CN100547233C - 内燃机 - Google Patents

内燃机 Download PDF

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CN100547233C
CN100547233C CNB2006800113639A CN200680011363A CN100547233C CN 100547233 C CN100547233 C CN 100547233C CN B2006800113639 A CNB2006800113639 A CN B2006800113639A CN 200680011363 A CN200680011363 A CN 200680011363A CN 100547233 C CN100547233 C CN 100547233C
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exhaust
storage
reducing catalyst
catalyzer
fuel ratio
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CN101155977A (zh
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吉田耕平
浅沼孝充
广田信也
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Toyota Motor Corp
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Toyota Motor Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9495—Controlling the catalytic process
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N11/00—Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
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    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/025—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust
    • F01N3/0253—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust adding fuel to exhaust gases
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0821—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with particulate filters
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0842—Nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/085—Sulfur or sulfur oxides
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0871—Regulation of absorbents or adsorbents, e.g. purging
    • F01N3/0885—Regeneration of deteriorated absorbents or adsorbents, e.g. desulfurization of NOx traps
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066—Selective catalytic reduction [SCR]
    • F01N3/208—Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/30—Sulfur compounds
    • B01D2257/302—Sulfur oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/012—Diesel engines and lean burn gasoline engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
    • B01D53/9477—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on separate bricks, e.g. exhaust systems
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    • F01N2550/00—Monitoring or diagnosing the deterioration of exhaust systems
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    • F01N2560/02—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor
    • F01N2560/027—Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor for measuring or detecting SOx
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    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
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    • F02B37/00—Engines characterised by provision of pumps driven at least for part of the time by exhaust
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    • Y02T10/10—Internal combustion engine [ICE] based vehicles
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • General Chemical & Material Sciences (AREA)
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  • Exhaust Gas After Treatment (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

一种发动机排气道，其具有构成后处理系统的SOx捕集催化剂(11)、拥有NOx存储/还原催化剂的颗粒过滤器(13)和NOx存储/还原催化剂(15)，以及用于向设置在所述排气道内的后处理系统供给后处理用燃料的燃料供给阀(17)。当任一催化剂劣化程度超过预定劣化程度时，供给后处理燃料的方法被重新设置以使排气净化所需的后处理燃料供给到具有最低劣化程度的催化剂中，以便使具有最低劣化程度的催化剂承担排气的净化作用。

Description

内燃机
技术领域
本发明涉及内燃机。
背景技术
排气的后处理系统包括多个连串联排列在发动机排气道中的排气净化催化剂的内燃机是本领域已知的，其中各催化剂的劣化程度被确定，并且后处理系统整体的的劣化程度由确定的催化剂的劣化程度确定(例如，请参见日本专利公布(A)2004-76681号)。
然而，在这种情况下，为了确保良好的排气净化作用，最好使这些催化剂中具有最低劣化程度的催化剂承担排气的净化作用。也就是说，在，例如，处理废气中的有害成分时供给后处理燃料的时候，如果使具有最低劣化程度的催化剂承担排气的净化作用，可确保良好的排气净化作用，另外，还可降低后处理燃料的消耗量。然而，在上述的内燃机中，这一点根本没被考虑。
发明内容
本发明的目的是提供一种能够确保良好的排气净化作用并降低燃料消耗量的内燃机。
本发明提供了一种内燃机，其排气的后处理系统设置在发动机的排气道中，用于处理有害成分的后处理燃料供给到后处理系统的排气中，并且供给后处理燃料的方法被预先设置，其中所述后处理系统具有多个串联排列在排气道中的排气净化催化剂，并且当任一催化剂劣化程度超过预定劣化程度时，供给后处理燃料的方法被重新设置以使排气净化所需的后处理燃料被供给到具有最低劣化程度的催化剂中，以便使具有最低劣化程度的催化剂承担排气的净化作用。
附图说明
图1为燃烧点火型内燃机的概观图；
图2为显示颗粒过滤器的结构的视图；
图3为NOx存储/还原催化剂的催化剂载体的表面部分的横截面视图；
图4为SOx捕集催化剂(trapping catalyst)的催化剂载体的表面部分的横截面视图；
图5为显示存储的NOx量NOXA的对应图；
图6为显示颗粒过滤器的NOx释放控制和升温控制的时间图；
图7为显示从燃料供给阀添加燃料的操作的时间图；
图8为显示从燃料供给阀添加燃料的操作的时间图；
图9为显示从燃料供给阀添加燃料的操作的时间图；
图10为后处理系统的控制的流程图；以及
图11为显示燃烧点火型内燃机的另一种实施方式的概观图。
具体实施方式
图1显示了一燃烧点火型内燃机的概观。
参照图1，1表示发动机体，2表示气缸的燃烧室，3表示将燃料注入到燃烧室2中的电子控制型的燃料喷射器，4表示进气歧管，以及5表示排气歧管。所述进气歧管4通过进气道6连接于排气涡轮增压器7的压缩机7a的出口，同时压缩机7a的入口连接于空气滤清器8。所述进气道6具有设置在其内部的由步进电机驱动的节流阀9。此外，在进气道6周围，设置了用于冷却流过进气道6内部的入口空气的冷却系统10。在图1所示的实施方式中，发动机冷却水被引入到冷却系统10中，在该冷却系统中发动机冷却水冷却入口空气。
另一方面，排气歧管5连接于排气涡轮增压器7的排气涡轮7b的入口，同时所述排气涡轮7b的出口连接于SOx捕集催化剂11的入口。此外，SOx捕集催化剂11的出口通过排气管12连接于颗粒过滤器13的入口。所述颗粒过滤器13的出口通过排气管14连接于NOx存储/还原催化剂15。所述排气管12设置有用于向流过排气管12内部的排气中供给后处理燃料的燃料供给阀17。此外，在所述的各排气管12和14以及连接于NOx存储/还原催化剂15的出口的排气管16的内部，设置了包括空燃比传感器、O2传感器、NOx传感器或SOx传感器的传感器18、19和20。
所述排气歧管5和进气歧管4通过排气再循环(下文中称为“排气EGR”)通道21连接。所述EGR通道21具有设置在其内部的电子控制型EGR控制阀22。此外，在EGR通道21周围设置了用于冷却流过EGR通道21的EGR气体的冷却系统23。在图1所示的实施方式中，发动机冷却水被引入到冷却系统23中，在所述冷却系统23中发动机冷却水冷却EGR气体。另一方面，各燃料喷射器3通过燃料供给管24连接于共轨25。该共轨25由电子控制型的可变量燃料排放泵26向供给燃料。供给到共轨25的燃料通过各燃料供给管24被供给到燃料喷射器3。
电子控制单元30包括数字计算机，并具有通过双向总线31彼此连接的部件，如ROM(只读存储器)32、RAM(随机存取存储器)33、CPU(微处理器)34、输入端口35和输出端口36。所述传感器18、19和20的输出信号通过相应的AD转换器37输入到所述输入端口35。此外，所述颗粒过滤器13具有差压传感器27，该差压传感器27用于检测其连接的所述颗粒过滤器13前后的差压。该差压传感器27的输出信号通过相应的AD转换器37输入到所述输入端口35。
加速踏板40具有负载传感器41，该负载传感器41产生与连接于其上的加速踏板40的下压量L成比例的输出电压。所述负载传感器41的输出电压通过相应的AD转换器37输入到所述输入端口35。进一步，所述输入端口35具有曲柄转角传感器42，每当连接于所述曲柄转角传感器42的曲轴旋转例如15度时，该曲轴转角传感器42产生输出脉冲。另一方面，所述输出端口36通过相应的驱动电路38连接于各燃料喷射器3、节流阀9驱动步进电机、燃料供给阀17、EGR控制阀22和燃料泵26。
在图1所示的实施方式中，设置在NOx存储/还原催化剂15的上游侧的颗粒过滤器13也承载有NOx存储/还原催化剂。因此，首先说明所述微粒过滤器13的结构，然后再对所述NOx存储/还原催化剂15和承载在所述颗粒过滤器13上的NOx存储/还原催化剂进行说明。
图2(A)和图2(B)显示了承载NOx存储/还原催化剂的颗粒过滤器13的结构。请注意，图2(A)为所述颗粒过滤器13的正视图，而图2(B)显示了所述颗粒过滤器13的侧面横截面图。如图2(A)和图2(B)所示，所述颗粒过滤器13形成了蜂窝结构，并具有多个彼此平行延伸的排气流通道60、61。这些排气流通道包括下游端由塞子62封闭的排气流入通道60和上游端由塞子63封闭的废气流出通道61。请注意，图2(A)中的阴影部分显示了塞子63。因此，排气流入通道60和排气流出通道61通过薄的分隔壁64交替排列。换句话说，所述排气流入通道60和排气流出通道61排列为每个排气流入通道60由四个排气流出通道61围绕而每个排气流出通道61由四个排气流入通道60围绕。
例如，所述颗粒过滤器13由多孔材料制成，比如，堇青石。因此，如图2(B)中的箭头所示，流入到排气流入通道60中的排气穿过环绕的分隔壁64流入到邻近的排气流出通道61。在该颗粒过滤器13中，NOx存储/还原催化剂被承载在排气流入通道60和排气流出通道61的周缘壁上，即所述分隔壁64的两个表面和所述分隔壁64中的孔的内壁。
在所述承载于颗粒过滤器13上的NOx存储/还原催化剂和所述NOx存储/还原催化剂15中，包括例如氧化铝的催化剂载体被支承在基底部件上。图3示意性地显示了所述催化剂载体45的表面部分的横截面。如图3所示，催化剂载体45的表面支承散布于其上的贵金属催化剂46。此外，催化剂载体45的表面形成有一层NOx吸收剂47。
在本发明的一种实施方式中，铂Pt用作贵金属催化剂46。作为形成NOx吸收剂47的成分，例如，使用选自钾K、钠Na、铯Cs和其它的碱金属，钡Ba、钙Ca和其它碱土，镧La、钇Y和其它的稀土元素中的至少一种成分。
如果将供给到发动机进气道、燃烧室2和颗粒过滤器13上游的排气道中的空气和燃料(碳氢化合物)的比称作“排气的空燃比”，则在所述排气的空燃比稀时，NOx吸收剂47吸收NOx，而在排气中的氧浓度下降时，释放吸收的NOx，即实现NOx的吸收和释放作用。
以使用钡Ba作为形成NOx吸收剂47的成分的情况作为例子对此进行说明，也就是说，当排气的空燃比稀时，即当排气中的氧浓度高时，包含在排气中的NO在铂Pt46上被氧化并变成NO2，如图3中所示，然后其被吸收到所述NOx吸收剂47中并且与氧化钡BaO结合，同时以硝酸根离子NO3 -的形式扩散到所述NOx吸收剂47中。以这种方式，NOx被吸收到NOx吸收剂47中。只要在排气中的氧浓度高，NO2就在铂Pt46的表面上形成。只要NOx吸收剂47的NOx吸收能力未饱和，NO2就被吸收到NOx吸收剂47中，并形成硝酸根离子NO3 -。
与此相反，如果使用燃料供给阀17供给燃料，以使排气的空燃比浓化或者达到理论空燃比，排气中的氧浓度下降，因而反应以相反的方向(NO3 -→NO2)进行，因此NOx吸收剂47中的硝酸根离子NO3 -以NO2的形式从NOx吸收剂47中释放。接着，释放出的NOx被包含在排气中的未燃烧的HC和CO还原。
当排气的空燃比以这种方式稀化时，也就是说，当在稀空燃比下进行燃烧时，排气中的NOx被吸收到NOx吸收剂47中。然而，如果持续地在稀空燃比下进行燃烧，则NOx吸收剂47的NOx吸收能力最终变饱和，因此NOx吸收剂47不能再吸收NOx。因此，在根据本发明的实施方式中，在NOx吸收剂47的吸收能力变饱和前，从燃料供给阀17供给燃料，致使排气的空燃比暂时变浓，从而使NOx吸收剂47释放NOx。
然而，排气包含SOx，即SO2。当所述SO2流入到颗粒过滤器13和NOx存储/还原催化剂15中时，所述SO2在铂Pt46处被氧化，并且变成SO3。接下来，所述SO3被吸收到吸收剂47中，并且与氧化钡BaO结合，同时以硫酸根离子SO4 2-的形式扩散到NOx吸收剂47中以形成稳定的硫酸盐BaSO4。然而，NOx吸收剂47具有强碱性，因此所述硫酸盐BaSO4是稳定的，并且难以破坏。仅通过使排气的空燃比变浓，硫酸盐BaSO4继续保持原样而不被破坏。因此，在NOx吸收剂47中，硫酸盐BaSO4随着时间的流逝而增加，因此随着时间流逝，NOx吸收剂47可吸收的NOx的量下降。
因此，在图1所示的实施方式中，SOx捕集催化剂11设置在所述颗粒过滤器13的上游，该SOx捕集催化剂11用于捕集包含在排气中的SOx，从而防止SOx流入所述颗粒过滤器13和NOx存储/还原催化剂15中。接着，将对所述SOx捕集催化剂11进行说明。
例如，所述SOx捕集催化剂11由具有大量沿SOx捕集催化剂11的轴向方向直线延伸的排气通孔的蜂窝结构的整体催化剂组成。当以这样的方式由蜂窝结构的整体催化剂形成SOx捕集催化剂11时，由例如氧化铝组成的催化剂载体被支承在排气流动孔的内圆周壁上。图4描述了所述催化剂载体50的表面部分的横截面。如图4所示，催化剂载体50的表面形成有涂层51。所述涂层51的表面支承散布于其中的贵金属催化剂52。
在图1所示的实施方式中，铂被用作贵金属催化剂52。作为形成涂层51的成分，例如，使用选自钾K、钠Na、铯Cs、或另一种碱金属、钡Ba、钙Ca、或另一种碱土、镧La、钇Y、或另一种稀土元素中的至少一种成分。也就是说，SOx捕集催化剂11的涂层51呈现出强碱性。
现在，如图4所示，包含在排气中的SOx，即SO2，在铂Pt52处被氧化，然后被捕集到涂层51中。也就是说，SO2以硫酸根离子SO4 2-的形成散布在涂层51中以形成硫酸盐。请注意，如上文所说明的，涂层51呈现出强碱性，因此如图4所示，包含在排气中的SO2部分直接被捕集在涂层51中。
图4中的涂层51中的阴影显示了捕集的SOx的浓度。从图4中我们可以理解，涂层51中的SOx浓度靠近涂层51的表面最高，并且向着内部逐渐降低。如果靠近涂层51的表面的SOx浓度变得更高，则涂层51的表面的碱性变得更弱，而捕集SOx的能力变弱。如果捕集SOx的能力变弱，则包含在排气中的SOx部分开始流入到颗粒过滤器13中，而NOx吸收剂47开始吸收SOx。
下面，参照图5和图6说明所述承载在颗粒过滤器13上的NOx存储/还原催化剂和所述NOx存储/还原催化剂15的处理。在图1所示的实施方式中，在所述承载于颗粒过滤器13上的NOx存储/还原催化剂的NOx吸收剂47和所述NOx存储/还原催化剂15的NOx吸收剂47中的单位时间吸收的NOx量NOXA作为所需转矩TQ和发动机速度N的函数以图5所示的对应图的形式预先保存在ROM 32中。所述NOx量NOXA被积分以计算NOx吸收剂47中吸收的NOx量∑NOX。此外，在该实施方式中，如图6所示，每当所述NOx量∑NOX达到允许的值NX时，使流入到所述颗粒过滤器13中的排气的空燃比A/F暂时变浓，从而NOx吸收剂47释放NOx。
请注意，当使所述流入到颗粒过滤器13中的排气的空燃比A/F变浓时，流入到所述SOx捕集催化剂11中的排气的空燃比必须保持较稀。因此，在图1所示的实施方式中，燃料供给阀17设置在所述SOx捕集催化剂11和所述颗粒过滤器13之间的排气管12中。当NOx吸收剂47要释放NOx时，所述燃料供给阀17将燃料，即后处理燃料，供给到排气管12，从而使流入到所述颗粒过滤器13中的排气的空燃比暂时变浓。
另一方面，包含在排气中的颗粒，即颗粒物质，被捕集到所述颗粒过滤器13上，并随后被氧化。然而，当捕集的颗粒量变得大于氧化的颗粒量时，颗粒逐渐在所述颗粒过滤器13上累积。在这种情况下，如果颗粒累积量增加，则最终引起发动机输出下降。因此，当颗粒累积量增加时，有必要消除累积的颗粒。在这种情况下，如果在过量空气的情况下将颗粒过滤器13的温度升高到大约600℃，则累积的微粒被氧化并被消除。
因此，在图1所示的实施方式中，当累积在所述颗粒过滤器13上的颗粒量超过允许量时，所述颗粒过滤器13的温度在稀的排气空燃比下升高，从而通过氧化消除累积的颗粒。具体地说，当如图6所示由所述差压传感器27检测到所述颗粒过滤器13前后的差压ΔP超过了允许值PX时，则判断累积的颗粒量已经超过允许量。这时，执行温度升高控制以在升高颗粒过滤器13的温度T的同时维持流入到所述颗粒过滤器13中的排气的空燃比较稀。请注意，当所述颗粒过滤器13的温度T升高时，NOx被NOx吸收剂47释放，因此捕集的NOx量∑NOX下降。
当升高所述颗粒过滤器13的温度时，不必升高所述SOx捕集催化剂11的温度。因此，当升高所述颗粒过滤器13的温度时，在排气的空燃比保持较稀的范围内由燃料供给阀17供给燃料，即后处理燃料。所述燃料氧化反应的热量用于升高所述颗粒过滤器13的温度T。
现在，在所述本发明的实施方式中，如图1所示，所述后处理系统具有多个串联排列在排气道中的排气净化催化剂，即，所述SOx捕集催化剂11、所述承载在颗粒过滤器13上的NOx存储/还原催化剂和所述NOx存储/还原催化剂15。对各个催化剂检测催化剂的劣化程度，并且依据催化剂的劣化程度重新设置供给后处理燃料的方法。
在这种情况下，在所述本发明的实施方式中，当所述SOx捕集催化剂11、所述承载在颗粒过滤器13上的NOx存储/还原催化剂和所述NOx存储/还原催化剂15中的任一催化剂的劣化程度超过预定劣化程度时，供给后处理燃料的方法被重新设置以使排气净化所需的后处理燃料能被供给到具有最低劣化程度的催化剂中，使得具有最低劣化程度的催化剂承担排气的净化作用。
也就是说，在所述本发明的实施方式中，当任一催化剂的劣化程度超过预定劣化程度时，具有最低劣化程度的、并因此能够最有效地被用来净化排气的催化剂被选择，并且通过以最适合的方法向所选择的催化剂供给后处理燃料使所选择的催化剂承担排气的净化作用以净化排气。通过这样做，能够保持高的排气净化率，同时使后处理燃料的消耗量最小化。
下面，将详细说明根据本发明的实施方式。
在所述根据本发明的实施方式中，随着时间的流逝，SOx逐渐存储到所述SOx捕集催化剂11和NOx吸收剂47中。在这种情况下，SOx中毒，即催化剂劣化从上游侧的催化剂相继出现。在图1所示的实施例中，使用SOx传感器，如所述传感器18、19和20。催化剂是否已经劣化通过SOx传感器18、19和20的输出信号进行检测。也就是说，当通过所述SOx传感器18检测到SOx浓度超过了预定浓度时，则判断所述SOx捕集催化剂11已经劣化。当通过所述SOx传感器19检测到SOx浓度超过了预定浓度时，则判断所述颗粒过滤器13上的NOx存储/还原催化剂已经劣化。当通过所述SOx传感器20检测到SOx浓度超过了预定浓度时，则判断所述NOx存储/还原催化剂15已经劣化。
接下来，将说明从所述NOx存储/还原催化剂释放NOx的控制，但是下文的说明中，所述承载在颗粒过滤器13上的NOx存储/还原催化剂将被称为“上游侧的NOx存储/还原催化剂13”，同时所述NOx存储/还原催化剂15将被称为“下游侧的NOx存储/还原催化剂15”。然而，如上文所说明的，在NOx吸收剂47变得对NOx饱和前，NOx吸收剂47释放NOx。图7显示了在所述上游侧的NOx存储/还原催化剂13或所述下游侧的NOx存储/还原催化剂15都没有劣化时NOx释放的控制。
在这种情况下，如图7所示，如果由所述燃料供给阀17添加燃料以使NOx吸收剂47释放NOx，则流入到所述上游侧的NOx存储/还原催化剂13中的排气的空燃比暂时变浓。这时，上游侧的NOx存储/还原催化剂13释放NOx的作用被执行。在这种情况下，所有由所述燃料供给阀17添加的燃料都被用于由所述上游侧的NOx存储/还原催化剂13释放和还原NOx的作用。
另一方面，当判断所述上游侧的NOx存储/还原催化剂13已经劣化时，使所述下游侧的NOx存储/还原催化剂15承担排气的净化作用，这时，排气中的NOx的吸收和释放作用在下游侧的NOx存储/还原催化剂15处执行。在这种情况下，如果使用图7所示的、与上游侧的NOx存储/还原催化剂13未劣化时一样的模式使燃料供给阀17添加燃料，则添加的燃料在到达所述下游侧的NOx存储/还原催化剂15之前最终会扩散，且流入到所述下游侧的NOx存储/还原催化剂15中的排气的空燃比不再变浓。
因此，在根据本发明的该实施方式中，在通过由燃料供给阀17添加燃料使得在这时流入到所述下游侧的NOx存储/还原催化剂15中的排气的空燃比浓化时，排气的空燃比的浓化程度高于图7所示的情况。
请注意，在这种情况下，如图8(A)所示，当升高排气的空燃比的浓化程度以使燃料的消耗量不增加时，空燃比的浓化时间缩短。或者，如图8(B)所示，当升高排气的空燃比的浓化程度且不改变空燃比的浓化时间时，空燃比浓化的间隔变长。
然而，如果NOx存储/还原催化剂已经劣化，则所述NOx存储/还原催化剂仅仅起选择性还原催化剂的作用。在这种情况下，如果燃料供给阀17在排气的空燃比较稀的状态下添加燃料，则未燃烧的HC被利用以便选择性地还原排气中的NOx。NOx的净化率不高，但是NOx可被净化到某一程度。因此，在根据本发明的该实施方式中，除了所述上游侧的NOx存储/还原催化剂13之外，燃料供给阀17在所述下游侧的NOx存储/还原催化剂14劣化时，在排气的空燃比保持在较稀范围内的状态下间歇地添加燃料，如图9所示。
图10显示了所述后处理系统的控制流程。
参照图10，首先，在步骤100，判断所述下游侧的NOx存储/还原催化剂15是否已经劣化。当所述下游侧的NOx存储/还原催化剂15未劣化时，程序进行到步骤101，在该步骤使用图5所示的对应图计算单位时间存储的NOx量NOXA。接着，在步骤102，所述NOXA被加到所述NOx吸收剂47中吸收的NOx量∑NOX上。
接下来，在步骤103，判断存储的NOx量∑NOX是否超过了允许值NX。当∑NOX≤NX时，程序跳转到步骤107。与此相反，当∑NOX＞NX时，程序进行到步骤104，在该步骤中判断所述上游侧的NOx存储/还原催化剂13是否已经劣化。当所述上游侧的NOx存储/还原催化剂13已经劣化时，程序进行到步骤105，在该步骤中进行图7中所示的浓化处理I，然后程序进行到步骤107。与此相反，当判断所述上游侧的NOx存储/还原催化剂13已经劣化时，程序进行到步骤106，在该步骤中执行图8(A)或图8(B)所示的浓化处理II，然后程序进行到步骤107。
在步骤107，所述差压传感器27被用于检测所述颗粒过滤器13前后的差压ΔP。接着，在步骤108，判断差压ΔP是否已经超过了允许值PX。当ΔP＞PX时，程序进行到步骤109，在该步骤中执行升高所述颗粒过滤器13的温度的控制。所述温度升高控制被执行以保持流入到所述颗粒过滤器13中的排气的空燃比较稀，同时燃料供给阀17供给燃料。另一方面，当在步骤100，判断所述下游侧的NOx存储/还原催化剂13已经劣化时，程序进行到步骤110，在该步骤中如图9所示进行处理以添加燃料。
图11显示了燃烧点火型内燃机的另一种实施方式。在该实施方式中，设置NOx存储/还原催化剂11′，代替所述SOx捕集催化剂。此外，在该实施方式中，燃料供给阀17设置在例如排气歧管5的一号气缸的歧支管中。在该实施方式中，当所述NOx存储/还原催化剂11′、承载在颗粒过滤器13上的NOx存储/还原催化剂或者NOx存储/还原催化剂15要释放NOx时，所述燃料供给阀17供给燃料。请注意，同样在该实施方式中，当任一NOx存储/还原催化剂劣化程度变高时，具有最低劣化程度的NOx存储/还原催化剂的位置越靠近下游，释放NOx时排气的浓化程度就越高。

Claims (6)

1、一种内燃机，其排气的后处理系统设置在发动机排气道中，用于处理排气中的有害成分的后处理燃料供给到所述后处理系统中，并且供给后处理燃料的方法被预先设置，其中，所述后处理系统具有多个串联排列在所述排气道中的排气净化催化剂，并且当任一催化剂的劣化程度超过预定劣化程度时，供给后处理燃料的方法被重新设置以使排气净化所需的后处理燃料被供给到具有最低劣化程度的催化剂中，以便使所述具有最低劣化程度的催化剂承担排气的净化作用。
2、按照权利要求1所述的内燃机，其中，所述多个串联排列在所述发动机排气道中的催化剂包括在流入排气的空燃比稀时存储包含在排气中的NOx和在流入排气的空燃比变成理论空燃比或浓时释放存储的NOx的NOx存储/还原催化剂，当使流入到NOx存储/还原催化剂中的排气的空燃比浓以使NOx存储/还原催化剂释放NOx时，后处理燃料供给到后处理系统中，或供给到位于最上游侧的NOx存储/还原催化剂的上游的排气道中，而此时，具有最低劣化程度的催化剂的位置越靠近下游，排气的空燃比的浓化程度就越高。
3、按照权利要求2所述的内燃机，其中，当升高排气的空燃比的浓化程度时，空燃比的浓化时间缩短。
4、按照权利要求2所述的内燃机，其中，当升高排气的空燃比的浓化程度时，空燃比浓化的时间间隔变长。
5、按照权利要求2所述的内燃机，其中，当所有所述NOx存储/还原催化剂的劣化程度都超过了预定的劣化程度、并且所述NOx存储/还原催化剂仅起选择性地还原排气中的NOx的还原催化剂的作用时，在排气的空燃比保持在稀范围内的状态下，后处理燃料被供给到后处理系统中或供给到位于最上游侧的NOx存储/还原催化剂的上游的排气道中。
6、按照权利要求2所述的内燃机，其中，在位于最上游侧的NOx存储/还原催化剂的上游的排气道具有设置在其中的能够捕集排气中的SOx的SOx捕集催化剂。
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