Gaseous-Fuelled Stoichiometric Compression Ignition Internal Combustion Engine

• US 20130179050A1
• Filed: 02/15/2013
• Published: 07/11/2013
• Est. Priority Date: 08/16/2010
• Status: Active Grant

• Current Assignee: Westport Fuel Systems Canada Inc. (Westport Fuel Systems, Inc.)
• Original Assignee: Westport Power Inc. (Westport Fuel Systems, Inc.)
• Inventors: Munshi, Sandeep, Welch, Alan B., McTaggart-Cowan, Gordon P.
• Granted Patent: US 8,555,852 B2
• Time in Patent Office: Days
• US Class Current: 701/104
• CPC Class Codes: B60T 1/06 acting otherwise than on tread, e.g. employing rim, drum, disc, or transmission or on double wheels
• CPC Class Codes: B60T 7/20 specially for trailers, e.g. in case of uncoupling of or overrunning by trailer inertia-actuated overrun brakes B60T13/08
• CPC Class Codes: B62D 63/08 Component parts or accessories
• CPC Class Codes: F01N 3/101 Three-way catalysts
• CPC Class Codes: F02B 2043/103 Natural gas, e.g. methane or LNG used as a fuel
• CPC Class Codes: F02B 43/10 Engines or plants characterised by use of other specific gases, e.g. acetylene, oxyhydrogen
• CPC Class Codes: F02B 7/06 the fuel in the charge being gaseous
• CPC Class Codes: F02B 7/08 Methods of operating
• CPC Class Codes: F02D 19/0689 for in-cylinder direct injection
• CPC Class Codes: F02D 19/0692 Arrangement of multiple injectors per combustion chamber
• CPC Class Codes: F02D 19/10 peculiar to compression-ignition engines in which the main fuel is gaseous
• CPC Class Codes: F02D 2041/0017 by simultaneous control of throttle and exhaust gas recirculation
• CPC Class Codes: F02D 2041/389 for injecting directly into the cylinder
• CPC Class Codes: F02D 41/0002 Controlling intake air
• CPC Class Codes: F02D 41/0025 Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures
• CPC Class Codes: F02D 41/005 according to engine operating conditions
• CPC Class Codes: F02D 41/30 Controlling fuel injection F02D41/182, F02D41/24 take precedence
• CPC Class Codes: F02D 41/3047 said means being a secondary injection of fuel
• CPC Class Codes: F02D 41/3094 the fuel injection being effected by at least two different injectors, e.g. one in the intake manifold and one in the cylinder
• CPC Class Codes: F02D 41/402 Multiple injections
• CPC Class Codes: F02M 26/00 : Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 : Use of alternative fuels, e.g. biofuels
• CPC Class Codes: Y02T 10/40 : Engine management systems

Abstract

In a gaseous-fuelled stoichiometric compression ignition internal combustion engine, a pilot fuel is injected directly into the combustion chamber to help initiate a multi-point ignition. The engine provides performance improvements approaching those of high pressure direct injection engines but with less complexity because the gaseous fuel is introduced into the intake air subsystem at relatively low pressure and as a result of the stoichiometric combustion, the low oxygen content in the combustion products exiting the combustion chamber allows the use of a three-way catalyst instead of other after treatment arrangements normally associated with conventional compression ignition engines that require the addition of a reductant.

Claims

1. A method for operating a gaseous-fuelled stoichiometric internal combustion engine comprising:

(a) determining by mass an amount of pilot fuel as a function of detected engine operating conditions;

(b) determining by mass an amount of gaseous fuel to introduce into a combustion chamber as a function of detected engine load and based on a total energy desired minus energy associated with said amount of pilot fuel;

(c) determining by mass an amount of exhaust gas recirculation from an engine exhaust system to an intake air system as a function of at least one of said engine load and/or another engine operating condition;

(d) determining an amount of air required for stoichiometric combustion as a function of said amount of pilot fuel, said amount of gaseous fuel and said amount of exhaust gas recirculation;

(e) controlling an exhaust gas recirculation system to direct a portion of said amount of recirculated exhaust gas through a cooler and then to said intake air system;

(f) controlling a pilot fuel injector to inject said amount of pilot fuel directly into said combustion chamber;

(g) controlling a gaseous fuel injector to introduce said amount of gaseous fuel into said combustion chamber where it forms a substantially homogenous mixture with said air and said recirculated exhaust gas;

(h) controlling said intake air system to introduce said amount of air into said combustion chamber; and

(i) igniting said pilot fuel by compressing an intake charge comprising said pilot fuel, said gaseous fuel, said intake air and said recirculated exhaust gas, whereby the combustion of said pilot fuel triggers the ignition and stoichiometric combustion of said gaseous fuel.

2. The method of claim 1 wherein said amount of gaseous fuel is injected through said gaseous fuel injector into an intake manifold of said engine.

3. The method of claim 1 wherein said amount of gaseous fuel is injected through said gaseous fuel injector into an intake port associated with said combustion chamber.

4. The method of claim 1 wherein said amount of gaseous fuel is injected from said gaseous fuel injector directly into said combustion chamber.

5. The method of claim 4 wherein the injection pressure of said gaseous fuel is below 50 bar.

6. The method of claim 4 wherein timing for gaseous fuel start of injection is between 80 and 180 crank angle degrees before top dead center.

7. The method of claim 4 wherein timing for gaseous fuel start of injection is during an intake stroke.

8. The method of claim 1 wherein controlling said intake air system comprises operating a throttle to increase or decrease said amount of air introduced into said combustion chamber as determined to be needed for said stoichiometric combustion.

9. The method of claim 1 wherein controlling said exhaust gas recirculation system comprises operating an EGR valve, which is part of said exhaust gas recirculation system, to increase or decrease said amount of exhaust gas recirculation as determined, as a function of at least one of said engine load and/or another engine operation condition.

10. The method of claim 1 wherein controlling said gaseous fuel injector further comprising pulse width modulating of gaseous fuel injections into said combustion chamber.

11. The method of claim 1 wherein controlling said air intake system comprises changing the timing for opening and/or closing an intake valve to increase or decrease said amount of air as determined to be needed for stoichiometric combustion, and/or to change an effective compression ratio within said combustion chamber to a compression ratio that is predetermined as a function of engine operating conditions.

12. The method of claim 1 further comprising changing an intake valve lift to increase or decrease said amount of air as determined to be needed for stoichiometric combustion, and/or to change an effective compression ratio within said combustion chamber to a compression ratio that is predetermined as a function of engine operating conditions.

13. The method of claim 1 further comprising reducing the occurrence of engine knock by using one of the following:

(j) lowering effective compression ratio within said combustion chamber by controlling timing for intake valve opening and closing and/or intake valve lift,

(k) lowering intake air temperature,

(l) increasing said amount exhaust gas recirculation, or

(m) further reducing the temperature of said portion of exhaust gas that is recirculated.

14. The method of claim 1 further comprising reducing the pumping losses when operating said engine below a predetermined low load by using one of the following:

(j) changing the timing of an intake valve opening and closing and/or an intake valve lift;

(k) in engines with a plurality of combustion chambers, deactivating at least one of said plurality of combustion chambers; and

(1) opening a bypass valve in said engine'"'"'s exhaust gas system;

whereby at least some exhaust gas flowing through an exhaust I line from said combustion chamber bypasses a turbocharger installed on said exhaust line.

15. The method of claim 1 further comprising opening an intake valve when a piston associated with said combustion chamber is at or near top dead center of an intake stroke and closing said intake valve before said piston reaches bottom dead center.

16. The method of claim 15 further comprising closing said intake valve before said piston reaches 20 crank angle degrees before bottom dead center.

17. The method of claim 1 further comprising opening an intake valve when a piston associated with said combustion chamber is at or near top dead center of an intake stroke and closing said intake valve when said piston is at a crank angle greater than 20 degrees after bottom dead center.

18. The method of claim 17 further comprising closing said intake valve before said piston reaches 120 crank angle degrees after bottom dead center.

19. The method of claim 1 wherein said engine operates with a compression ratio up to 14:

1.

34. The engine of claim 1 wherein said gaseous fuel is one of natural gas, biogas, biomethane, and mixtures thereof.

35. The engine of claim 1 wherein said pilot fuel is diesel.

20. A gaseous-fuelled stoichiometric internal combustion engine comprising:

(a) a combustion chamber;

(b) a gaseous fuel injector for introducing an amount of gaseous fuel into said combustion chamber;

(c) a pilot fuel injector for introducing an amount of pilot fuel directly into said combustion chamber;

(d) an intake air system comprising an intake manifold for introducing an amount of air into said combustion chamber;

(e) an exhaust gas system comprising an exhaust gas line in communication with said combustion chamber;

(f) an exhaust gas recirculation system for recirculating an amount of exhaust gas from said exhaust gas system to said intake air system, said exhaust gas recirculation system comprising a cooler for cooling recirculated exhaust gas before delivering it to said air intake system; and

(g) an engine controller programmed to control said gaseous fuel injector, said pilot fuel injector, said intake air system and said exhaust gas recirculation system to provide a stoichiometric oxygen/fuel ratio during normal operation of said engine, whereby said pilot fuel is ignited by compressing an intake charge comprising said pilot fuel, said gaseous fuel, said intake air and said recirculated exhaust gas, and combustion of said pilot fuel triggers ignition and stoichiometric combustion of said gaseous fuel.

21. The engine of claim 20 wherein said gaseous fuel injector has a nozzle that is located to inject said gaseous fuel into said intake manifold.

22. The engine of claim 20 wherein said combustion chamber has an intake port, and said gaseous fuel injector has a nozzle that is located to inject said gaseous fuel into said intake port.

23. The engine of claim 20 wherein said gaseous fuel injector has a nozzle that is located inside said combustion chamber whereby said gaseous fuel can be injected directly into said combustion chamber.

24. The engine of claim 20 wherein said intake air system further comprises a throttle.

25. The engine of claim 20 wherein said controller is programmed to control an intake valve by changing timing for its opening and closing and/or intake valve lift to affect said amount of air introduced into said combustion chamber to provide said stoichiometric combustion.

26. The engine of claim 25 wherein said controller is programmed to control said intake valve such that said intake valve opens when a piston associated with said combustion chamber is at or near top dead center of an intake stroke and said intake valve closes before said piston reaches bottom dead center.

27. The engine of claim 26 wherein said controller is programmed to control said intake valve such that said intake valve closes before said piston reaches 20 crank angle degrees before bottom dead center.

28. The engine of claim 25 wherein said controller is programmed to control said intake valve such that said intake valve opens when a piston associated with said combustion chamber is at or near top dead center of an intake stroke and said intake valve closes when said piston has reached a crank angle greater than 20 degrees after bottom dead center.

29. The engine of claim 28 wherein said controller is programmed to control said intake valve such that said intake valve closes before 120 crank angle degrees after bottom dead center.

30. The engine of claim 20 wherein said exhaust gas recirculation system comprises an EGR valve and wherein said controller is programmable to control said EGR valve to increase said amount of recirculated exhaust gas compared to an amount of exhaust recirculated in a conventional engine using spark plug ignition.

31. The engine of claim 20 wherein said exhaust gas line connected to said combustion chamber comprises a turbocharger and a bypass valve for bypassing said turbocharger, wherein said controller controls said bypass valve such that exhaust gas completely or partially bypasses said turbocharger when the engine operates below a predetermined low load.

32. The engine of claim 20 wherein said engine comprises a plurality of combustion chambers and said controller is programmed to deactivate at least one of said plurality of combustion chambers when said engine operates below a predetermined low load.

33. The engine of claim 20 further comprising a three way catalyst exhaust treatment system.