Method for diagnosing an engine using computer based models

• US 5,377,112 A
• Filed: 12/19/1991
• Issued: 12/27/1994
• Est. Priority Date: 12/19/1991
• Status: Expired due to Fees

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Rutan, W. Kent, Brown, William L. Jr., Schricker, David R.
• Primary Examiner(s): Black, Thomas G.
• Assistant Examiner(s): LOUIS JACQUES, JACQUES H
• Application Number:
  US07/934,642
• Time in Patent Office: 1,104 Days
• Field of Search: 364/424.03, 364/431.01, 364/424.04, 364/550, 364/900, 60/608, 60/607, 60/597, 123/357, 123/373, 123/385, 74/859, 74/860
• US Class Current: 701/115
• CPC Class Codes: C01B 25/163 Phosphorous acid; Salts thereof
• CPC Class Codes: C08K 3/32 Phosphorus-containing compounds
• CPC Class Codes: C08L 57/08 containing halogen atoms
• CPC Class Codes: F02D 2041/288 for performing a transformation into the frequency domain, e.g. Fourier transformation
• 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 41/22 Safety or indicating devices for abnormal conditions in air/fuel ratio feedback systems F02D41/1495, in electric control linkage F02D11/107, in purge control systems F02M25/0809
• CPC Class Codes: G01M 15/00 Testing of engines
• CPC Class Codes: G01M 15/05 by combined monitoring of two or more different engine parameters
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A method for diagnosing an engine (102) including the steps of sensing a first set of parameters of the engine (102) and determining a modeled value of a first operating characteristic. A second set of parameters of the engine (102) is sensed and used to determined a modeled value of a second operating characteristic. The modeled values are compared to actual values and the engine is responsively diagnosed.

Claims

1. A method for diagnosing an engine, including the steps of:

sensing a first operating characteristic of said engine and responsively delivering a first operating characteristic signal;

sensing at least one parameter of said engine and responsively producing at least one parameter signal;

receiving said at least one parameter signal and responsively determining a modeled value of said first operating characteristic;

receiving said first operating characteristic signal, comparing said first operating characteristic signal and said first operating characteristic modeled value and responsively producing a first difference signal;

sensing a second operating characteristic of said engine and responsively delivering a second operating characteristic signal;

sensing at least one other parameter of said engine and responsively producing at least one other parameter signal;

receiving said at least one other parameter signal and responsively determining a modeled value of said second operating characteristic;

receiving said second operating characteristic signal, comparing said second operating characteristic signal and said second operating characteristic modeled value and responsively producing a second difference signal; and

receiving said first and second difference signals, comparing said first and second difference signals, and responsively diagnosing said engine.

2. A method, as set forth in claim 1, including the step of storing said at least one parameter signal and said at least one other parameter signal in a time history data file.

3. A method, as set forth in claim 2, including the step of producing a visual representation of said time history data file.

4. A method, as set forth in claim 1, including the step of storing said first and second difference signals in a time history data file.

5. A method, as set forth in claim 4, wherein said time history data file includes a series of averages of said first and second difference signals.

6. A method, as set forth in claim 5, wherein each of said averages is taken over a predetermined amount of time.

7. A method, as set forth in claim 4, including the step of producing a visual representation of said time history data file.

8. A method, as set forth in claim 1, wherein said engine includes a plurality of cylinders, an intake manifold, and an exhaust manifold and wherein said first operating characteristic is the temperature of exhaust gases in said exhaust manifold.

9. A method, as set forth in claim 8, wherein the step of sensing at least one parameter of said engine includes the step of sensing a first set of parameters of said engine.

10. A method, as set forth in claim 9, wherein said first set of parameters includes the pressure of said intake manifold, the temperature of said intake manifold, and the temperature of fuel delivered to said engine.

11. A method, as set forth in claim 9, including the step of storing said first set of parameters in a time history data file.

12. A method, as set forth in claim 11, including the step of producing a visual representation of said time history data file.

13. A method, as set forth in claim 11, wherein said time history data file includes averages of said operating characteristic signals over a predetermined time period.

14. A method, as set forth in claim 9, including the step of storing said first and second operating characteristic modeled values in a time history data file.

15. A method, as set forth in claim 14, wherein said time history data file includes a series of averages of said modeled values.

16. A method, as set forth in claim 15, wherein each of said averages is taken over a predetermined amount of time.

17. A method, as set forth in claim 14, including the step of producing a visual representation of said time history data file.

18. A method, as set forth in claim 9, including the step of storing said first and second operating characteristic signals in a time history data file.

19. A method, as set forth in claim 18, including the step of producing a visual representation of said time history data file.

20. A method, as set forth in claim 1, wherein said engine includes a turbocharger and said second operating characteristic is a boost pressure associated with said turbocharger.

21. A method, as set forth in claim 20, wherein the step of sensing at least one other parameter of said engine includes the step of sensing a second set of parameters of said engine.

22. A method, as set forth in claim 20, wherein said turbocharger includes a compressor, said engine includes an intake manifold, an exhaust manifold, and an air filter connected to said compressor and wherein said second set of parameters includes the pressure of said intake manifold, the temperature of said intake manifold, the temperature and pressure of the air between said compressor and said air filter, and the temperature of said exhaust manifold.

23. A method, as set forth in claim 1, wherein said step of diagnosing said engine includes the step of producing an error signal as a function of the magnitudes of said first and second difference signals.

24. A method, as set forth in claim 1, wherein said step of diagnosing said engine includes the steps:

producing an acceptable signal in response to a first set of conditions of said first and second difference signals;

producing a fuel system error signal in response to a second set of conditions of said first and second difference signals;

producing a valve error signal in response to a third set of conditions of said first and second difference signals;

producing an air error signal in response to a fourth set of conditions of said first and second difference signals; and

producing a timing error signal in response to a fifth set of conditions of said first and second difference signals.

25. A method for diagnosing an engine having an exhaust manifold and a turbocharger, including the steps of:

sensing an exhaust temperature of said exhaust manifold and responsively delivering an exhaust temperature signal;

sensing at least one parameter of said engine and responsively producing at least one parameter signal;

receiving said at least one parameter signal and responsively determining a modeled exhaust temperature value;

receiving said exhaust temperature signal, comparing said exhaust temperature signal and said modeled exhaust temperature value and responsively producing a first difference signal;

sensing a boost pressure of said turbocharger and responsively delivering a boost pressure signal;

sensing at least one other parameter of said engine and responsively producing at least one other parameter signal;

receiving said at least one other parameter signal and responsively determining a modeled boost pressure value;

receiving said boost pressure signal, comparing said boost pressure signal and said modeled boost pressure value and responsively producing a second difference signal; and

receiving said first and second difference signals, comparing said first and second difference signals, and responsively diagnosing said engine.

26. A method, as set forth in claim 25, including the step of storing said first and second difference signals in a time history data file.

27. A method, as set forth in claim 26, wherein said time history data file includes a series of averages of said first and second difference signals.

28. A method, as set forth in claim 27, wherein each of said averages is taken over a predetermined amount of time.

29. A method, as set forth in claim 28, including the step of producing a visual representation of said time history data file.

30. A method, as set forth in claim 25, wherein said engine includes a plurality of cylinders, each cylinder having a corresponding piston and wherein the step of determining a modeled exhaust temperature value includes the steps:

determining a mass flow efficiency of said engine and responsively producing a volumetric efficiency signal;

determining a fuel to air ratio and responsively producing a fuel to air ratio signal;

receiving said fuel to air ratio signal and said volumetric efficiency signal, responsively determining the power delivered to the pistons of said engine, and producing an indicated power signal indicative of said determined power;

receiving said indicated power signal, responsively determining the heat lost through said cylinders, and producing a cylinder heat loss signal indicative of said determine lost heat;

receiving said cylinder heat loss signal, responsively determining the temperature of the exhaust gas and producing a first temperature signal indicative of said determined temperature;

calculating the temperature of said exhaust manifold and responsively producing a manifold temperature signal;

receiving said first temperature signal and said manifold temperature signal, responsively determining the heat lost through said exhaust manifold, and producing a manifold heat loss signal indicative of said determined heat lost; and

receiving said manifold heat loss signal, responsively determining a probe exhaust temperature, and producing a probe exhaust temperature signal indicative of said determined probe exhaust temperature.

31. A method, as set forth in claim 25, wherein said step of determining a modeled boost pressure value includes the steps of:

initializing a turbine speed of said turbocharger to a predetermined value;

determining the mass flow rate into the engine and responsively producing a mass flow signal;

sensing a filtered air pressure and temperature and responsively producing filtered air pressure and temperature signals, respectively;

sensing an intake manifold air temperature and responsively producing an intake manifold air temperature signal;

sensing an exhaust temperature and responsively producing an exhaust temperature signal;

receiving said mass flow signal, turbine speed, said filtered air pressure and temperature signals, and said intake manifold air temperature signal and responsively producing a boost pressure signal.

32. A method, as set forth in claim 31, including the steps of:

updating said turbine speed value;

receiving said mass flow signal, turbine speed, said filtered air pressure and temperature signals, and said intake manifold air temperature signal and responsively producing an updated boost pressure signal.

33. A method, as set forth in claim 25, wherein the step of sensing at least one parameter of said engine includes the step of sensing a first set of parameters of said engine.

34. A method, as set forth in claim 33, wherein said first set of parameters includes an intake manifold pressure, an intake manifold temperature, and the temperature of fuel delivered to said engine.

35. A method, as set forth in claim 34, including the step of storing said first set of parameters in a time history data file.

36. A method, as set forth in claim 35, including the step of producing a visual representation of said time history data file.

37. A method, as set forth in claim 34, including the step of storing said first and second operating characteristic modeled values in a time history data file.

38. A method, as set forth in claim 37, including the step of producing a visual representation of said time history data file.

39. A method, as set forth in claim 34, including the step of storing said first and second operating characteristic signals in a time history data file.

40. A method, as set forth in claim 39, including the step of producing a visual representation of said time history data file.

41. A method, as set forth in claim 25, wherein the step of sensing at least one other parameter of said engine includes the step of sensing a second set of parameters of said engine.

42. A method, as set forth in claim 41, wherein said turbocharger includes a compressor, said engine includes an intake manifold, an exhaust manifold, and an air filter connected to said compressor and wherein said second set of parameters includes the pressure of said intake manifold, the temperature of said intake manifold, the temperature and pressure between said compressor and said air filter, and the temperature of said exhaust manifold.

43. A method, as set forth in claim 41, including the step of storing said second set of parameters in a time history data file.

44. A method, as set forth in claim 43, including the step of producing a visual representation of said time history data file.

45. A method, as set forth in claim 25, wherein said step of diagnosing said engine includes the step of producing an error signal in response to the magnitudes of said first and second difference signals.

46. A method, as set forth in claim 25, wherein said step of diagnosing said engine includes the steps:

producing an acceptable signal in response to a first set of conditions of said first and second difference signals;

producing an fuel system error signal in response to a second set of conditions of said first and second difference signals;

producing a valve error signal in response to a third set of conditions of said first and second difference signals;

producing an air manifold error signal in response to a fourth set of conditions of said first and second difference signals; and

producing a timing error signal in response to a fifth set of conditions of said first and second difference signals.

47. A method for diagnosing an engine having a turbocharger and a plurality of cylinders, each cylinder having an associated piston, including the steps of:

determining the volumetric efficiency of said engine and responsively producing a volumetric efficiency signal indicative of the mass flow efficiency of said engine;

determining the fuel to air ratio and responsively producing a fuel to air ratio signal;

receiving said fuel to air ration signal and said volumetric efficiency signal, responsively determining the power delivered to the pistons, and producing a brake power signal indicative of said determined power;

determining the heat lost through said cylinders and responsively producing a cylinder heat loss signal;

receiving said cylinder heat loss signal, responsively determining the temperature of the exhaust gas and producing a modeled exhaust temperature signal indicative of said determined temperature;

sensing the actual exhaust temperature and responsively producing an actual exhaust temperature signal;

receiving said modeled exhaust temperature signal and said actual exhaust temperature signal, comparing said modeled and actual exhaust temperature signals and responsively producing a first difference signal;

initializing a turbine speed to a predetermined value;

determining an intake manifold air temperature and responsively producing an intake manifold air temperature signal, respectively;

receiving said intake manifold air temperature signal and responsively determining the mass flow rate into the engine and responsively producing a mass flow signal;

determining a filtered air pressure and temperature and responsively producing filtered air pressure and temperature signals, respectively;

receiving said mass flow signal, turbine speed, said filtered air pressure and temperature signals, and said intake manifold air temperature signal and responsively producing a modeled boost pressure signal;

sensing an actual boost pressure and responsively producing an actual boost pressure signal;

receiving said modeled and actual boost pressure signals and responsively producing a second difference signal;

receiving said first and second difference signals, comparing said first and second difference signals, and responsively diagnosing said engine.

48. A method, as set forth in claim 47, wherein engine includes an exhaust manifold and said step of producing a modeled exhaust temperature signal includes the steps of:

calculating a temperature of said exhaust manifold and responsively producing a manifold temperature signal;

receiving said manifold temperature signal, responsively determining the heat lost through said exhaust manifold, and producing a manifold heat loss signal indicative of said determined heat lost;

and wherein said modeled exhaust temperature signal is a function of said manifold heat loss signal.

49. A method, as set forth in claim 47, including the steps of:

updating said turbine speed value;

receiving said mass flow signal, turbine speed, said filtered air pressure and temperature signals, and said intake manifold air temperature signal and responsively producing an updated boost pressure signal.

50. A method, as set forth in claim 47, wherein said engine includes a fuel delivery system and said step of determining the volumetric efficiency of said engine includes the step of determining the amount of fuel delivered to said engine and an engine speed of said engine and wherein said volumetric efficiency is determined as a function of said delivered fuel and engine speed.

51. A method, as set forth in claim 47, wherein said engine includes a rack for controlling the fuel supplied to the engine and said step of determining the volumetric efficiency of said engine includes the step of determining a rack position and an engine speed of said engine, and wherein said volumetric efficiency of said engine is determined by an engine performance map using said rack position and engine speed.

52. A method, as set forth in claim 47, wherein said engine includes an intake manifold and said fuel to air ratio calculating step includes the steps of:

sensing the temperature and pressure of the air flow in the engine and responsively producing an air temperature signal;

receiving said air temperature and pressure signals and responsively calculating an air density signal;

receiving said air density signal and said volumetric efficiency signal and responsively producing an air flow mass signal; and

sensing the mass fuel flow of fuel into said engine and responsively producing a mass fuel flow signal.

53. A method, as set forth in claim 47, wherein the step of determining said brake power signal includes the steps of:

receiving a timing signal, said rack signal, said speed signal, and said fuel to air ratio signal and responsively producing a indicated specific fuel consumption signal indicative of the efficiency of fuel consumption;

receiving said mass fuel flow signal and said indicated specific fuel consumption signal and responsively producing an indicated power signal; and

receiving said engine speed signal and responsively producing a friction signal indicative of the mechanical friction losses in the engine;

and wherein said brake power signal is determined as a function of said indicated power signal and said friction power signal.