Controller system and method for selecting a firing fraction for a skip fire controlled internal combustion engine based at least on non-drive train levels of noise, vibration and harshness

• US 10,519,876 B2
• Filed: 07/13/2018
• Issued: 12/31/2019
• Est. Priority Date: 03/13/2014
• Status: Active Grant

• Current Assignee: Tula Technology, Incorporated
• Original Assignee: Tula Technology, Incorporated
• Inventors: Srinivasan, Vijay, Serrano, Louis J., Hashemi, Siamak, Bailey, Robert S., Routledge, Geoffrey
• Primary Examiner(s): Huynh, Hai H
• Application Number:
  US16/035,273
• Publication Number:
  US 20180328292A1
• Time in Patent Office: 536 Days
• Field of Search: 701111, 701112, 123198 F, 123198 DB, 123198 DC, 123481
• CPC Class Codes: F02D 17/02 Cutting-out cutting-out engines in multiple engine arrangements F02D25/04
• CPC Class Codes: F02D 2200/021 Engine temperature
• CPC Class Codes: F02D 2200/025 Engine noise, e.g. determined by using an acoustic sensor
• CPC Class Codes: F02D 2200/101 Engine speed
• CPC Class Codes: F02D 2200/501 Vehicle speed
• CPC Class Codes: F02D 2200/702 Road conditions
• CPC Class Codes: F02D 2250/18 Control of the engine output torque
• CPC Class Codes: F02D 41/0087 Selective cylinder activation, i.e. partial cylinder operation deceleration cut-off F02D41/123
• CPC Class Codes: F02D 41/021 Introducing corrections for particular conditions exterior to the engine conjoint control of vehicle sub-units for propelling the vehicle B60W30/18
• CPC Class Codes: F02D 41/0225 in relation with the gear ratio or shift lever position
• CPC Class Codes: F02D 41/047 Taking into account fuel evaporation or wall wetting; special correction after fuel cut-off F02D41/126
• CPC Class Codes: F02D 41/1406 with use of a optimisation method, e.g. iteration
• CPC Class Codes: F02D 41/2422 Selective use of one or more tables
• CPC Class Codes: F02P 5/1512 with particular means concerning an individual cylinder
• CPC Class Codes: F02P 9/002 Control of spark intensity, intensifying, lengthening, suppression by means of current control in the storage devices F02P3/05, F02P3/09, during starting F02P15/12

Abstract

Methods and controllers are described that facilitate the determination of an operational skip fire firing fraction for an engine based at least in part noise levels and/or vehicle vibration levels that are not induced by engine operation. In some embodiments, the firing fraction is determined based at least in part of noise or vibrations associated with road roughness and/or cabin noise levels.

Claims

1. A skip fire engine controller, comprising:

a skip fire profile module arranged to monitor noise and vibration generated by one or more sources external to an engine and determine an operational firing fraction and associated cylinder load for delivering a desired engine output, wherein the selection of the operational firing fraction is based at least in part on whether the noise and vibration generated external to the engine at least partially masks noise and vibration generated by the engine; and

a firing controller arranged to direct firings of one or more cylinders of the engine in a skip fire manner that delivers the selected operational firing fraction,

wherein the engine when operating at the selected operational firing fraction has at least one cylinder that is fired, skipped and either fired or skipped over successive firing opportunities.

2. The skip fire engine controller of claim 1, wherein the skip fire profile module is arranged to select the operational firing fraction from a set of available firing fractions.

3. The skip fire engine controller of claim 2, wherein the selection of the operational firing fraction comprises calculating a candidate cylinder load such that a combination of the candidate firing fraction and the candidate cylinder load delivers the desired engine output and forms a candidate skip fire firing profile;

and

determining whether the candidate skip fire firing profile is allowed, wherein an allowance of the skip fire firing profile depends in part on whether the first candidate cylinder load exceeds a threshold,

wherein the threshold varies as a function of engine speed and transmission gear, and

wherein the threshold depends on noise and vibration associated with at least one of road roughness and a cabin noise level.

4. The skip fire engine controller of claim 3, wherein the selection of the operational firing fraction includes selecting a lookup table, from a plurality of lookup tables, based on the road roughness and the cabin noise level and the selected lookup table indicates maximum allowable cylinder loads at different engine speeds and firing fractions.

5. The skip fire engine controller of claim 4, wherein the selecting of the lookup table is further selected based on an economy mode input.

6. The skip fire engine controller of claim 3, wherein:

the selection of the operational firing fraction involves using a lookup table that indicates different maximum allowable cylinder loads at different engine speeds and firing fractions; and

the road roughness and cabin noise level are used as to determine a correction to an output of the lookup table and the corrected output is used to select the operational firing fraction.

7. The skip fire engine controller of claim 1, wherein the noise and vibration generated by the one or more sources external to the engine comprises at least one of noise and vibration generated by road roughness and acoustic noise within a vehicle cabin.

8. The skip fire engine controller of claim 7, wherein the skip fire controller is configured to detect wheel acceleration and vehicle speed and utilize the wheel acceleration and vehicle speed to determine road roughness.

9. The skip fire engine controller of claim 7, wherein the skip fire controller is configured to monitor at least one of a microphone output and an entertainment system signal to detect a cabin noise level.

10. The skip fire engine controller of claim 1, wherein an economy mode input setting is used to define an acceptable noise and vibration level.

11. A skip fire engine controller, comprising:

at least one lookup table embodied in a non-transitory computer readable media, the at least one lookup table including table entries that indicate different maximum allowable cylinder loads at different vehicle operating parameters;

a skip fire profile module arranged to determine an operational firing fraction suitable for delivering a requested engine output for an engine, wherein the skip fire profile module utilizes the at least one lookup table to determine the operational firing fraction and adjusts the operational firing fraction based at least in part on whether noise and vibration generated external to the engine at least partially masks noise and vibration generated by the engine; and

a firing controller arranged to direct firings of one or cylinders of the engine in a skip fire manner that delivers the operational firing fraction,

wherein when the engine is operating at the operational firing fraction, at least one of the cylinders is fired, skipped and either fired or skipped over successive firing opportunities.

12. The skip fire engine controller of claim 11, wherein the noise and vibration generated external to the engine comprises at least one of noise and vibration generated by road roughness and acoustic noise within a vehicle cabin.

13. The skip fire engine controller as recited in claim 11, wherein:

the at least one lookup table includes a set of available firing fractions; and

the skip fire profile module is further arranged to select a candidate firing fraction from the set of available firing fractions in the at least one lookup table,

wherein the candidate firing fraction is a firing fraction in the at least one lookup table that is closer to a base firing fraction than other firing fractions in the at least one lookup table.

14. The skip fire engine controller as recited in claim 11, wherein:

the candidate firing fraction is associated with a maximum allowed cylinder load in the at least one lookup table; and

the skip fire profile module is further arranged to;

determine a candidate cylinder load that, together with the candidate firing fraction, is able to deliver the requested engine output; and

determine whether the candidate cylinder load exceeds the maximum allowed cylinder load.

15. The skip fire engine controller as recited in claim 11, wherein:

the at least one lookup table is one dimensional; and

each table entry indicates a maximum allowed cylinder load for a vehicle parameter, the vehicle parameter being selected from the group consisting of engine speed, transmission gear, and firing fraction.

16. The skip fire engine controller as recited in claim 11, wherein:

the at least one lookup table is two dimensional; and

each table entry indicates a maximum allowed cylinder load for a set of two vehicle parameters, each of the two vehicle parameters being selected from the group consisting of engine speed, transmission gear, and firing fraction.

17. The skip fire engine controller as recited in claim 11, wherein:

the at least one lookup table is three dimensional; and

each table entry indicates a maximum allowed cylinder load for a firing fraction, a range of engine speeds and a transmission gear.

18. A method of selecting an operational skip fire firing profile suitable for use in operating an internal combustion engine in a skip fire manner to produce a desired engine output, the method comprising:

determining the desired engine output;

detecting noise and vibration masking associated with noise and vibration generated external to the internal combustion engine at least partially masking noise and vibration generated by the internal combustion engine;

selecting a firing fraction based at least in part on the detected noise and vibration masking; and

operating the internal combustion engine at the selected firing fraction, wherein at least one cylinder of the internal combustion engine is fired, skipped and either fired or skipped over successive firing opportunities when operating at the selected firing fraction.

19. The method of claim 18, further comprising:

selecting a plurality of candidate firing fractions from an allowed list of firing fractions;

calculating a candidate cylinder load for each of the plurality of candidate firing fractions such that the combination of the candidate cylinder load and each associated candidate firing fraction substantially yields the desired engine output, each such combination being a candidate skip fire firing profile;

selecting one of the candidate skip fire firing profiles as the operational skip fire firing profile based at least in part on the noise and vibration masking level; and

operating the internal combustion engine based at least in part on the operational skip fire firing profile.

20. The method as recited in claim 19, wherein:

the plurality of candidate firing fractions includes a first and a second candidate firing fraction;

calculating a first candidate cylinder load such that a combination of the first candidate firing fraction and the first candidate cylinder load delivers the desired engine output and forms a first candidate skip fire firing profile; and

determining whether the first candidate skip fire firing profile is allowed wherein the allowance of the first candidate skip fire firing profile depends in part on whether the first candidate cylinder load exceeds a threshold wherein the threshold varies as a function of engine speed and transmission gear.

21. The method as recited in claim 20, wherein the threshold further varies based on noise and vibration associated with at least one of road roughness and cabin noise level.