code or flag and/or illuminating a fault indicator light. If the curve fit slopes are determined to differ by less than the threshold (such as when the curve fit slopes are substantially the same), at 324, it may be indicated that the GPF is not degraded.
An alternative embodiment of the method of fig. 3 is depicted in fig. 4 and 5. Turning first to FIG. 4,
After confirming that the exhaust flow rate is above the threshold, at 408, the method includes confirming that the engine speed (Ne) is above a second threshold, such as the second threshold applied in the diagnostics of fig. 3. The second threshold is higher than the first threshold and may include engine speeds above 3000rpm, such as the higher engine speed range of the method of FIG. 3. If the engine speed is not above the second threshold, the method moves to 407 where the controller waits for the engine speed to rise to or above the second threshold speed.
Upon confirming that the engine speed is within the higher speed range, the method moves to 410 to collect pressure and flow data for the GPF. As one example, the exhaust flow rate may be estimated based on engine operating conditions or based on the output of an intake or exhaust flow sensor, while pressure data may be collected by a pressure sensor, such as in any of the pressure sensor configurations of FIGS. 2A-2C. The pressure data may include pressure changes or pressure drops sensed across the GPF. The pressure sensor may be a gauge pressure sensor or a differential pressure sensor.
At 412, the method includes comparing the pressure to a threshold pressure, such as a threshold pressure having a value between a pressure value corresponding to a complete GPF and a pressure value corresponding to a degraded GPF (such as a pressure value between curve fits 602 and 604 in fig. 6). If the pressure value is above the threshold pressure (Thr _ P), then at 414, it may be indicated that the GPF is not degraded. Otherwise, if the pressure value is below the threshold pressure, at 416, GPF degradation may be indicated. For example, a GPF having a leak of intermediate size, or a GPF missing, may be indicated based on a difference from a threshold pressure. Degradation may be indicated by setting a diagnostic code or flag and/or illuminating a fault indicator light.
In another variation of the method of FIG. 4, after identifying an exhaust flow rate above a threshold at 404, the method may move to 408 to estimate a threshold pressure (Thr _ P) for diagnosis based on the exhaust flow rate and the engine speed. For example, as the exhaust flow rate exceeds the threshold flow rate, the threshold pressure increases. As another example, as the current engine speed increases, the threshold pressure decreases. Specifically, at higher engine speeds (e.g., above a threshold speed), the threshold pressure is decreased, and/or at lower engine speeds (e.g., below a threshold speed), the threshold pressure is increased. The method then returns to 410 to collect pressure and flow data and diagnose the GPF based on the pressure relative to a threshold pressure.
In yet another variation, the pressure threshold of the GPF leak monitor is determined from the GPF flow, engine speed, and altitude to account for all dependencies. For example, the threshold pressure may be determined according to equation (1) as:
gpf _ leak _ thr ═ f1(p _ baro) × g _ sea level (RPM, GPF flow) + (1-f1(p _ baro)) × g _ high _ alt (RPM, GPF flow) (1)
Where f1 is a function of atmospheric pressure, accounting for altitude, g _ sea level is a threshold for sea level, and g _ high _ alt is a threshold for 8000 feet of altitude. If the GPF pressure is below this threshold, the controller may set a fault; if the GPF pressure is above this threshold pressure, the fault may be repaired (or eliminated).
Turning now to FIG. 5, method 500 begins by estimating and/or measuring engine operating conditions at 502 as at 302 and 402. At 504, as at 404, it may be confirmed that the exhaust flow rate is above a threshold. For example, it can be confirmed that the exhaust gas flow rate is higher than 200m3And/hr. By confirming that the exhaust flow rate is above the threshold, the separation efficiency between the curves for the degraded and non-degraded filters is improved. If the exhaust flow rate is not above the threshold, at 506, the method includes disabling the GPF monitor and not collecting any GPF related data.
After confirming that the exhaust flow rate is above the threshold, at 508, the method includes confirming that one or more other GPF monitor activation conditions have been met. These enabling conditions include, for example, confirming that ambient pressure and temperature are within target ranges. Other enabling conditions may include engine coolant temperature, exhaust temperature, engine speed, and load being within target ranges. These conditions can be calibrated to improve diagnostic stability. For example, exhaust temperatures between 300-700 ℃ may indicate stable engine operation such that the temperature gradient is small and flow measurements are not disrupted. If any other enabling conditions are not met, the method returns to 506 to disable the GPF monitor. Otherwise, if other enabling conditions are met, the monitor is started, and at 510, a monitor completion timer is started.
Next, at 512, the method determines a threshold pressure (Thr _ P) to be used for diagnosis. The threshold pressure may be determined based on the exhaust flow rate and the engine speed. The controller may reference a look-up table that is populated based on engine speed and exhaust flow rate. As one example, the threshold pressure in the lookup table increases as the exhaust flow rate exceeds the threshold flow rate. As another example, as the current engine speed increases, the threshold pressure in the lookup table increases. Further, the threshold pressure may be determined via a model or algorithm.
Next, at 514, the method includes collecting pressure and flow data for the GPF. As one example, the exhaust flow rate may be estimated based on engine operating conditions or based on the output of an intake or exhaust flow sensor, while pressure data may be collected by a pressure sensor, such as in any of the pressure sensor configurations of FIGS. 2A-2C. The pressure data may include pressure changes or pressure drops sensed across the GPF. The pressure sensor may be a gauge pressure sensor or a differential pressure sensor.
At 516, the method includes comparing the pressure to an earlier determined threshold pressure. Thereafter, the fault counter may be incremented or decremented by an amount that is a function of the difference between the observed pressure and the threshold pressure. The fault counter may be software or an algorithm stored in the memory of the controller and may be configured to increment or decrement a certain value when certain criteria are met. Specifically, if the pressure value is above the threshold pressure (Thr _ P), then a fault counter in the memory of the controller may be decremented at 518 in anticipation of no GPF degradation. The fault counter may be decremented by an amount that is based on the difference between the threshold pressure and the observed pressure. Therefore, as the pressure difference increases, the fault counter is decremented by a greater amount, indicating that the likelihood of GPF degradation is low.
Otherwise, if the pressure value is below the threshold pressure (Thr _ P), then a fault counter in the controller's memory may be incremented at 520 in anticipation of GPF degradation. The fault counter may be incremented by an amount based on the difference between the threshold pressure and the observed pressure. Therefore, as the pressure difference increases, the fault counter increments by a larger amount, indicating a higher likelihood of GPF degradation.
At 522, it may be determined whether the elapsed time on the monitor completion timer has exceeded a threshold duration. For example, it may be determined whether the timer value has exceeded a threshold duration, which may be between 5 seconds and 30 seconds. If not, the method returns to 514 to continue collecting pressure and flow data at the GPF and incrementing or decrementing the fault counter based on the observed pressure relative to the threshold pressure. If the timer duration has elapsed, then at 524, the counter value is retrieved. For example, the current value on the failure counter is retrieved from the controller's memory. At 526, the retrieved counter value is compared to a non-zero threshold count. For example, the threshold count may be 10 counts and may indicate a GPF that is operating normally. If the counter value exceeds the threshold count, then at 530, GPF degradation may be indicated. For example, a GPF leak or a GPF miss may be indicated. Furthermore, it is possible to distinguish a medium size leak from a missing GPF based on the counter value counted against the threshold. Degradation may be indicated by setting a diagnostic code or flag and/or illuminating a fault indicator light. If the counter value does not exceed the threshold count, then at 528, it may indicate that the GPF is not degraded.
In another variation, the pressure threshold of the GPF leak monitor is determined from the GPF flow, engine speed, and altitude to account for all dependencies. For example, the threshold pressure may be determined according to equation (1) as:
gpf _ leak _ thr ═ f1(p _ baro) × g _ sea level (RPM, GPF flow) + (1-f1(p _ baro)) × g _ high _ alt (RPM, GPF flow) (1)
Where f1 is a function of atmospheric pressure, accounting for altitude, g _ sea level is a threshold for sea level, and g _ high _ alt is a threshold for 8000 feet of altitude. If the GPF pressure is below this threshold, the controller may increment a fault counter, and if the GPF pressure is above this threshold pressure, the controller may decrement the fault counter.
In one example, the method of fig. 3 may be selected in response to a first condition, the method of fig. 4 may be selected in response to a second condition, and the method of fig. 5 may be selected in response to a third condition, the first, second, and third conditions being different from one another. Further, different algorithms may be optimized for different exhaust configurations (such as single or dual bank engines, different angles of elbows, etc.).
Turning now to FIG. 7, an example of diagnosing GPF using pressure-flow data that has been parsed while taking into account engine speed is shown. Specifically, FIG. 7 depicts a first map 700 showing pressure-flow data collected over a range of engine speeds at a GPF for normal operation. In contrast, map 702 shows pressure-flow data collected over a range of engine speeds at a degraded GPF. In the case of a normally operating GPF, the curve fits of the data collected in the low speed range (see curve fit 704) and the high speed range (see curve fit 706) of the normally operating GPF substantially overlap. In the case of a degraded GPF, the curve fit of the data collected in the low speed range (see curve fit 714) and the high speed range (see curve fit 716) of a normally operating GPF shows significant divergence. Here, when the GPF deteriorates (e.g., is missing), resonance may form in the exhaust passage, which is driven by flow pulsations caused by engine ignition. Higher resonance results in higher voltage drop. At higher engine speeds, the resonant frequency may be too high to form standing waves, resulting in much less pressure drop. Thus, by considering the variation of the pressure-flow relationship with engine speed, a greater pressure drop at lower engine speeds may be associated with degraded GPF health as compared to higher engine speeds.
Thus, the controller may compare a first relationship between exhaust flow rate and GPF differential pressure measured over a first engine speed range to a second relationship between exhaust flow rate and GPF differential pressure measured over a second, non-overlapping engine speed range. The controller performs a comparison of a first relationship within a first flow and pressure range with a second relationship within the same first flow and pressure range, and then indicates a degradation of the GPF based on the comparison. Wherein the controller may indicate no degradation when the first relationship and the second relationship are aligned with each other within a threshold (as shown in map 700) and may indicate degradation when the first relationship and the second relationship are misaligned with each other by more than the threshold (as shown in map 710).
In this manner, by taking into account the effect of engine speed on changes in the pressure-flow relationship across the GPF, the confounding effect of ash loading on the GPF is reduced, thereby enabling a more reliable diagnosis of the GPF using existing pressure sensors. A technical effect of learning the relationship between pressure and flow across the GPF over different engine speed ranges is that a larger separation between pressure-flow curve fits can be identified even at lower flow rates. Further, a greater separation at higher and lower engine speeds may be used to correlate GPF health. Specifically, a greater pressure drop at lower engine speeds relative to higher engine speeds may be used to identify a leaking or missing filter. In general, the functionality of a pressure-based GPF monitor is improved.
An example method for engine exhaust includes: comparing a first relationship between an exhaust flow rate and a pressure differential across an exhaust particulate filter measured in a first engine speed range with a second relationship between an exhaust flow rate and a pressure differential across the particulate filter measured in a second engine speed range; and indicating particulate filter degradation based on the comparison. In the foregoing example, additionally or alternatively, the indication comprises illuminating a warning light. In any or all of the foregoing examples, additionally or optionally, the comparing is performed when the exhaust flow rate is above a threshold flow rate. In any or all of the foregoing examples, additionally or optionally, the first engine speed range includes engine speeds below a threshold speed, the second engine speed range includes engine speeds above the threshold speed, and wherein the first engine speed range is non-overlapping with the second engine speed range. In any or all of the foregoing examples, additionally or optionally, the comparing comprises comparing the first relationship within a first flow and pressure range to the second relationship within the same first flow and pressure range, and wherein the indicating based on the comparing comprises indicating no degradation when the first relationship and the second relationship are aligned with each other within a threshold, and comprises indicating degradation when the first relationship and the second relationship are misaligned with each other by more than the threshold. In any or all of the foregoing examples, additionally or optionally, the pressure differential is estimated by one of: a single gauge pressure sensor coupled upstream of the particulate filter in the engine exhaust, a differential pressure sensor coupled across the filter, and a pair of gauge pressure sensors coupled upstream and downstream of the filter in the engine exhaust. In any or all of the foregoing examples, additionally or optionally, the indicating comprises indicating degradation in response to being above a threshold difference between the first relationship and the second relationship, the threshold difference adjusted according to atmospheric pressure. In any or all of the preceding examples, additionally or optionally, the first relationship comprises a first curve fit of the exhaust flow rate and the pressure differential measured over the first speed range, and the second relationship comprises a second curve fit of the exhaust flow rate and the pressure differential measured over the second speed range. In any or all of the preceding examples, additionally or optionally, the indicating includes indicating degradation in response to a threshold pressure differential across the filter being above in the first engine speed range and below in the second engine speed range for a given exhaust flow rate. In any or all of the foregoing examples, additionally or optionally, the indicating degradation comprises indicating a leak or a lack of the filter. In any or all of the foregoing examples, additionally or optionally, the exhaust gas particulate filter is a gasoline particulate filter.
Another example engine method includes: activating the monitor in response to the exhaust flow being above a threshold rate; incrementing or decrementing a counter based on the sensed pressure differential across the gasoline particulate filter relative to a threshold pressure, the threshold pressure based on engine speed; retrieving an output of the counter after a duration of time since the monitor was activated; and in response to the output being above a threshold, indicating degradation of the filter. In any or all of the foregoing examples, additionally or alternatively, the threshold pressure is further based on atmospheric pressure, and the incrementing or decrementing comprises incrementing the counter in response to the sensed pressure differential falling below the threshold pressure; and decrementing the counter in response to the sensed pressure differential exceeding the threshold pressure. In any or all of the preceding examples, additionally or optionally, the incrementing comprises incrementing the output of the counter by an amount based on a difference between the sensed pressure differential and the threshold pressure, and wherein the decrementing comprises decrementing the output of the counter by an amount based on a difference between the sensed pressure differential and the threshold pressure. In any or all of the foregoing examples, additionally or alternatively, the duration is based on each of an integrated value of exhaust flow and an integrated value of engine speed over an average travel period. In any or all of the foregoing examples, additionally or optionally, the sensed differential pressure is sensed via one of: a single gauge pressure sensor coupled upstream of the particulate filter in the engine exhaust, a differential pressure sensor coupled across the filter, and a pair of gauge pressure sensors coupled upstream and downstream of the filter in the engine exhaust. In any or all of the foregoing examples, additionally or alternatively, a filter leak is distinguished from a filter absence based on a measured relationship between the exhaust flow and the sensed pressure differential.
Another example engine system includes: an engine including an exhaust passage; a gasoline particulate filter coupled in the exhaust passage; one or more gauge pressure sensors coupled to the filter for estimating a pressure differential across the filter; a flow sensor coupled in the exhaust passageway upstream of the filter for estimating an exhaust flow rate through the filter; and a controller having computer readable instructions stored on non-transitory memory that, when executed, cause the controller to measure pressure data via the one or more pressure sensors when the exhaust flow rate is above a threshold rate; and indicating the filter degradation in response to a curve fit of the pressure data being below a threshold, the threshold being based on the exhaust flow rate and engine speed. In any or all of the foregoing examples, additionally or alternatively, the engine further comprises an engine intake, the engine intake comprising an intake throttle, and wherein the controller includes further instructions to limit an opening of the intake throttle to limit engine output torque in response to the indicated degradation. In any or all of the foregoing examples, additionally or optionally, the indicating degradation comprises: incrementing a counter stored in the memory of the controller in response to the curve fit of the pressure data being below the threshold; and indicating degradation of the filter in response to the retrieved output of the counter being above a threshold after measuring the duration of the pressure data. In any or all of the foregoing examples, additionally or alternatively, the pressure data is measured at engine speeds above an idle speed.
In another expression, the engine system is coupled in a hybrid vehicle or an autonomous vehicle.
In another expression, a method for a gasoline particulate filter coupled in a direct injection engine includes: estimating a difference between a first curve fit between an exhaust flow rate and a pressure differential across an exhaust particulate filter in a first engine speed range and a second curve fit between an exhaust flow rate and a pressure differential across the particulate filter in a second engine speed range; and indicating particulate filter degradation based on the difference relative to a threshold, the threshold adjusted according to altitude or barometric pressure.
It should be noted that the exemplary control and estimation routines included herein may be used with various engine and/or vehicle system configurations. The control methods and routines disclosed herein may be stored as executable instructions in a non-transitory memory and may be executed by a control system, including a controller, in conjunction with 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 acts, 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 acts, operations, and/or functions may be repeatedly performed depending on the particular strategy being used. Further, the described acts, operations, and/or functions may graphically represent code to be programmed into the non-transitory memory of the computer readable storage medium in the engine control system, wherein the described acts are carried out by executing instructions in conjunction with the electronic controller in the system including the various engine hardware components.
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 techniques may be applied to V6 cylinders, inline 4 cylinders, inline 6 cylinders, V12 cylinders, opposed 4 cylinders, and other engine types. The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.
As used herein, unless otherwise specified, the term "about" is to be interpreted to mean ± 5% of the range.
The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. 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 subcombinations 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.
According to the present invention, there is provided a method for engine exhaust having: comparing a first relationship between an exhaust flow rate and a pressure differential across an exhaust particulate filter in a first engine speed range with a second relationship between an exhaust flow rate and a pressure differential across the particulate filter in a second engine speed range; and indicating particulate filter degradation based on the comparison.
According to one embodiment, the indication comprises illuminating a warning light.
According to one embodiment, the comparison is performed when the exhaust flow rate is above a threshold flow rate.
According to one embodiment, the first engine speed range comprises engine speeds below a threshold speed and the second engine speed range comprises engine speeds above the threshold speed, and wherein the first engine speed range and the second engine speed range do not overlap.
According to one embodiment, the comparing comprises comparing the first relationship within a first flow and pressure range with the second relationship within the same first flow and pressure range, and wherein the indicating based on the comparing comprises indicating no degradation when the first relationship and the second relationship are aligned with each other within a threshold, and comprises indicating degradation when the first relationship and the second relationship are misaligned with each other by more than the threshold.
According to one embodiment, the pressure difference is estimated by one of: a single gauge pressure sensor coupled upstream of the particulate filter in the engine exhaust, a differential pressure sensor coupled across the filter, and a pair of gauge pressure sensors coupled upstream and downstream of the filter in the engine exhaust.
According to one embodiment, the indicating comprises indicating degradation in response to being above a threshold difference between the first relationship and the second relationship, the threshold difference being adjusted according to atmospheric pressure.
According to one embodiment, the first relationship comprises a first curve fit of the exhaust flow rate and the pressure differential measured over the first speed range, and the second relationship comprises a second curve fit of the exhaust flow rate and the pressure differential measured over the second speed range.
According to one embodiment, the indicating comprises indicating degradation in response to a threshold pressure differential across the filter being above in the first engine speed range and below in the second engine speed range for a given exhaust flow rate.
According to one embodiment, said indicating degradation comprises indicating a leak or a loss of said filter, and wherein said exhaust gas particulate filter is a gasoline particulate filter.
According to the present invention, there is provided an engine method having: activating the monitor in response to the exhaust flow being above a threshold rate; incrementing or decrementing a counter based on the sensed pressure differential across the gasoline particulate filter relative to a threshold pressure, the threshold pressure based on engine speed; retrieving an output of the counter after a duration of time since the monitor was activated; and in response to the output being above a threshold, indicating degradation of the filter.
According to one embodiment, the threshold pressure is further based on atmospheric pressure, and the incrementing or decrementing comprises incrementing the counter in response to the sensed pressure differential falling below the threshold pressure; and decrementing the counter in response to the sensed pressure differential exceeding the threshold pressure.
According to one embodiment, the incrementing includes incrementing the output of the counter by an amount based on a difference between the sensed pressure differential and the threshold pressure, and wherein the decrementing includes decrementing the output of the counter by an amount based on a difference between the sensed pressure differential and the threshold pressure.
According to one embodiment, the duration is based on the total time taken for the flow and the engine speed within the respective target range within the average driving period.
According to one embodiment, the sensed differential pressure is sensed via one of: a single gauge pressure sensor coupled upstream of the particulate filter in an engine exhaust, a differential pressure sensor coupled across the filter, and a pair of gauge pressure sensors coupled upstream and downstream of the filter in the engine exhaust.
According to one embodiment, indicating degradation of the filter comprises distinguishing between filter leakage and filter absence based on a measured relationship between the exhaust flow and the sensed pressure differential.
According to the present invention, there is provided an engine system having: an engine including an exhaust passage; a gasoline particulate filter coupled in the exhaust passage; one or more gauge pressure sensors coupled to the filter for estimating a pressure differential across the filter; a flow sensor coupled in the exhaust passageway upstream of the filter for estimating an exhaust flow rate through the filter; and a controller having computer readable instructions stored on non-transitory memory that, when executed, cause the controller to measure pressure data via the one or more pressure sensors when the exhaust flow rate is above a threshold rate; and indicating the filter degradation in response to a curve fit of the pressure data being below a threshold, the threshold being based on the exhaust flow rate and engine speed.
According to one embodiment, the engine further comprises an engine intake, the engine intake comprising an intake throttle, and wherein the controller comprises further instructions to limit an opening of the intake throttle to limit engine output torque in response to the indication of degradation.
According to one embodiment, the indicating degradation comprises: incrementing a counter stored in the memory of the controller in response to the curve fit of the pressure data being below the threshold; and indicating degradation of the filter in response to the retrieved output of the counter being above a threshold after measuring the duration of the pressure data.
According to one embodiment, the pressure data is measured at engine speeds above idle speed.
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