CONTROLLING EXHAUST GAS RECIRCULATION THROUGH MULTIPLE PATHS IN A TURBOCHARGED ENGINE SYSTEM

• US 20110088674A1
• Filed: 05/28/2009
• Published: 04/21/2011
• Est. Priority Date: 06/02/2008
• Status: Abandoned Application

• Current Assignee: BorgWarner Incorporated
• Original Assignee: BorgWarner Incorporated
• Inventors: Benali, Houcine Ben Bechir, Shutty, John
• Application Number:
  US12/995,592
• Publication Number:
  US 20110088674A1
• Time in Patent Office: Days
• US Class Current: 123/568.21
• CPC Class Codes: F02B 29/0406 Layout of the intake air cooling or coolant circuit
• CPC Class Codes: F02D 13/0207 changing valve lift or valve lift and timing
• CPC Class Codes: F02D 2041/141 using a feed-forward control element
• CPC Class Codes: F02D 2041/1431 the system including an input-output delay
• CPC Class Codes: F02D 2200/0402 the parameter being determined by using a model of the engine intake or its components
• 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 41/006 using internal EGR control of valve overlap for internal EGR F02D13/0261; arrangements for internal EGR F02M26/01
• CPC Class Codes: F02D 41/0065 Specific aspects of external EGR control constructional details of EGR system F02M26/00
• CPC Class Codes: F02M 26/01 Internal exhaust gas recirculation, i.e. wherein the residual exhaust gases are trapped in the cylinder or pushed back from the intake or the exhaust manifold into the combustion chamber without the use of additional passages
• CPC Class Codes: F02M 26/05 High pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust system upstream of the turbine and reintroduced into the intake system downstream of the compressor
• CPC Class Codes: F02M 26/06 Low pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust downstream of the turbocharger turbine and reintroduced into the intake system upstream of the compressor
• CPC Class Codes: F02M 26/10 having means to increase the pressure difference between the exhaust and intake system, e.g. venturis, variable geometry turbines, check valves using pressure pulsations or throttles in the air intake or exhaust system
• CPC Class Codes: F02M 26/15 in relation to engine exhaust purifying apparatus
• CPC Class Codes: F02M 26/16 with EGR valves located at or near the connection to the exhaust system
• CPC Class Codes: F02M 26/24 with two or more coolers
• CPC Class Codes: F02M 26/48 EGR valve position sensors details of the sensor installation in the valve housing F02M26/72
• CPC Class Codes: F02M 26/71 Multi-way valves
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A method of controlling exhaust gas recirculation (EGR) in a turbocharged engine system including multiple EGR paths to account for at least one of system constraints, or dead time and/or lag time associated with at least one of the EGR paths.

Claims

1. A method of controlling exhaust gas recirculation (EGR) in a turbocharged engine system including a first EGR path and a second EGR path, the method comprising:

a) providing first and second EGR setpoints, which are associated with the first and second EGR paths and contribute to a total EGR setpoint; and

b) applying a transfer function to at least one of the first and second EGR setpoints to account for at least one of dead time or lag time associated with the second EGR path.

2. The method of claim 1 wherein the first and second EGR setpoints are established by multiplying a target total EGR flow setpoint by target first and second EGR contributions.

3. The method of claim 2 wherein the target total EGR flow setpoint is determined on a basis of compliance with exhaust emissions criteria, and the target first and second EGR contributions are determined first on the basis of compliance with exhaust emissions criteria and then to optimize other criteria.

4. The method of claim 1 wherein the transfer function is a dynamic compensation transfer function derived from a first transfer function associated with the first EGR path and a second transfer function associated with the second EGR path.

5. The method of claim 1, further comprising:

c) determining first and second EGR actuator commands corresponding to at least one of the first and second EGR setpoints established in step a) or the adjusted first and second EGR setpoints from step h);

d) applying respective actuator limits to the first and second EGR actuator commands determined in step c) to produce constrained first and second EGR actuator commands;

e) determining updated first and second EGR setpoints corresponding to the constrained first and second EGR actuator commands from step d);

f) wherein the transfer function from step b) is applied to the updated second EGR setpoint from step e) to produce a modified second EGR setpoint;

g) comparing the updated first and modified second EGR setpoints to the first and second EGR setpoints from step a); and

h) adjusting the first and second EGR setpoints from step a) based on the comparison from step g) to generate adjusted first and second EGR setpoints.

6. The method of claim 5 wherein the first and second EGR actuator commands are associated with at least one of exhaust valve opening or closing percentages.

7. A method of controlling exhaust gas recirculation (EGR) in a turbocharged engine system including a first EGR path and a second EGR path, the method comprising:

a) determining first and second EGR actuator commands corresponding to first and second EGR setpoints;

b) applying system constraints to the first and second EGR actuator commands to produce constrained first and second EGR actuator commands;

c) determining updated first and second EGR setpoints corresponding to the constrained first and second EGR actuator commands;

d) comparing the first EGR setpoint to the updated first EGR setpoint; and

e) adjusting the first and second EGR setpoints in response to the comparison of step d) to produce adjusted first and second EGR setpoints.

8. The method of claim 7 wherein the first and second EGR setpoints are initially established by multiplying a target total EGR flow setpoint by target first and second EGR contributions.

9. The method of claim 8 wherein the target total EGR flow setpoint is determined on a basis of compliance with exhaust emissions criteria, and the target first and second EGR contributions are determined first on the basis of compliance with exhaust emissions criteria and then to optimize other criteria.

10. The method of claim 7, further comprising:

g) applying a transfer function to the updated second EGR setpoint from step c) to produce a modified second EGR setpoint;

h) comparing the second EGR setpoint to the modified second EGR setpoint; and

i) adjusting the first and second EGR setpoints from step a) in response to the comparisons of steps d) and h) to generate adjusted first and second EGR setpoints.

11. The method of claim 10 wherein the transfer function is a dynamic compensation transfer function derived from a first transfer function associated with the first EGR path and a second transfer function associated with the second EGR path.

12. The method of claim 7 wherein the first and second EGR actuator commands are associated with at least one of exhaust valve opening or closing percentages.

13. The method of claim 7, wherein the first and second EGR paths are high pressure (HP) and low pressure (LP) EGR paths.

14. The method of claim 13, wherein the HP EGR path is an internal HP EGR path in an engine of the engine system.

15. A method of controlling exhaust gas recirculation (EGR) in a turbocharged engine system including a first EGR path and a second EGR path, the method comprising:

a) establishing base first and second EGR setpoints;

b) applying system constraints to the base first and second EGR setpoints to produce constrained first and second EGR setpoints;

c) determining first and second EGR actuator commands from the constrained first and second EGR setpoints;

d) determining updated first and second EGR setpoints corresponding to the determined first and second EGR actuator commands;

e) comparing the base first EGR setpoint to the updated first EGR setpoint; and

f) adjusting the base second EGR setpoint in response to the comparison of step e) to produce an adjusted second EGR setpoint.

16. The method of claim 15, wherein the system constraints include first and second EGR mass flow constraints.

17. A method of controlling exhaust gas recirculation (EGR) in a turbocharged engine system including a high pressure (HP) EGR path and a low pressure (LP) EGR path, the method comprising:

a) establishing base HP and LP EGR setpoints, which are associated with the HP and LP EGR paths and contribute to a total EGR setpoint;

b) applying system constraints to at least one of the base HP and LP EGR setpoints of step a) or the adjusted HP and LP EGR setpoints from step h) to produce constrained RP and LP EGR setpoints;

c) determining HP and LP EGR actuator commands corresponding to at least one of the base HP and LP EGR setpoints established in step a), the constrained HP and LP EGR setpoints of step b), or the adjusted HP and LP EGR setpoints from step h);

d) applying respective actuator limits to the HP and LP EGR actuator commands determined in step c) to produce updated HP and LP EGR actuator commands;

e) determining updated HP and LP EGR setpoints corresponding to the updated HP and LP EGR actuator commands from step d);

f) applying a transfer function to the updated LP EGR setpoint from step e) to produce a modified LP EGR setpoint;

g) comparing the updated HP and modified LP EGR setpoints to the base RP and LP EGR setpoints from step a); and

h) adjusting the base HP and LP EGR setpoints based on the comparison from step g) to generate adjusted HP and LP EGR setpoints.

18. The method of claim 17 wherein the base HP and LP EGR setpoints are established by multiplying a target total EGR flow setpoint by target HP and LP EGR contributions.

19. The method of claim 18 wherein the target total EGR flow setpoint is determined on a basis of compliance with exhaust emissions criteria and the target HP and LP EGR contributions are determined first on the basis of compliance with exhaust emissions criteria and then to optimize other criteria.

20. The method of claim 17 wherein the transfer function is a dynamic compensation transfer function derived from an HP transfer function associated with the HP EGR path and an LP transfer function associated with the LP EGR path.

21. The method of claim 17 wherein the HP and LP actuator commands are associated with at least one of exhaust valve opening or closing percentages.

22. The method of claim 17, wherein the HP EGR path is an internal HP EGR path in an engine.

23. The method of claim 17 wherein the HP EGR path is disposed on one side of a turbocharger between an engine and the turbocharger such that the RP EGR path is connected to an exhaust subsystem upstream of a turbine of the turbocharger and connected to an induction subsystem downstream of a compressor of the turbocharger, and the LP EGR path is disposed on another side of the turbocharger from the engine such that the LP EGR path is connected to the exhaust subsystem downstream of the turbocharger turbine and connected to the induction subsystem upstream of the turbocharger compressor.

24. A product comprising:

a controller to control exhaust gas recirculation (EGR) and configured to;

provide first and second EGR setpoints, which are associated with first and second EGR paths and contribute to a total EGR setpoint, and

apply a transfer function to at least one of the first and second EGR setpoints to account for at least one of dead time or lag time associated with the second EGR path.

25. The product of claim 24 wherein the first and second EGR setpoints are established by multiplying a target total EGR flow setpoint by target first and second EGR contributions.

26. The product of claim 25 wherein the target total EGR flow setpoint is determined on a basis of compliance with exhaust emissions criteria, and the target first and second EGR contributions are determined first on the basis of compliance with exhaust emissions criteria and then to optimize other criteria.

27. The product of claim 24 wherein the transfer function is a dynamic compensation transfer function derived from a first transfer function associated with the first EGR path and a second transfer function associated with the second EGR path.

28. The product of claim 24, wherein the controller is further configured to:

determine first and second EGR actuator commands corresponding to at least one of the established first and second EGR setpoints or adjusted first and second EGR setpoints;

apply respective actuator limits to the determined first and second EGR actuator commands to produce constrained first and second EGR actuator commands;

determine updated first and second EGR setpoints corresponding to the produced constrained first and second EGR actuator commands;

apply the transfer function to the updated second EGR setpoint to produce a modified second EGR setpoint;

compare the updated first and modified second EGR setpoints to the determined first and second EGR setpoints; and

adjust the provided first and second EGR setpoints based on the comparison, to generate the adjusted first and second EGR setpoints.

29. The product of claim 28 wherein the controller is further configured to associate the determined first and second EGR actuator commands with at least one of exhaust valve opening or closing percentages.

30. A product comprising:

a controller to control exhaust gas recirculation (EGR) and configured to;

determine first and second EGR actuator commands corresponding to first and second EGR setpoints;

apply system constraints to the determined first and second EGR actuator commands to produce constrained first and second EGR actuator commands;

determine updated first and second EGR setpoints corresponding to the constrained first and second EGR actuator commands;

compare the first EGR setpoint to the updated first EGR setpoint; and

adjust the first and second EGR setpoints in response to the comparison to produce adjusted first and second EGR setpoints.

31. The product of claim 30 wherein the controller is further configured to initially establish the first and second EGR setpoints by multiplying a target total EGR flow setpoint by target first and second EGR contributions.

32. The product of claim 31 wherein the controller is further configured to determine the target total EGR flow setpoint on a basis of compliance with exhaust emissions criteria, and to determine the target first and second EGR contributions first on the basis of compliance with exhaust emissions criteria and then to optimize other criteria.

33. The product of claim 30 wherein the controller is further configured to:

apply a transfer function to the updated second EGR setpoint to produce a modified second EGR setpoint;

compare the second EGR setpoint to the modified second EGR setpoint; and

adjust the determined first and second EGR setpoints in response to the comparisons to generate adjusted first and second EGR setpoints.

34. The product of claim 33 wherein the transfer function is a dynamic compensation transfer function derived from a first transfer function associated with the first EGR path and a second transfer function associated with the second EGR path.

35. The product of claim 30 wherein the controller is further configured to associate the determined first and second EGR actuator commands with at least one of exhaust valve opening or closing percentages.

36. The product of claim 30, wherein the first and second EGR paths are high pressure (HP) and low pressure (LP) EGR paths.

37. The product of claim 36, wherein the HP EGR path is an internal HP EGR path in an engine of an engine system.

38. A product comprising:

a controller to control exhaust gas recirculation (EGR) and configured to;

establish base first and second EGR setpoints;

apply system constraints to the base first and second EGR setpoints to produce constrained first and second EGR setpoints;

determine first and second EGR actuator commands from the constrained first and second EGR setpoints;

determine updated first and second EGR setpoints corresponding to the determined first and second EGR actuator commands;

compare the base first EGR setpoint to the updated first EGR setpoint; and

adjust the base second EGR setpoint in response to the comparison to produce an adjusted second EGR setpoint.

39. The product of claim 38, wherein the system constraints include first and second EGR mass flow constraints.

40. A product comprising:

a controller to control exhaust gas recirculation (EGR) and configured to;

establish base HP and LP EGR setpoints, which are associated with HP and LP EGR paths and contribute to a total EGR setpoint;

apply system constraints to at least one of the established base HP and LP EGR setpoints or adjusted HP and LP EGR setpoints to produce constrained HP and LP EGR setpoints;

determine HP and LP EGR actuator commands corresponding to at least one of the established base HP and LP EGR setpoints, the constrained HP and LP EGR setpoints, or the adjusted HP and LP EGR setpoints;

apply respective actuator limits to the determined HP and LP EGR actuator commands to produce updated HP and LP EGR actuator commands;

determine updated HP and LP EGR setpoints corresponding to the updated HP and LP EGR actuator commands;

apply a transfer function to the updated LP EGR setpoint to produce a modified LP EGR setpoint;

compare the updated HP and modified LP EGR setpoints to the established base HP and LP EGR setpoints; and

adjust the base HP and LP EGR setpoints based on the comparison to generate the adjusted HP and LP EGR setpoints.

41. The product of claim 40 wherein the controller is further configured to establish the base HP and LP EGR setpoints by multiplying a target total EGR flow setpoint by target HP and LP EGR contributions.

42. The product of claim 41 wherein the controller is further configured to determine the target total EGR flow setpoint on a basis of compliance with exhaust emissions criteria and to determine the target HP and LP EGR contributions first on the basis of compliance with exhaust emissions criteria and then to optimize other criteria.

43. The product of claim 40 wherein the transfer function is a dynamic compensation transfer function derived from an HP transfer function associated with the HP EGR path and an LP transfer function associated with the LP EGR path.

44. The product of claim 40 wherein the HP and LP actuator commands are associated with at least one of exhaust valve opening or closing percentages.

45. The product of claim 40, wherein the HP EGR path is an internal HP EGR path in an engine.

46. The product of claim 40 wherein the HP EGR path is disposed on one side of a turbocharger between an engine and the turbocharger such that the HP EGR path is connected to an exhaust subsystem upstream of a turbine of the turbocharger and connected to an induction subsystem downstream of a compressor of the turbocharger, and the LP EGR path is disposed on another side of the turbocharger from the engine such that the LP EGR path is connected to the exhaust subsystem downstream of the turbocharger turbine and connected to the induction subsystem upstream of the turbocharger compressor.

47. A product comprising:

an intake throttle valve to control exhaust gas recirculation, and located downstream of an inlet end of an induction subsystem and upstream of a turbocharger compressor.

48. The product of claim 47, wherein the induction subsystem includes the intake throttle valve, a charge air cooler downstream of the turbocharger compressor, and an other intake throttle valve downstream of the charge air cooler.

49. The product of claim 48, further comprising:

an engine;

an exhaust subsystem to convey combustion gases away from the engine;

a turbocharger in communication across the exhaust and induction subsystems; and

an exhaust gas recirculation (EGR) subsystem across the exhaust and induction subsystems to recirculate exhaust gases for mixture with fresh air to improve emissions performance of the engine system, and having at least two EGR paths including a first EGR path, and a second EGR path connected to the induction subsystem downstream of the intake throttle valve.

50. The product of claim 49, wherein the first EGR path is disposed on one side of the turbocharger between the engine and the turbocharger such that the first EGR path is connected to the exhaust subsystem upstream of the turbocharger turbine but connected to the induction subsystem downstream of the turbocharger compressor, and wherein the second EGR path is disposed on the other side of the turbocharger from the engine such that the second EGR path is connected to the exhaust subsystem downstream of the turbocharger turbine but connected to the induction subsystem upstream of the turbocharger compressor.

51. The product of claim 50, wherein the first EGR path includes a first EGR valve to control recirculation of exhaust gases from the exhaust subsystem to the induction subsystem, wherein the first EGR path is connected upstream of the turbocharger turbine and downstream of the other intake throttle valve.

52. The product of claim 51, wherein the second EGR path includes a second EGR valve to control recirculation of exhaust gases from the exhaust subsystem to the induction subsystem, wherein the second EGR path is connected downstream of the turbocharger turbine and upstream of the turbocharger compressor to mix EGR gases with inlet air.

53. The product of claim 52, wherein the intake throttle valve is controlled to lower pressure in the induction subsystem and control EGR.