Engine-out emissions controls

• US 10,100,768 B2
• Filed: 05/03/2016
• Issued: 10/16/2018
• Est. Priority Date: 11/04/2013
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Garimella, Phanindra V., Osburn, Andrew W., Hsieh, Ming-Feng
• Primary Examiner(s): Nguyen, Hung Q
• Assistant Examiner(s): Mo, Xiao
• Application Number:
  US15/144,956
• Publication Number:
  US 20160245208A1
• Time in Patent Office: 896 Days
• CPC Class Codes: F02D 2041/141 using a feed-forward control element
• CPC Class Codes: F02D 2200/0614 Actual fuel mass or fuel injection amount
• CPC Class Codes: F02D 2200/101 Engine speed
• CPC Class Codes: F02D 37/02 one of the functions being ignition
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/0052 Feedback control of engine parameters, e.g. for control of air/fuel ratio or intake air amount
• CPC Class Codes: F02D 41/1441 Plural sensors
• CPC Class Codes: F02D 41/1456 with sensor output signal being linear or quasi-linear with the concentration of oxygen
• CPC Class Codes: F02D 41/1461 of the exhaust gases emitted by the engine
• CPC Class Codes: F02D 41/40 with means for controlling injection timing or duration
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

Unique apparatuses, methods, and systems including engine-out emissions controls are disclosed. One embodiment is a system including an internal combustion engine system including at least one fueling actuator and at least one air handling actuator and an electronic controller. The electronic structure may be structured to determine initial values for a plurality of combustion references, determine a plurality of target emissions values or ranges based upon the plurality of combustion references, determine errors between the emissions target values or ranges and sensed emissions information, determine correction factors and weighting factors for the combustion references, the weighting factors being based at least in part upon the errors between the between the emissions target values or ranges and sensed emissions information, selectably determine modified values for the combustion references based upon the correction factors and the weighting factors, and control operation of the at least one fueling actuator and at least one air handling actuator based upon the modified values.

Claims

1. A method comprising:

determining with a control system structured to control operation of an internal combustion engine system initial values for a plurality of combustion reference parameters;

determining with the control system a first difference between an engine-out NOx value for the engine and a target engine-out NOx value and a second difference between an engine-out AFR value for the engine and a target engine-out AFR value;

providing the first difference and the second difference to both a correction factor control component and a weighting factor control component, the correction factor control component and the weighting factor control component being in parallel control paths of a feedback control loop;

selecting with the correction factor control component which if any of the initial values to modify based upon the first difference and the second difference;

determining with the control system respective modification values for each of the initial values which is selected, the act of determining being performed by applying weighting factors determined by the weighting factor control component to the initial values selected by the control factor correction component;

modifying with the control system each of the initial values which is selected based upon the one or more respective modification values to provide respective modified values; and

determining with the control system one or more actuator control values based upon the values of the combustion reference parameters including the one or more modified values; and

controlling with the control system at least one of an air handling system actuator and a fueling system actuator utilizing the one or more actuator control values.

2. The method of claim 1 wherein the plurality of combustion reference values comprise an EGR reference value, a charge flow reference value, a fueling quantity reference value, an injection timing reference value, and a rail pressure reference value.

3. The method of claim 2 wherein the act of selecting comprises:

selecting at least the charge flow reference value if the first difference does not exceed a first difference threshold, and the second difference exceeds a second difference threshold;

selecting at least the EGR reference value if the first difference exceeds the first difference threshold, and the second difference does not exceed the second difference threshold;

selecting at least one of the fueling quantity reference value, the injection timing reference value, and the rail pressure reference value if the first difference exceeds the first difference threshold, and the second difference exceeds the second difference threshold; and

selecting none of the plurality of combustion reference values if the first difference does not exceed the first difference threshold, and the second difference does not exceed the second difference threshold.

4. The method of claim 3 wherein the act of selecting comprises selecting all of the plurality of combustion reference values if the first difference exceeds the first difference threshold and the second difference exceeds the second difference threshold.

5. The method of claim 3 wherein the act of selecting comprises:

selecting only the charge flow reference value if the first difference does not exceed a first difference threshold, and the second difference exceeds a second difference threshold; and

selecting only the EGR reference value if the first difference exceeds the first difference threshold, and the second difference does not exceed the second difference threshold.

6. The method of claim 1 wherein the act of controlling at least one of an air handling system actuator and a fueling system actuator with the control system is based upon a static relationship between the plurality of combustion reference parameters and one or more engine operating conditions.

7. The method of claim 6 wherein the one or more engine operating conditions comprise engine speed and engine fueling.

8. A system comprising:

an internal combustion engine system including at least one fueling actuator and at least one air handling actuator; and

an electronic controller structured to;

determine initial values for a plurality of combustion references,

determine a plurality of target emissions values or ranges based upon the plurality of combustion references,

determine errors between the emissions target values or ranges and sensed emissions information;

provide the errors to both a correction factor control component and a weighting factor control component in separate control paths of a feedback controller,

determine correction factors with the correction factor control component and weighting factors with the weighting factor control component for the combustion references, the weighting factors for an engine-out NOx and an engine-out AFR being based at least in part upon the errors between the emissions target values or ranges and sensed emissions information,

selectably determine modified values for the combustion references based upon the correction factors and the weighting factors; and

control operation of the at least one fueling actuator and at least one air handling actuator based upon the modified values.

9. The system of claim 8 wherein the plurality of target emissions values or ranges comprise a target NOx value or range and a target AFR value or range and the errors comprise a first error between the target NOx value or range and a sensed engine-out NOx value and a second error between the target AFR value or range and a sensed engine-out AFR value.

10. The system of claim 9 wherein the controller is structured to:

determine a modified charge flow reference value if the first error does not exceed a first threshold and the second error exceeds a second threshold;

determine a modified EGR flow reference value if the first error exceeds the first threshold, and the second error does not exceed the second threshold; and

determine a modified fueling reference value if the first error exceeds the first threshold, and the second error exceeds the second threshold.

11. The system of claim 10 wherein the modified fueling reference value comprises at least one of an injector rail pressure value and a start of injection value.

12. The system of claim 10 wherein the controller is structured to leave unmodified the initial combustion reference values if the first difference does not exceed the first difference threshold and the second difference does not exceed the second difference threshold.

13. The system of claim 8 wherein the controller is structured to determine correction factors and weighting factors for the combustion references in parallel.

14. The system of claim 8 wherein the controller is structured to first determine weighting factors for the combustion references and second determine correction factors for the combustion references.

15. A method comprising:

operating a combustion manager controller for an internal combustion engine to determine a plurality of combustion reference values;

determining a first error between a NOx output of the engine and a target NOx output and a second error between an oxygen output of the engine and a target oxygen output of the engine;

provide the first error and the second error to both of a first control component and second control component, the first control component and the second control component being in divergent control paths of a combined feedback control loop;

determining with the first control component which if any of the plurality of combustion reference values to modify based upon the first error and the second error;

determining a modification value for each selected combustion reference parameter;

modifying the selected combustion reference parameter based upon the modification value, the modifying being based upon output of the first control component and output of the second control component; and

operating at least one air handling actuator and at least one fueling system actuator utilizing the plurality of combustion reference values including the modified combustion reference parameter.

16. The method of claim 15 wherein the plurality of combustion reference values comprise an EGR reference value, a charge flow reference value, a fueling quantity reference value, an injection timing reference value, and a rail pressure reference value.

17. The method of claim 16 wherein the act of determining which if any of the plurality of combustion reference values to modify based upon the first error and the second error comprises:

selecting at least the charge flow reference value if the first error does not exceed a first error threshold, and the second error exceeds a second error threshold;

selecting at least the EGR reference value if the first error exceeds the first error threshold, and the second error does not exceed the second error threshold;

selecting at least one of the fueling quantity reference value, the injection timing reference value, and the rail pressure reference value if the first error exceeds the first error threshold, and the second error exceeds the second error threshold; and

selecting none of the plurality of combustion reference values if the first error does not exceed the first error threshold, and the second error does not exceed the second error threshold.

18. The method of claim 17 wherein the act of determining which if any of the plurality of combustion reference values to modify based upon the first error and the second error comprises selecting all of the plurality of combustion reference values if the first error exceeds the first error threshold.

19. The method of claim 17 wherein the act of determining which if any of the plurality of combustion reference values to modify based upon the first error and the second error comprises:

selecting only the charge flow reference value if the first error does not exceed a first error threshold, and the second error exceeds a second error threshold; and

selecting only the EGR reference value if the first error exceeds the first error threshold, and the second error does not exceed the second error threshold.

20. The method of claim 17 wherein the acts of determining which if any of the plurality of combustion reference values to modify based upon the first error and the second error and determining a modification value for each selected combustion reference parameter occur in parallel.

21. The method of claim 15 wherein the act of determining a first error between a NOx output of the engine and a target NOx output is based upon a virtual measurement of NOx output of the engine.

22. The method of claim 15 wherein the act of determining a first error between a NOx output of the engine and a target NOx output is based upon information of a physical sensor.