WO2018071030A1 - Systèmes et procédés de diagnostic de catalyseur basé sur un modèle - Google Patents

Systèmes et procédés de diagnostic de catalyseur basé sur un modèle Download PDF

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Publication number
WO2018071030A1
WO2018071030A1 PCT/US2016/056880 US2016056880W WO2018071030A1 WO 2018071030 A1 WO2018071030 A1 WO 2018071030A1 US 2016056880 W US2016056880 W US 2016056880W WO 2018071030 A1 WO2018071030 A1 WO 2018071030A1
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Prior art keywords
model
threshold
value
circuit
catalyst
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PCT/US2016/056880
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English (en)
Inventor
Avra Brahma
Pardis KHAYYER
Pingen CHEN
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Cummins Inc.
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Priority to PCT/US2016/056880 priority Critical patent/WO2018071030A1/fr
Publication of WO2018071030A1 publication Critical patent/WO2018071030A1/fr

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/101Three-way catalysts
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N11/00Monitoring or diagnostic devices for exhaust-gas treatment apparatus, e.g. for catalytic activity
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00Exhaust 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
    • F01N13/08Other arrangements or adaptations of exhaust conduits
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/18Exhaust 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
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N9/00Electrical control of exhaust gas treating apparatus
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2560/00Exhaust systems with means for detecting or measuring exhaust gas components or characteristics
    • F01N2560/02Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor
    • F01N2560/025Exhaust systems with means for detecting or measuring exhaust gas components or characteristics the means being an exhaust gas sensor for measuring or detecting O2, e.g. lambda sensors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2900/00Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/04Methods of control or diagnosing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2900/00Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/04Methods of control or diagnosing
    • F01N2900/0421Methods of control or diagnosing using an increment counter when a predetermined event occurs
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2900/00Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/04Methods of control or diagnosing
    • F01N2900/0422Methods of control or diagnosing measuring the elapsed time
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2900/00Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06Parameters used for exhaust control or diagnosing
    • F01N2900/08Parameters used for exhaust control or diagnosing said parameters being related to the engine
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2900/00Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06Parameters used for exhaust control or diagnosing
    • F01N2900/14Parameters used for exhaust control or diagnosing said parameters being related to the exhaust gas
    • F01N2900/1402Exhaust gas composition
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2900/00Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06Parameters used for exhaust control or diagnosing
    • F01N2900/16Parameters used for exhaust control or diagnosing said parameters being related to the exhaust apparatus, e.g. particulate filter or catalyst
    • F01N2900/1602Temperature of exhaust gas apparatus
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2900/00Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06Parameters used for exhaust control or diagnosing
    • F01N2900/16Parameters used for exhaust control or diagnosing said parameters being related to the exhaust apparatus, e.g. particulate filter or catalyst
    • F01N2900/1624Catalyst oxygen storage capacity
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/12Improving ICE efficiencies
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/40Engine management systems

Definitions

  • the present disclosure relates to exhaust aftertreatment systems. More particularly, the present disclosure relates to operating an aftertreatment diagnostic system.
  • Three-Way catalysts are a key component of emissions control systems in
  • Stoichiometric Spark-Ignited engines such as those fueled by gasoline, ethanol, and natural gas.
  • CARB requires engine systems to monitor the three-way catalyst(s) for any malfunctions that might lead to system emissions exceeding a pre-defined threshold.
  • One embodiment relates to an apparatus that includes a constituent storage model circuit, a detection circuit, and a notification circuit.
  • the constituent storage model circuit is structured to determine a model state value based at least in part on a constituent flux value across a catalyst in an exhaust system.
  • the detection circuit is communicably coupled to the constituent storage model circuit and structured to compare the model state value to a model value threshold.
  • the notification circuit is communicably coupled to the detection circuit and structured to selectively provide a notification in response to the comparison of the model state value and the model value threshold.
  • Another embodiment relates to a system that includes an exhaust gas treatment system including a catalyst and a controller in communication with the exhaust gas treatment system.
  • the controller is structured to determine a model state value of a constituent storage model based at least in part on a constituent flux across the catalyst and an exhaust gas characteristic, compare the model state value to a model value threshold, and trigger an action in response to the comparison of the model state value and the model value threshold.
  • Another embodiment relates to a method.
  • the method includes receiving, by a controller in an exhaust gas system, operation data regarding the exhaust gas system, and determining, by the controller, a model state value based on the operation data.
  • the model state value is indicative of a constituent flux across a catalyst in the exhaust gas system.
  • the method also includes comparing, by the controller, the model state value to a model value threshold, and triggering, by the controller, an action based on the comparison of the model state value to the model value threshold.
  • FIG. 1 is schematic diagram of an exhaust aftertreatment system with a controller, according to an example embodiment.
  • FIG. 2 is a schematic of the controller used with the exhaust aftertreatment system of FIG. 1, according to an example embodiment.
  • FIG. 3 is a schematic of a catalyst used in the exhaust aftertreatment system of FIG. 1, according to an example embodiment.
  • FIG. 4 is a schematic of a diagnostic system of the controller, according to an example embodiment.
  • FIG. 5 is a flow chart of a first diagnostic method, according to an example
  • FIG. 6 is a flow chart of a second diagnostic method, according to an example embodiment.
  • FIG. 7 is a graph of air-to-fuel ratios over time, according to an example embodiment.
  • FIG. 8 is a flow chart of a third diagnostic method, according to an example embodiment.
  • the various embodiments disclosed herein relate to systems, apparatuses, and methods for operating an engine system and monitoring or diagnosing a catalyst of an exhaust aftertreatment system (e.g., a three-way catalyst).
  • the engine system includes an internal combustion engine that in one embodiment is a spark- ignition engine. In other embodiments, another engine type making use of stoichiometric combustion may be used.
  • a compression-ignition engine e.g., a diesel engine
  • the engine system also includes an engine exhaust pipe that provides engine exhaust gases to a catalyst.
  • a catalyst exhaust pipe is connected to the catalyst and provides treated exhaust gas to a muffler or another component of the exhaust aftertreatment system.
  • An engine control system includes a controller, a first exhaust gas oxygen sensor (EGO) arranged to sense a condition of the engine exhaust gas, and a second EGO arranged to sense a condition of the treated exhaust gas.
  • This sensor may be located after the Three-way catalyst or at any location upstream such that there is a volume of the catalyst between it and the first Oxygen sensor.
  • the Oxygen sensors may be heated or unheated, or of the switching or wide-band types.
  • the engine control system monitors the catalyst to confirm that the catalyst is functioning according to a threshold or standard (e.g., such as those set by a government organization, such as the EPA or CARB).
  • the engine control system monitors the catalyst to confirm that the criteria pollutant emissions in the treated exhaust gas are below a predefined emissions threshold.
  • the engine control system uses a model of how the catalyst should react and/or treat the engine exhaust gas to generate a model state indicative of a predicted nominal performance.
  • the model state is then compared to actual results detected by the EGO sensors.
  • the comparison can be used to determine the level to which the catalyst is stored or depleted of oxygen compared to the model or a maximum capacity, thereby providing an indication of the functionality of the catalyst.
  • the engine control system may take an action, such as providing a notification or indication that the catalyst is failing, has failed, or needs to be replaced and/or serviced.
  • an engine system 20 includes an engine 24, an engine exhaust pipe 28 that receives engine exhaust gases from the engine 24, a catalytic converter 32 including a catalyst 36 that receives the engine exhaust gas from the engine exhaust pipe 28 and treats the engine exhaust gases, a catalyst exhaust pipe 40 that receives the treated exhaust gases from the catalytic converter 32, and a downstream component 44 such as a muffler or another aftertreatment component.
  • the engine system 20 also includes an engine control system 48 that includes a controller 52, a first exhaust gas oxygen sensor (EGO) 56 that communicates with the controller 52 and is positioned to detect a characteristic of the engine exhaust gas, and a second EGO 60 that communicates with the controller 52 and is positioned to detect a characteristic of the treated exhaust gas.
  • the catalytic converter 32 is part of a larger exhaust aftertreatment system that may include the controller 52 and the sensors 56, 60 as well as other components.
  • the engine 24 can be an internal combustion engine such as a spark-ignition engine fueled by gasoline, natural gas, ethanol, propane, or another fuel suitable for spark-ignition.
  • a spark-ignition engine fueled by gasoline, natural gas, ethanol, propane, or another fuel suitable for spark-ignition.
  • the engine 24 can be a compression-ignition engine fueled by diesel, or another fuel suitable for compression-ignition.
  • the engine 24 can include a combustion chamber and an exhaust port or manifold that couples to the engine exhaust pipe 28 to contain the engine exhaust gases.
  • the catalytic converter 32 includes a three-way catalyst 36 and is intended to be used with spark-ignition engines.
  • the catalyst may be a two-way catalyst intended to be used with a compression-ignition engine, or another type of catalyst that benefits from a monitoring system.
  • the catalyst exhaust pipe 40 and the downstream component 44 receive the treated exhaust gases from the catalytic converter 32 and may perform other emissions treatment steps, and may muffle the noise of the engine 24.
  • the arrangement of the catalyst exhaust pipe 40 and the downstream component 44 are non-limiting examples.
  • the controller 52 includes a processing circuit 64 and a
  • the communication interface 68 structured to communicate with the first EGO 56, the second EGO 60, the engine 24, and a display 72.
  • the communication interface 68 may receive signals from the first EGO 56, the second EGO 60, and the engine 24, provide operation instructions to the engine 24, and provide display or alert information to the display 72.
  • the display 72 is a data port on the engine 24 or in a vehicle associated with the engine 24.
  • the processing circuit 64 includes a processor 76, a memory 80, and a diagnostic circuit 84.
  • the processor 76 can include a notification circuit, and may be implemented as a general-purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a digital signal processor (DSP), a group of processing components, or other suitable electronic processing components.
  • the memory 80 e.g., RAM, ROM, Flash Memory, hard disk storage, etc.
  • the memory 80 may be communicably connected to the processor 76, the diagnostic circuit 84, and the communication interface 68 and structured to provide computer code or instructions to the processor 76 for executing the processes described in regard to the controller 52. Additionally, the memory 80 may be or include tangible, non-transient volatile memory or non-volatile memory. Accordingly, the memory 80 may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described herein.
  • the diagnostic circuit 84 includes various circuits (e.g., processor and memory circuits having executable code stored therein)for completing the activities described herein. More particularly, the diagnostic circuit 84 includes circuits structured to operate components of the engine 24 and the aftertreatment system. While various circuits with particular functionality are shown in FIG. 2, it should be understood that the controller 52, memory 80, and diagnostic circuit 84 may include any number of circuits for completing the functions described herein and that any number of the circuits described may be combined into a single circuit. For example, the activities and functionalities of the circuits of the diagnostic circuit 84 may be embodied in the memory 80, or combined in multiple circuits or as a single circuit. Additional circuits with additional functionality may be included. Further, it should be understood that the controller 52 may further control other vehicle activity beyond the scope of the present disclosure.
  • the controller 52 may further control other vehicle activity beyond the scope of the present disclosure.
  • the diagnostic circuit 84 includes an engine circuit 88 structured to control various operations of the engine 24 as well as communicate with various sensors arranged in the engine 24; a fuel circuit 92 structured to monitor an amount of fuel provided to the engine 24 or a characteristic of the fuel provided to the engine 24; an oxygen in circuit 96 structured to communicate with the first EGO 56 and to analyze the signals provided by the first EGO 56; an oxygen out circuit 100 structured to communicate with the second EGO 60 and to analyze the signals provided by the second EGO 60; a lambda circuit 104 structured to communicate with the engine circuit 88, the fuel circuit 92, the oxygen in circuit 96, and the oxygen out circuit 100 and to determine an air-to-fuel equivalence ratio of the treated exhaust gas (outlet lambda o ut ); a theta circuit 108 structured to determine a model state ⁇ of the catalyst 36 based on a model; a timer circuit 112; and an oxygen storage circuit 116 structured to communicate with the lambda circuit 104, the theta circuit
  • the catalyst 36 receives engine exhaust gas from the engine exhaust pipe 28 including an inlet quantity of oxygen Ri n .
  • An adsorbed quantity of oxygen R a d S of the gaseous oxygen is adsorbed into the catalyst 36 and a desorbed quantity of oxygen Rd es is released back into the gaseous oxygen (this being a simplified representation of the Oxygen Storage material reduction phenomenon).
  • a slip quantity of oxygen R s ii P exits the catalytic converter 32 with the treated exhaust gas.
  • the mass flow rates of the inlet quantity of oxygen Rin, the adsorbed quantity of oxygen R a d S , the desorpted quantity of oxygen Rd es , and the slip quantity of oxygen R s i ip can be determined by the diagnostic circuit 84. More specifically, the oxygen in circuit 96 monitors the first EGO 56, and communicates with the timer circuit 112 to determine an inlet oxygen mass flow rate rhi n . The oxygen out circuit 100 monitors the second EGO 60, and communicates with the timer circuit 112 to determine a slip oxygen mass flow rate m s ii P .
  • the oxygen storage circuit 116 communicates with the oxygen in circuit 96 and the oxygen out circuit 100 and determines, based at least in part on the inlet oxygen mass flow rate rhin and the slip oxygen mass flow rate m s iip, an adsorption mass flow rate m a d S and a desorpted mass flow rate hides-
  • the controller 52 utilizes various inputs to produce the model state ⁇ and an estimated outlet lambda es t-
  • the engine circuit 88 and the fuel circuit 92 determine how much fuel is added to the combustion chamber, the engine 24 combusts the fuel in the presence of air, and the engine exhaust gases pass into the engine exhaust pipe 28.
  • the oxygen in circuit 96 then communicates with the first EGO 56 and the oxygen in circuit 96 determines a mass flow rate of inlet air m A ir in the engine exhaust gas.
  • the oxygen in circuit 96 also communicates with the lambda circuit 104 to determine an inlet lambda ( ⁇ ⁇ ) of the engine exhaust gas. Using the mass flow rate of inlet air riiAir and the inlet lambda ⁇ ⁇ , the engine circuit 88 determines inlet oxygen mass flow rate rhi n into the catalyst 36.
  • the theta circuit 108 receives the inlet oxygen mass flow rate rhi n from the engine circuit 88 and optionally communicates with the lambda circuit 104, the oxygen out circuit 100, and the oxygen storage circuit 116 to determine a model state ⁇ based on the model. How the model is used to determine the model state ⁇ may depend at least in part on an operating parameter of the engine 24. Exemplary models and model states ⁇ will be discussed below. [0030] The lambda circuit 104 receives the inlet oxygen mass flow rate r i n from the engine circuit 88 and optionally communicates the oxygen out circuit 100 and the oxygen storage circuit 1 16 to determine the estimated outlet lambda out , est-
  • a first method 200 of diagnosing the catalyst 36 using the diagnostic circuit 84 includes initiating the method 200 by starting the engine 24 at step 202.
  • the theta circuit 108 resets the model state ⁇ to a default value of, for example, zero (0) or one (1).
  • the diagnostic circuit 84 runs the model to determine a new model state ⁇ . This generated model state ⁇ will represent a normal or properly functioning catalyst 36 (e.g., based on a life of the catalyst in terms of years in use, runtime, miles driven). Once the model state ⁇ is established, the method 200 proceeds to step 208 and checks for enabling conditions.
  • the enabling conditions include a temperature of the catalyst (as measured by a catalyst temperature probe or estimated via a model) being greater than a catalyst temperature threshold, the mass flow rate of inlet air riiAir in the engine exhaust gas being below an inlet air threshold, the amount of fuel added to the combustion chamber being greater than a fuel threshold, and there being no fuel cut action where fuel is being inhibited from entering the combustion chamber (e.g., braking).
  • the enabling conditions are met when the outlet lambda X oUt undergoes a lean breakthrough and is not experiencing a fuel cut.
  • step 208 If the enabling conditions are not met in step 208, the method 200 continues to update the model state ⁇ to represent the catalyst 36 at step 206. If the enabling conditions are met in step 208, the diagnostic circuit 84 begins monitoring the catalyst 36 using model based diagnostics at step 210. During monitoring, the model state ⁇ and the outlet lambda out are updated by the theta circuit 108 and the lambda circuit 104, respectively.
  • the oxygen storage circuit 116 compares the model state ⁇ to a theta threshold, and the outlet lambda out to a corresponding lambda threshold. If the model state ⁇ is less than the theta threshold and the outlet lambda X oUt is greater than the lambda threshold, then the timer circuit 1 12 increments the timer at step 214. Because the model state ⁇ is representing a properly functioning catalyst 36, the outlet lambda should be close to the model state ⁇ within a predefined tolerance. If the model state ⁇ is less than the theta threshold, that indicates that the outlet lambda Xo Ut should also be below the lambda threshold. The model state ⁇ and the outlet lambda Xo Ut are both indications of the oxygen storage capacity of the catalyst 36. Again, the model state ⁇ is based on a model, and the outlet lambda is based on measurements.
  • the timer value is compared to a timer threshold at step 216. If the timer value exceeds the timer threshold, then a fault is triggered at step 218 and sent to the display 72 from the processor 76 via the communication interface 68. The comparison between the timer value and the timer threshold lowers the likelihood of a false or inaccurate fault being triggered.
  • the timer threshold is between about thirty and about thirty-two seconds (30-32 seconds). In some embodiments, the timer threshold may be between about thirty seconds and about sixty seconds.
  • the model is dependent at least in part on the inlet oxygen mass flow rate r i n and an oxygen capacity Mc ap ,o2 of the catalyst 36 determined by the oxygen storage circuit 1 16.
  • the model state ⁇ may be defined as the following when running lean:
  • is the model state (theta) over time as a function of the model state (theta)
  • Mc ap 02 is an oxygen capacity of the catalyst
  • Ki is a constant
  • rh in is a mass flow rate of air passing through the catalyst
  • F(A in ) is a function of the air-to-fuel equivalence ratio (lambda).
  • model state ⁇ may be defined as the following when running rich:
  • is the model state (theta) over time as a function of the model state (theta)
  • Mc ap 02 is an oxygen capacity of the catalyst
  • K 2 is a constant
  • rh in is a mass flow rate of air passing through the catalyst
  • F(A in ) is a function of the air-to-fuel equivalence ratio (lambda)
  • the method 200 may utilize the timer circuit 112 to monitor the time that the model state ⁇ predicts that the treated exhaust gas from a nominal healthy system would be rich while the outlet lambda X oUt indicates that the treated exhaust gas from the actual catalyst is actually lean. If a ratio of the actual lean time to the maximum theoretically allowed lean time is greater than a threshold, then the timer value is incremented.
  • a second method 300 of diagnosing the catalyst 36 using the diagnostic circuit 84 includes initiating the method 300 by starting the engine 24 at step 302.
  • the theta circuit 108 resets the model state ⁇ to a default value of zero (0) or one (1).
  • the diagnostic circuit 84 runs the model to determine a new model state ⁇ .
  • Steps 302, 304, and 306 of the method 300 are similar to the steps 202, 204, and 206 of the method 200 and may be conducted by the controller 52 simultaneously, or the steps 202, 204, 206 and the steps 302, 304, 306 may be the same.
  • the diagnostic circuit 84 monitors for an enabling condition.
  • An exemplary enabling condition may be a fuel cut event where fuel is inhibited from entering the combustion chamber of the engine 24 (e.g., during braking). If no fuel cut event has occurred, then the method 300 returns to step 306. If a fuel cut has occurred at step 308, then the method proceeds to step 310 and starts monitoring the catalyst 36. During monitoring, the model state ⁇ and the outlet lambda are updated by the theta circuit 108 and the lambda circuit 104, respectively.
  • the oxygen storage circuit 116 begins to monitor the model state ⁇ .
  • the model state ⁇ is an indication of theoretical oxygen flux of the catalyst 36 (e.g., based
  • the oxygen storage circuit 116 calculates an integrated oxygen flux from the time of the actual signal breakthrough to the time of the modelled breakthrough.
  • the oxygen storage circuit 116 may utilize a function as follows to determine the integrated oxygen flux:
  • Integrated Oxygen Flux f tm m in (t)dt , where t m is the time of the modelled lean breakthrough, t s is the time of the actual lean breakthrough, and m in is the inlet oxygen mass flow rate.
  • FIG. 7 shows a first line 318 of the model predicted outlet lambda over time and a second line 320 of the actual measured outlet lambda X oUt over time according to an example embodiment.
  • the integrated oxygen flux can be found between the first line 318 and the second line 320 between the time of actual lean breakthrough t s and the modelled lean breakthrough t m .
  • the graph may help to visualize the value of the integrated oxygen flux.
  • the integrated oxygen flux is compared to an oxygen flux threshold at step 322. If the integrated oxygen flux is larger than the oxygen flux threshold, then a fault is triggered at step 324 and an alert or notification is sent to the display 72 via the communication interface 68.
  • the diagnostic circuit 84 uses a time difference between the actual lean breakthrough and the modelled lean breakthrough to identify a fault.
  • the method 300 identifies when a healthy catalyst would fill with oxygen and compares that theoretically healthy catalyst to the actual catalyst 36 and how it is reacting.
  • the method 300 allows the diagnostic circuit 84 to identify when the catalyst 36 has degraded past an acceptable threshold. In other words, when the difference between the mass of oxygen adsorbed by the actual catalyst 36 and the mass of oxygen adsorbed by the modelled catalyst is greater than a threshold value, a fault is triggered.
  • the method 300 is not dependent on the first EGO 56 and may operate independent of the oxygen in circuit 96. [0045] As shown in FIG.
  • a third method 400 of diagnosing the catalyst 36 using the diagnostic circuit 84 includes initiating the method 400 by starting the engine 24 at step 402.
  • the theta circuit 108 resets the model state ⁇ to a default value of zero (0) or one (1).
  • the diagnostic circuit 84 runs the model to determine a new model state ⁇ .
  • the diagnostic circuit 84 monitors for an enabling condition (e.g., a fuel cut or fuel cut exit). When the enabling condition is met, the method 400 proceeds to step 412 and the catalyst 36 is monitored.
  • an enabling condition e.g., a fuel cut or fuel cut exit
  • the method 400 can utilize a non-recursive non-Kalman filter based method.
  • the equations described above may be used by the method 400 and the model parameter K 2 may be continually tuned (adapted) while monitoring occurs at step 412.
  • the model parameter K 2 determined in the method 400 is representative of a parameter that indicates an age of the catalyst 36.
  • the parameter Mc ap, 02 is an oxygen storage capacity of the catalyst 36.
  • the oxygen storage capacity may be determined based at least in part on oxygen flux in/out of the catalyst 36, and/or measurements based on the first EGO 56 and the second EGO 60.
  • the model parameter K 2 may be calculated in a feedback loop and determined at step 414.
  • the model parameter K 2 is compared to a threshold at step 416.
  • the capacity threshold represents an oxygen capacity that would not meet standards or otherwise indicates that the catalyst 36 needs maintenance or replacement. If the model parameter K 2 or M Cap, 02 is less than the capacity threshold, a fault is triggered at step 418 and sent to the display 72 via the communication port 68.
  • a method includes monitoring an oxygen flux across a three- way catalyst, developing an oxygen storage model based at least in part on the oxygen flux, outputting a model state (theta) from the oxygen storage model, monitoring an air-to-fuel equivalence ratio (lambda) of a flow of exhaust gas, comparing the model state (theta) to a theta threshold, comparing the air-to-fuel equivalence ratio (lambda) to a lambda threshold, incrementing a timer if the model state (theta) is less than the theta threshold and the air-to-fuel equivalence ratio is greater than or equal to the lambda threshold, and triggering a fault condition if the timer exceeds a time threshold.
  • incrementing the timer includes incrementing a lambda lean time when the air-to-fuel equivalence ratio (lambda) is greater than one, and incrementing a theta lean time when the model state (theta) is greater than the theta threshold.
  • triggering a fault condition may include comparing a ratio of the lambda lean time to the theta lean time to the time threshold.
  • the time threshold is between about thirty seconds and about thirty- two seconds.
  • the oxygen storage model is representative of a three-way catalyst with a maximum oxygen capacity. In one embodiment, the oxygen storage model is not based on the monitored air-to-fuel equivalence ratio (lambda).
  • outputting the model state (theta) includes utilizing the following equation:
  • is the model state (theta) over time as a function of the model state (theta)
  • Mc ap 02 is an oxygen capacity of the three-way catalyst
  • Ki is a constant
  • m Air in is a mass flow rate of air passing through the three-way catalyst
  • F(A in ) is a function of the air-to-fuel equivalence ratio (lambda).
  • outputting the model state (theta) includes utilizing the following equation:
  • V" Cap ( where ⁇ is the model state (theta) over time as a function of the model state (theta), Mc ap, 02 is an oxygen capacity of the three-way catalyst, K 2 is a constant, m Air in is a mass flow rate of air passing through the three-way catalyst, F(A in ) is a function of the air-to-fuel equivalence ratio (lambda), and is a stoichiometric air-to-fuel ratio.
  • a method includes recognizing a fuel cut event, monitoring an air-to-fuel equivalence ratio (lambda) of a flow of exhaust gas, identifying a lean breakthrough when a three-way catalyst has been substantially fully oxidized, developing an actual oxygen flux as a function of the time between the fuel cut event and the lean breakthrough, developing a predicted oxygen flux as a function of an oxygen storage model, developing an integrated oxygen flux based at least in part on a difference between the predicted oxygen flux and the actual oxygen flux, and triggering a fault condition if the integrated oxygen flux exceeds a threshold.
  • an air-to-fuel equivalence ratio (lambda) of a flow of exhaust gas
  • predicted oxygen flux and the actual oxygen flux are functions of time.
  • the oxygen storage model is representative of a three-way catalyst with a maximum oxygen capacity.
  • developing the integrated oxygen flux includes estimating an amount of excess oxygen consumed by the predicted oxygen flux compared to the actual oxygen flux.
  • the oxygen storage model is not based on the monitored air-to-fuel equivalence ratio (lambda).
  • the predicted oxygen flux is based at least in part on the following equation: where ⁇ is the model state (theta) over time as a function of the model state (theta), Mc ap, 0 2 is an oxygen capacity of the three-way catalyst, Ki is a constant, rh Air in is a mass flow rate of air passing through the three-way catalyst, and F(A in ) is a function of the air-to-fuel equivalence ratio (lambda).
  • the predicted oxygen flux is based at least in part on the following equation:
  • is the model state (theta) over time as a function of the model state (theta)
  • Mc ap 02 is an oxygen capacity of the three-way catalyst
  • K 2 is a constant
  • m Air in is a mass flow rate of air passing through the three-way catalyst
  • F(A in ) is a function of the air-to-fuel equivalence ratio (lambda)
  • a method includes developing an oxygen storage model, developing a predicted oxygen flux of a three-way catalyst as a function of the oxygen storage model, monitoring an air-to-fuel equivalence ratio (lambda) of a flow of exhaust gas, developing an actual oxygen flux as a function of the air-to-fuel equivalence ratio (lambda), updating the oxygen storage model in view of the actual oxygen flux, and triggering a fault condition when the predicted oxygen flux is less than a threshold.
  • the predicted oxygen flux and the actual oxygen flux are functions of time.
  • the oxygen storage model is representative of a three-way catalyst with a maximum oxygen capacity in view of the actual oxygen flux.
  • the oxygen storage model utilizes a non-recursive non-Kalman filter based methodology.
  • the method further includes triggering the development of the predicted oxygen flux when the flow of exhaust gas undergoes a lean-to-rich transition.
  • embodiment or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention.
  • appearances of the phrases “in one embodiment”, “in an embodiment”, “in an example embodiment”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
  • circuits may be implemented as a hardware circuit comprising custom very-large- scale integration (VLSI) circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components.
  • VLSI very-large- scale integration
  • a circuit may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
  • circuits may also be implemented in machine-readable medium for execution by various types of processors.
  • An identified circuit of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions, which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified circuit need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the circuit and achieve the stated purpose for the circuit.
  • a circuit of computer readable program code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices.
  • operational data may be identified and illustrated herein within circuits, and may be embodied in any suitable form and organized within any suitable type of data structure.
  • the operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.
  • the computer readable medium (also referred to herein as machine-readable media or machine-readable content) may be a tangible computer readable storage medium storing the computer readable program code.
  • the computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, holographic, micromechanical, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing.
  • examples of the computer readable storage medium may include but are not limited to a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), a digital versatile disc (DVD), an optical storage device, a magnetic storage device, a holographic storage medium, a micromechanical storage device, or any suitable combination of the foregoing.
  • a computer readable storage medium may be any tangible medium that can contain and/or store computer readable program code for use by and/or in connection with an instruction execution system, apparatus, or device.
  • the computer readable medium may also be a computer readable signal medium.
  • a computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electrical, electro-magnetic, magnetic, optical, or any suitable combination thereof.
  • a computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport computer readable program code for use by or in connection with an instruction execution system, apparatus, or device.
  • computer readable program code embodied on a computer readable signal medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, Radio Frequency (RF), or the like, or any suitable combination of the foregoing.
  • the computer readable medium may comprise a combination of one or more computer readable storage mediums and one or more computer readable signal mediums.
  • computer readable program code may be both propagated as an electro-magnetic signal through a fiber optic cable for execution by a processor and stored on RAM storage device for execution by the processor.
  • Computer readable program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages.
  • the computer readable program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone computer-readable package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server.
  • the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
  • LAN local area network
  • WAN wide area network
  • Internet Service Provider an Internet Service Provider
  • the program code may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the schematic flowchart diagrams and/or schematic block diagrams block or blocks.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Materials Engineering (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

Un appareil comprend un circuit de modèle de stockage constitutif, un circuit de détection et un circuit de notification. Le circuit de modèle de stockage constitutif est structuré pour déterminer une valeur d'état de modèle sur la base, au moins en partie, d'une valeur de flux constitutive à travers un catalyseur dans un système d'échappement. Le circuit de détection est couplé de manière à communiquer avec le circuit de modèle de stockage constitutif, et est structuré pour comparer la valeur d'état de modèle à un seuil de valeur de modèle. Le circuit de notification est couplé de manière à communiquer avec le circuit de détection, et est structuré pour fournir sélectivement une notification en réponse à la comparaison de la valeur d'état de modèle et du seuil de valeur de modèle.
PCT/US2016/056880 2016-10-13 2016-10-13 Systèmes et procédés de diagnostic de catalyseur basé sur un modèle WO2018071030A1 (fr)

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CN110552803A (zh) * 2018-06-01 2019-12-10 罗伯特·博世有限公司 用于调节催化器的用于废气成分的存储器的填充水平的方法和控制器
CN111022199A (zh) * 2018-10-10 2020-04-17 罗伯特·博世有限公司 用于调节滑行运行中用于废气成分的催化器的存储器的填充度的方法和控制器

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