Exhaust gas purification system for an internal combustion engine

• US 5,201,802 A
• Filed: 01/31/1992
• Issued: 04/13/1993
• Est. Priority Date: 02/04/1991
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Hirota, Shinya, Katoh, Kenji
• Primary Examiner(s): Lazarus, Ira S.
• Assistant Examiner(s): HEYMAN, LEONARD
• Application Number:
  US07/829,212
• Time in Patent Office: 438 Days
• Field of Search: 60/276, 60/277, 60/285, 60/287, 60/298, 60/300, 60/301
• US Class Current: 60/276
• CPC Class Codes: F01N 11/00 Monitoring or diagnostic devices for exhaust-gas treatment apparatus , e.g. for catalytic activity safety, indicating or supervising devices for internal combustion engines F02B77/08; testing of machines G01M13/00
• CPC Class Codes: F01N 11/002 the diagnostic devices measuring or estimating temperature or pressure in, or downstream of the exhaust apparatus
• CPC Class Codes: F01N 2240/02 a heat exchanger
• CPC Class Codes: F01N 2260/024 using a liquid
• CPC Class Codes: F01N 2510/063 zeolites
• CPC Class Codes: F01N 2550/02 Catalytic activity of catalytic converters
• CPC Class Codes: F01N 2550/05 Systems for adding substances into exhaust
• CPC Class Codes: F01N 2560/026 for measuring or detecting NOx
• CPC Class Codes: F01N 2560/06 the means being a temperature sensor
• CPC Class Codes: F01N 2610/03 the substance being hydrocarbons, e.g. engine fuel
• CPC Class Codes: F01N 2610/146 Control thereof, e.g. control of injectors or injection valves
• CPC Class Codes: F01N 2900/102 Travelling distance
• CPC Class Codes: F01N 3/2006 Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/2033 using a fuel burner or introducing fuel into exhaust duct
• CPC Class Codes: F01N 3/2046 Periodically cooling catalytic reactors
• CPC Class Codes: F01N 3/208 Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
• CPC Class Codes: F01N 9/00 Electrical control of exhaust gas treating apparatus monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

An exhaust gas purification system for an internal combustion engine includes an engine capable of fuel combustion at lean air-fuel ratios, a catalyst constructed of zeolite carrying at least one metal selected from the transition metals and noble metals to reduce NOx under oxidizing gas conditions and in the presence of HC. The exhaust gas purification system also includes a device for determining degradation of the catalyst, and a device for increasing the amount of HC or changing a catalyst temperature to a higher side when it is determined that the catalyst has been degraded. The NOx purification rate of the catalyst is maintained high even after the catalyst has been degraded.

Claims

1. An exhaust gas purification system for an internal combustion engine comprising:

an internal combustion engine capable of fuel combustion at lean air-fuel ratios and having an exhaust conduit;

a catalyst installed in the exhaust conduit of the engine and constructed of zeolite, said catalyst carrying at least one metal selected from the group consisting of transition metals and noble metals to reduce nitrogen oxides included in exhaust gas from the engine under oxidizing gas conditions and in the presence of hydrocarbons;

means for determining degradation of the catalyst; and

means for increasing the amount of hydrocarbons supplied to the catalyst when the means for determining degradation of the catalyst determines that the catalyst has been degraded.

2. An exhaust gas purification system for an internal combustion engine according to claim 1, further comprising an exhaust gas temperature control device installed in a portion of the exhaust conduit upstream of the catalyst.

3. An exhaust gas purification system for an internal combustion engine according to claim 1, and further comprising a hydrocarbon supply device which includes a hydrocarbon source, a hydrocarbon supply port for introducing the hydrocarbons from the hydrocarbon source into a portion of the exhaust conduit upstream of the catalyst, and a control valve, installed in a conduit connecting the hydrocarbon source and the hydrocarbon supply port, for controlling the amount of hydrocarbons supplied into the exhaust conduit.

4. An exhaust gas purification system for an internal combustion engine according to claim 1, wherein the means for determining degradation of the catalyst includes:

a first temperature sensor installed in a portion of the exhaust conduit upstream of the catalyst;

a second temperature sensor installed in a portion of the exhaust conduit downstream of the catalyst; and

an NO_x sensor installed in the portion of the exhaust conduit downstream of the catalyst.

5. An exhaust gas purification system for an internal combustion engine according to claim 1, wherein the means for determining degradation of the catalyst comprises means for determining degradation of the catalyst based on an accumulated running distance of an automobile to which the engine is mounted.

6. An exhaust gas purification system for an internal combustion engine according to claim 5, wherein the means for increasing the amount of hydrocarbons includes means for calculating an object amount of hydrocarbons to be supplied to the catalyst such that the larger the accumulated running distance is, the more the object amount of hydrocarbons to be supplied to the catalyst is.

7. An exhaust gas purification system for an internal combustion engine according to claim 5, further comprising catalyst temperature changing means for calculating upper and lower limits of an object catalyst temperature range such that the more catalyst has been degraded, the higher the upper and lower limits of the object catalyst temperature range are.

8. An exhaust gas purification system for an internal combustion engine according to claim 1, wherein the means for determining degradation of the catalyst comprises means for modifying a reference NOx value by a current detected NOx amount and storing the modified reference NOx value until an accumulated running distance of an automobile to which the engine is mounted finally reaches a predetermined value, and means for calculating a NOx value difference between a current detected NOx amount and the stored reference NOx value to determine a degradation extent of the catalyst based on the NOx value difference.

9. An exhaust gas purification system for an internal combustion engine according to claim 8, wherein the means for increasing the amount of hydrocarbons supplied to the catalyst includes means for calculating an object hydrocarbon concentration based on the calculated NOx value difference such that the larger the calculated NOx value differnce is, the higher the object hydrocarbon concentration is.

10. An exhaust gas purification system for an internal combustion engine according to claim 8, further comprising means for calculating a catalyst temperature modification factor based on the calculated NOx value difference such that the larger the calculated NOx value difference is, the larger the catalyst temperature modification factor is, and means for controlling an object exhaust gas temperature based on the calculated catalyst temperature modification factor such that the larger the calculated catalyst temperature modification factor is, the higher the object exhaust gas temperature is.

11. An exhaust gas purification system for an internal combustion engine according to claim 1, wherein the means for determining degradation of the catalyst includes means for calculating a reference temperature difference between inlet gas and outlet gas of the catalyst at a non-degraded state from an engine load versus engine speed map, detecting a current temperature difference between the inlet gas and the outlet gas of the catalyst, and calculating a degradation extent of the catalyst based on a difference between the detected current temperature difference and the reference temperature difference.

12. An exhaust gas purification system for an internal combustion engine according to claim 11, wherein the means for increasing the amount of hydrocarbons supplied to the catalyst includes means for calculating an object hydrocarbon concentration based on the calculated degradation extent of the catalyst such that the larger the calculated degradation extent of the catalyst is, the higher the object hydrocarbon concentration is.

13. An exhaust gas purification system for an internal combustion engine according to claim 11, further comprising catalyst temperature changing means for calculating upper and lower limits of an object catalyst temperature range based on the calculated degradation extent of the catalyst such that the larger the calculated degradation extent of the catalyst is, the higher the upper and lower limits of the object catalyst temperature range are.

14. An exhaust gas purification system for an internal combustion engine comprising:

an internal combustion engine capable of fuel combustion at lean air-fuel ratios and having an exhaust conduit;

a catalyst installed in the exhaust conduit of the engine and constructed of zeolite, said catalyst carrying at least one metal selected from the group consisting of transition metals and noble metals to reduce nitrogen oxides included in exhaust gas from the engine under oxidizing gas conditions and in the presence of hydrocarbons;

means for determining degradation of the catalyst; and

means for changing a catalyst temperature to a higher side when the means for determining degradation of the catalyst determines that the catalyst has been degraded.

15. An exhaust gas purification system for an internal combustion engine according to claim 14, further comprising an exhaust gas temperature control device installed in a portion of the exhaust conduit upstream of the catalyst.

16. An exhaust gas purification system for an internal combustion engine according to claim 14, further comprising a hydrocarbon supply device which includes a hydrocarbon source, a hydrocarbon supply port for introducing the hydrocarbons from the hydrocarbon source into a portion of the exhaust conduit upstream of the catalyst, and a control valve, installed in a conduit connecting the hydrocarbon source and the hydrocarbon supply port, for controlling the amount of hydrocarbons supplied into the exhaust conduit.

17. An exhaust gas purification system for an internal combustion engine according to claim 14, wherein the means for determining degradation of the catalyst includes:

a first temperature sensor installed in a portion of the exhaust conduit upstream of the catalyst;

a second temperature sensor installed in a portion of the exhaust conduit downstream of the catalyst; and

an NO_x sensor installed in the portion of the exhaust conduit downstream of the catalyst.

18. An exhaust gas purification system for an internal combustion engine according to claim 14, wherein the means for determining degradation of the catalyst comprises means for determining degradation of the catalyst based on an accumulated running distance of an automobile to which the engine is mounted.

19. An exhaust gas purification system for an internal combustion engine according to claim 14, wherein the means for determining degradation of the catalyst comprises means for modifying a reference NOx value by a current detected NOx amount and storing the modified reference NOx value until an accumulated running distance of an automobile to which the engine is mounted reaches a predetermined value, and means for calculating an NOx value difference between a current detected NOx amount and the stored reference NOx value to determine a degradation extent of the catalyst based on the NOx value difference.

20. An exhaust gas purification system for an internal combustion engine according to claim 14, wherein the exhaust gas temperature control device includes an air pump, an air nozzle for injecting air from the air pump to a converter case housing the catalyst therein, and a control valve installed in an air conduit connecting the air pump and the air nozzle.

21. An exhaust gas purification system for an internal combustion engine according to claim 20, wherein the means for determining degradation of the catalyst includes means which determines that the catalyst has been degraded when a temperature difference between inlet gas and outlet gas of the catalyst exceeds a predetermined value.

22. An exhaust gas purification system for an internal combustion engine according to claim 21, wherein the means for changing a catalyst temperature includes means for closing the control valve when the means for determining degradation of the catalyst determines that the catalyst has been degraded.