Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
  • H01T19/00—Devices providing for corona discharge
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
  • F02P17/00—Testing of ignition installations, e.g. in combination with adjusting; Testing of ignition timing in compression-ignition engines
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
  • F02P23/00—Other ignition
  • F02P23/04—Other physical ignition means, e.g. using laser rays
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
  • F02P3/00—Other installations
  • F02P3/02—Other installations having inductive energy storage, e.g. arrangements of induction coils
  • F02P3/04—Layout of circuits
  • F02P3/0407—Opening or closing the primary coil circuit with electronic switching means
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
  • F02P5/00—Advancing or retarding ignition; Control therefor
  • F02P5/04—Advancing or retarding ignition; Control therefor automatically, as a function of the working conditions of the engine or vehicle or of the atmospheric conditions
  • F02P5/145—Advancing or retarding ignition; Control therefor automatically, as a function of the working conditions of the engine or vehicle or of the atmospheric conditions using electrical means
  • F02P5/15—Digital data processing
  • F02P5/1502—Digital data processing using one central computing unit
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
  • G01M15/00—Testing of engines
  • G01M15/02—Details or accessories of testing apparatus
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
  • G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
  • H01T15/00—Circuits specially adapted for spark gaps, e.g. ignition circuits
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
  • F02N2300/00—Control related aspects of engine starting
  • F02N2300/20—Control related aspects of engine starting characterised by the control method
  • F02N2300/2011—Control involving a delay; Control involving a waiting period before engine stop or engine start
• • 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
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/10—Internal combustion engine [ICE] based vehicles
  • Y02T10/40—Engine management systems

Definitions

• This invention relates generally to a corona discharge ignition system, and more particularly to methods for controlling energy supplied to the corona igniter system,
• Corona discharge ignition systems provide an alternating voltage and current, reversing high and low potential electrodes in rapid succession which enhances the formation of corona discharge and minimizes the opportunity for arc formation.
• the system includes a corona igniter with a central electrode charged to a high radio frequency voltage potential and creating a strong radio frequency electric field in a combustion chamber.
• the electric field causes a portion of a mixture of foe! and air in the combustion chamber to ionize and begin dielectric breakdown, facilitating combustion of the fuel-air mixture, which is referred to as an ignition event.
• the electric field is preferably controlled so that the fuel-air mixture maintains dielectric properties and corona discharge occurs, also referred to as a nonthermal plasma.
• the ionized portion of the feel-air mixture forms a flame front which then becomes self-sustaining and combusts the remaining portion of the fuel-air mixture.
• the electric field is controlled so that the fuel-air mixture does not lose all dielectric properties, which would create a thermal plasma and an electric are between the electrode and grounded cylinder walls, piston, metal shell, or other portion of the igniter.
• preferred corona discharge ignition systems operate such that the corona igniter is driven at its resonant frequency, because resonant frequency operation allows the corona igniter to provide a high output and efficiency.
• accurately controlling the drive frequency of the corona igniter to be equal or close to the resonant frequency presents challenges; especially since the design of the corona Igniter is constantly developing and improving, leading to changes in the resonant frequency.
• one recently developed method used in effort to achieve resonant frequency operation require multiple cycles in order to achieve a lock to the correct frequency and is unable to accurately follow rapid frequency changes.
• Another method allows operation over only a limited range of frequencies.
• a third method utilizes a programmable digital or mixed-signal controller to control switches of the system with suitable timing and accuracy, but this type of controller requires complex specifications leading to high overhead and thus high costs.
• One aspect of the invention provides a corona ignition system capable of operating at or near the resonant frequency of a corona igniter, and capable of quickly adjusting to changes in the resonant frequency, without a costly controller.
• the system includes the corona igniter receiving current at a radio frequency and providing a radio frequency electric field.
• a current sensor obtains an unfiltered current signal including information about the current received by the corona Igniter
• At least one of a signal filter and a signal conditioner receives the unfiltered current signal from the current sensor and provides a conditioned current signal, wherein the conditioned current signal includes a falling edge occurring at the end of a first time delay following a first zero crossing of the unfiltered current signal
• a first timer receives the conditioned current signal and initiates a second time delay in response to tlie falling edge of the conditioned current signal.
• the first timer also provides a first timer signal, wherein the first timer signal includes a falling edge at the end of the second time delay, and the second time delay ends before a second zero crossing of the unfiltered current signal following the first zero crossing.
• a second timer receives the first timer signal from the first timer and provides a first output signal
• a third time delay starts at the end of the second time delay at the falling edge of the first timer signal, and the first output signal includes a rising edge at the start of the third time delay
• a first switch receives the first output signal and is activated at the end of the third time delay, wherein the third time delay ends at or after the second zero crossing of the unfiltered current signal The activated first switch allows the current to flow from an energy supply to the corona igniter.
• Another aspect of the invention provides a method of controlling a corona discharge system.
• the method includes providing energy to a corona igniter at a radio frequency; and obtaining an unfiltered current signal including information about the current received by the corona igniter.
• the method further includes providing a conditioned current signal which includes a falling edge occurring at the end of a first time delay following a first zero crossing of the unfiltered current signal; initiating a second time delay in response to the falling edge of the conditioned current signal and providing a first timer signal, wherein the first timer signal includes a falling edge at the end of the second time delay and the second time delay ends before a second zero crossing of the unfiltered current signal following the first zero crossing; and providing an output signal which includes a rising edge at the start of a third time delay, wherein the third time delay starts at the end of the second time delay at the falling edge of the first timer signal.
• the method then includes activating a first switch by the first output signal at the end of the third time delay, wherein the third time delay ends at or after the second zero crossing of the unfiltered current signal, and the activated first switch allows the current to flow from an energ supply to the corona igniter,
• the system and method provides for control of the timing of the switches based on the detection of a single zero crossing of the current and hence can quickly lock on to the correct frequency and quickly respond to changes in the resonant frequency.
• the timers used to activate the switches can be programmed over a wide range of intervals allowing a wide range of drive frequencies to be accommodated.
• the generation of timing signals by the timers to activate the switches is independent from the other functions of the controller, for example, communication with the vehicle, management of power supplies and so on.
• the present invention provides a more cost effective system and method for maintaining the drive frequency at or close to the resonant frequency of the corona igniter, while still allowing for high resolution control.
• Figure 1 is a block diagram of a corona discharge ignition system according to a first exemplary embodiment of the invention
• fGOlOJ Figure 2 includes graphs of an unfiltered current signal St illustrating current at an input of a corona igniter of the system of Figure L a filtered current signal S2 closely resembling the current at the corona igniter, and a conditioned current signal S3 indicating the phase of the current at the corona igniter, according to an exemplary embodiment;
• S3 of Figure 2 is used to control energy provided to the corona igniter according to an exemplary embodiment
• FIG. 4 is a block diagram of a corona discharge ignition system according to a second exemplar)' embodiment of the invention.
• One aspect of the invention provides a cost effective corona ignition system 20 for accurately maintaining a drive frequency approximately equal to the resonant frequency of a corona igniter 22 of the system 20, I addition to the corona igniter 22, the system 2D also includes a current sensor 24, at least two cascaded timers 26, 2S, 311, 32 which are electrically independent of a controller 34, and at least two switches 36* 38.
• the current sensor 24 measures the current at an input 40 of the corona igniter 22, A conditioned current signal S3 including information related to the current ultimately activates a pair of the timers 26, 2S ⁇ 30, 32 which in turn control and drive one of the switches 36, 3S.
• the conditioned current signal S3 is not processed by the controller 34 before driving the switch 36 or 3S.
• [01 1 1 T3 ⁇ 4 e system 20 and method provides for control of the timing of the switches 36, 38 based on the detection of a single zero crossing of the current and hence can quickly lock on to the correct frequency and quickly respond to changes in the resonant frequency.
• the timers 26, 2 ⁇ , 3% 32 used to activate the switches 3fi ? 38 can be programmed over a wide range of intervals allowing a wide range of drive frequencies to be accommodated.
• the generation of output signals SS from the timers 26, 28, 3 ⁇ 3 32 to activate the switches 36, 38 is independent from the other functions of the controller 34, for example, communication with the vehicle, management of power supplies and so on.
• FIG. 1 illustrates a corona ignition system 2CI according to an exemplary embodiment of the invention which accommodates a wide range of drive frequencies, for example 700 kHz to 2 MHz, but requires a less costly controller 34, without compromising the performance of the system 20.
• the system 20 of Figure 1 includes an energy supply +V3 for providing energy to a transformer 42 and then to the corona igniter 22.
• the controller 34 initiates an enable signal 46 to one of the timers 26, 28, 30 s 32 to activate the first switch 36 and allow current to flow from the energy supply +V3 through the transformer 42 and to the corona igniter 22.
• the corona igniter 22 receives current at a radio frequency and provides a radio frequency electric field, referred to as corona discharge 44.
• the current sensor 24 obtains information about the current provided to the corona igniter 22 at an output of the transformer 42 s also referred to as an input 40 of the corona igniter 22.
• the current sensor 24 obtains this information in the form of an nfiltered current signal SI which includes high frequency noise,
• the current sensor 24 conveys the itnfi!tered current signal SI to at least one of a signal filter 48, such as a low-pass filter, and a signal conditioner 50 ⁇
• the signal filter 48 can remove high frequency noise from the signal, if required.
• the signal conditioner 5 ⁇ can extract information about the phase of the current.
• a conditioned current signal S3 is provided, which typically contains only information relating to the phase (direction of current flow) at the input 40 offset by a time delay due to the current sensor 24, signal filter 48, and signal conditioner SO
• Figure 2 includes graphs showing current signals SI, 82, S3 which include information about the current at the input 40 to the corona igniter 22.
• the conditioned current signal S3 includes a falling edge F occurring at the end of a first time delay T! following a first zero crossing XI of the nfiltered current signal SI,
• the first time delay Tl is caused by a time delay T!A of the current sensor 24 and a time delay TIB of the signal filter 48.
• Both T1A and TIB are known and can he compensated for by the controller 34,
• the time delays T1A and TIB added together equal the first time delay Tl.
• the first time delay Tl is deterministic and may be known and therefore compensated by the controller 34.
• the conditioned current signal S3 is not sent to the controller 34 to be processed and to produce signals that drive the switches 36 > 38. Rather, the current information is used to directly trigger a pair of the the cascaded timers 26 s 28, 30, 32 which in turn control the timing of one of the switches 36, 3 ⁇ through a driver 52 or 54.
• the cascaded timers 6, 28, 3 32 are electrically independent of the controller 34, and thus the resolution of the timers 26, 28, 30, 32 is independent of the clock speed of the processing unit of the controller 34,
• a first timer 26 receives the conditioned current signal S3 and initiates a second time delay T2 in response to the falling edge F of the conditioned current signal S3.
• the first timer 26 also provides a first timer signal S4, wherein the first timer signal S4 includes a falling edge F at the end of the second time delay T2.
• the second time delay T2 ends before a second zero crossing X2 of the unfiftered current signal SI following the first zero crossing XL
• a second tinier 28 receives the first timer signal S4 from the Fsrst timer 26 and provides a first output signal S5.
• a third time delay T3 starts at the end of the second time delay T2 at the falling edge F of the first timer signal S4, and the first output signal S5 includes a rising edge at the start of the third time delay T3.
• the first switch 36 receives the first output signal SS and is activated at the end of the third time delay T3, In this exemplary embodiment, the third time delay T3 ends at or after the second zero crossing XI of the unfiltered current signal SI. The activated first switch 36 allows the current to flow from an energy supply +V3 to the corona igniter 22.
• the second timer 28 also initiates a fourth time delay T4 starting at the rising edge R of the first output signal SS and ending at a falling edge F of the first output signal S5.
• the end of the fourth time delay T4 occurs before a third zero crossing X3 of the unfsltered current signal SL
• the first switch 36 is deactivated at the end of a fifth time delay T5 which starts at the falling edge F of the first output signal $5 and ends before or at the third zero crossing X3.
• the controller 34 sets the second time delay T2 and the fourth time delay T4 so that the first switch 36 activated or deactivated at or adjacent one of the zero crossings XI, X2, X3 of the current received by the corona igniter 22,
• the conditioned current signal S3 is sampled by the controller 34 via the digital input (DIG EM) and compared to the voltage to determine whether adjustments to the second time delay T2 or the fourth time delay T4 should be made,
• a voltage sensor 56 can be used to measure the voltage at the input 40 to the corona igniter 22 and then provide an unaltered voltage signal VI s which is filtered to provide a filtered voltage signal V2 ⁇ conditioned to provide a conditioned voltage signal V3, and conveyed in the conditioned voltage signal V3 to the controller 34,
• the controller 34 compares the conditioned voltage signal V3 to the conditioned current signal 53, adjusts at least one of the seeond time delay T2 and the fourth time delay T4 if zero crossings XI,
• a sixth time delay follows the fifth time delay TS S and die conditioned current signal S3 includes a rising edge occurring at the end of the sixth time delay following a fourth zero crossing of the unfil ered current signal SI.
• the duration of the sixth time delay is equal to the duration of the first time delay XL
• a third timer 30 receives the conditioned current signal S3 and initiates a seventh time delay in response to a rising edge of the conditioned current signal S3 and provides a second timer signal S4.
• the seventh time delay is equal to the second time delay T2 S the second timer signal S4 includes a rising edge at the end of the seventh time delay, and the seventh time delay ends before a fifth zero crossing of the unfiltered current signal Si following the fourth zero crossing.
• the fourth timer 32 receives the timer signal S4 from the third timer 3 ⁇ and provides a second output signal S5.
• An eighth time delay starts at the end of the seventh time delay at the rising edge of the timer signal S4,
• the eighth time delay is equal to the third time delay T3, and the second output signal S5 includes a falling edge F at the start of the eighth time delay.
• Tlie second switch 38 receives the second output signal S5 and is activated at the end of the eighth time delay, wherein the eighth time delay ends at or after the fifth zero crossing of the unfiltered current signal SI, and the activated second switch 38 allows the current to flow from the energy supply +V3 to the corona igniter 22.
• tlie fourth timer 32 initiates a ninth time delay starting at the failing edge F of the second output signal SS and ending at a rising edge of the second output signal SS.
• the ninth time delay is equal to the fourth time delay T4, and the end of the ninth time delay occurs hefore a sixth zero crossing of tlie unfiltered current signal SL
• the second switch 38 is deactivated at the end of a tenth time delay which starts at the rising edge R of the second output signal SS and ends before or at tlie sixth zero crossing.
• the tenth time delay is equal to the fifth time delay TS,
• the controller 34 sets the seventh time delay and the ninth time delay so that the switch is activated or deactivated at or adjacent one of the zero crossings of the unfiltered current signal SI, just like the third time delay T3 and the fifth time delay T5.
• the first, third, fifth, sixth, eighth, and tenth time delays are fixed and based at least in part on design of the current sensor 24 t the signal filter 48 and/or the signal conditioner 5 ⁇ , the timers 26, 28 s 30, 32 and the switches 36, 3 ⁇ ,
• the controller 34 however adjusts at least one of the second time delay T2 and the fourth time delay T4 if zero crossings of tlie voltage received by the corona igniter 22 are not simultaneous with the zero crossings of the unfiltered current signal SI which represents the current received by the corona igniter 22.
• the voltage sampling may be omitted if the controller 34 is adequately able to compensate for delays ⁇ , » T2 S T3 5 T4 S TS in all elements of the current control loop, including the current sensor 24, signal filter 4 ⁇ ⁇ signal conditioner 50, timers 26, 2 30, 32, switches 36, 38, drivers S2, 54, and the transformer 42,
• one or more of the elements in the loop may be omitted or modified depending on the requirements of the specific installation.
• the timers 26 s 28, 30, 32 may be able to operate the switches 36, 38 without the use of the separate drivers 52, 54.
• the timers 26, 2 ⁇ , 30, 32 are physically located in tlie controller 34, while still being electrically independent from the processing unit.
• the current sensor 24 has suitable frequency response characteristics and thus die signal filter 48 is not required,
• the dead- time is a brief period of time that occurs while changing from one switch 52, 54 to another to allow conduction in one switch 52, 54 to completely cut off before enabling conduction in another to avoid overlap ⁇ f current flow through both switches 52, 54 at the same time.
• This dead-time may easily be implemented in this scheme by adjustment of the timer intervals T4 and T6.
• FIG. 4 shows a corona discharge 44 ignition system 20 according to another exemplar ⁇ ' embodiment of the invention.
• a separate phase detector 5 ⁇ compares the phase difference between the conditioned current signal S3 and the conditioned voltage signal to Identify errors, for example if the current passes through zero before or after the voltage passes through zero, in which case the system 20 is not at resonance,
• the phase detector 58 provides the identified error and a direction signal which is passed to the controller 34 via the digital inputs.
• the controller 34 can then adjust the fourth time delay T4 and the sixth time delay T6 accordingly to correct the error, for example speed up or slow down the process, so that the current and voltage cross through zero simultaneously.
• phase detector SB can be selected from those well known in the art, as phase detectors Si are commonly used in circuits to control a phase-locked loop (PLL), for example.
• This phase detector 5S may compare the phase of the conditioned current signal S3 with the phase of the conditioned voltage signal.
• the phase detector 58 can compare the phase of the conditioned current signal S3 with the voltage phase derived from any other point in the loop as previously described, for example, at the timer signal or output signal S5.
• the system 28 of the present invention includes cascaded timers 26* 2 ⁇ , 30, 32 which are electrically independent from the controller 34 of the system 2 ⁇ and can be triggered directly by hardware signals derived from measurements of the behavior of the current and voltage in the corona igniter 22. These timers 26, 28, 3 32 then directly activate switches 36, 38 controlling the circuit which drives the frequency of
• the controller 34 only needs to supervise the timers 26 s 2S, 3 32 to ensure they are properly configured, instead of having to monitor feedback signals and correctly activate the switches 36, 3S directly.
• the resolution of the timers 26, 28, 30, 32 is therefore independent of the clock speed of the processing unit of the controller 34.
• the cascaded timers 26, 2S S 3 ⁇ , 32 also allow for a slower, cheaper processing unit to be used In the controller 34 without compromising system performance. Thus, the processing overhead is greatly reduced.
• a programmable digital or mixed-signal controller 34 to ensure accurate frequency control offers several advantages, the high accuracy required in frequency control leads to a high resolution requirement in the controller 34, often leading to a high computational load on the processing unit, and requiring a high clock speed and hence higher costs.
• the timers 26, 28, 30, 32 can be programmed over a wide range of intervals which allows a wide range of drive frequencies to be used,

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