Adaptive exhaust temperature estimation and control

• US 5,722,236 A
• Filed: 12/13/1996
• Issued: 03/03/1998
• Est. Priority Date: 12/13/1996
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Cullen, Michael John, Davey, Christopher K., Hieb, Bradley John
• Primary Examiner(s): Hart, Douglas
• Application Number:
  US08/768,004
• Time in Patent Office: 445 Days
• Field of Search: 60/274, 60/276, 60/289, 60/297, 60/301, 73/118.1
• US Class Current: 60/274
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 2570/14 Nitrogen oxides
• CPC Class Codes: F01N 3/0814 combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
• CPC Class Codes: F01N 3/106 Auxiliary oxidation catalysts
• CPC Class Codes: F01N 3/22 Control of additional air supply only, e.g. using by-passes or variable air pump drives
• CPC Class Codes: F01N 3/222 using electric valves only
• CPC Class Codes: F01N 3/2882 Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices combined with absorbents or adsorbents only F01N3/0814; combined with particulate filters F01N3/035
• 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: F01N 9/005 using models instead of sensors to determine operating characteristics of exhaust systems, e.g. calculating catalyst temperature instead of measuring it directly
• CPC Class Codes: F02D 2200/0804 Estimation of the temperature of the exhaust gas treatment apparatus
• CPC Class Codes: F02D 35/0038 by means of air pumps
• CPC Class Codes: F02D 41/1441 Plural sensors
• CPC Class Codes: F02D 41/18 by measuring intake air flow
• 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

A method and apparatus for inferring and controlling the temperature of a NO_x trap located downstream from a three-way catalyst that employs a temperature sensor to correct a temperature estimation model under relatively steady-state conditions to provide a more accurate estimate of NO_x trap temperature and three-way catalyst temperature. In a second embodiment, the three-way catalyst also includes a temperature sensor for improving the instantaneous catalyst temperature estimation.

Claims

1. A method of estimating the temperature of a NO_x trap located in an exhaust passage of an engine, said trap including a sensor for measuring the temperature of the trap, said method comprising a sequence of the steps of:

estimating the instantaneous temperature of said trap;

estimating temperature output of said sensor based on a previous estimate of said sensor output, said instantaneous trap temperature, and a predetermined temperature rate of change of said sensor as a function of engine air mass flow;

calculating the temperature error between the said estimated sensor output and the actual output of the sensor;

learning a trap temperature correction term based on said temperature error; and

correcting said estimated trap temperature using said correction term.

2. The method of claim 1 wherein said trap is located in said exhaust passage downstream from a catalytic converter;

said method comprising the additional steps of;

estimating the instantaneous midbed temperature of said converter;

calculating the exothermic temperature at the trap entrance;

said step of estimating the instantaneous temperature of said trap is based on said midbed temperature and said exothermic temperature.

3. The method of claim 2 wherein said exhaust passage includes a pierce point located between said converter and said trap for adding controlled amounts of air to the exhaust prior to entry into said trap, and wherein said learning step comprises:

learning an adaptive exotherm temperature correction term based on said error and correcting said exothermic temperature calculation using said adaptive exotherm correction term.

4. The method of claim 2 comprising the further steps of:

learning an adaptive catalyst midbed temperature correction term based on said error;

correcting said estimated midbed temperature using said midbed temperature correction term.

5. A method of controlling the temperature of a NO_x trap including the trap temperature estimating steps of claim 3, and further comprising the steps of:

reducing the amount of air if the NO_x trap temperature exceeds a predetermined maximum temperature;

increasing the amount and commanding a closed loop stoichiometric mode of engine operation, if the NO_x trap temperature drops below a predetermined minimum temperature.

6. A method of estimating the temperature of a NO_x trap located in an exhaust passage of an engine downstream from a catalytic converter, said trap including a sensor for measuring the temperature of the trap, said exhaust passage including a pierce point located between said converter and said trap for adding controlled amounts of air from an air pump to the exhaust prior to entry into said trap resulting in a total exhaust flow, said method comprising a sequence of the steps of:

calculating the instantaneous temperature at a first location upstream of said pierce point based on a previous instantaneous temperature value at said first location, an estimated steady-state value, and a predetermined temperature rate of change at said first location as a function of engine air mass flow;

calculating the total exhaust heat flow at a second location at the front face of the NO_x trap before accounting for any exothermic reaction;

calculating the heat capacity of said total exhaust flow;

calculating the instantaneous temperature at said second location by dividing said heat flow by said heat capacity;

calculating the total exhaust air/fuel ratio at said second location;

if said total exhaust air/fuel ratio is rich, calculating the exothermic energy as a function of the amount of air pump air mass and the total exhaust air/fuel ratio;

if said total exhaust air/fuel ratio is lean, calculating the exothermic energy as a function of the amount of engine air mass and the total exhaust air/fuel ratio;

calculating the temperature generated by the exothermic energy at said second location;

calculating the steady-state temperature at said second location by adding the calculated temperature before any exothermic reaction to the calculated temperature generated by the exothermic energy;

calculating the instantaneous temperature at said second location based on a previous instantaneous temperature value at said second location, said estimated steady-state value at said second location, and a predetermined temperature rate of change at said second location as a function of the sum of engine air mass flow and air pump air mass flow;

inferring the temperature within the NO_x trap at the location of said sensor based on a previous estimated instantaneous temperature value at the sensor location, said estimated steady-state value at said sensor location, and a predetermined temperature rate of change of said sensor output as a function of total exhaust flow;

calculating the error between the estimated temperature at the sensor location and the actual temperature measured by the sensor;

learning an adaptive exotherm temperature correction term based on said error; and

correcting the exothermic temperature calculation using said adaptive exotherm temperature correction term.

7. The method of claim 6 further comprising the steps of:

estimating the instantaneous exhaust gas temperature at a midbed location in the catalyst of said catalytic converter;

estimating the drop in exhaust gas temperature from said midbed location to said first location upstream of said pierce point;

learning a catalyst midbed temperature correction term based on said error; and

correcting said estimated midbed temperature using the amount of said midbed correction term.

8. The method of claim 6 wherein said steady-state value at said first location is based on the estimated instantaneous midbed temperature of said converter minus the loss between said converter and said first location.

9. A method of controlling the temperature of a NO_x trap including the trap temperature estimating steps of claim 6, and further comprising the steps of:

reducing the amount of air if the NO_x trap temperature exceeds a predetermined maximum temperature;

increasing the amount of air and commanding a closed loop stoichiometric mode of engine operation, if the NO_x trap temperature drops below a predetermined minimum temperature.

10. A method of controlling the temperature of a NO_x trap including the trap temperature estimating steps of claim 6, and further comprising the steps of:

turning the air pump ON if a SO_x purge criteria is met to raise the temperature of the trap above a predetermined minimum temperature;

turning the air pump OFF if the NO_x trap temperature exceeds a predetermined maximum temperature.

11. A method of correcting the estimated temperature of a catalytic converter located in an exhaust passage of an engine with a NO_x trap located downstream from said catalytic converter, said trap including a sensor for measuring the temperature of the trap, said method comprising a sequence of the steps of:

estimating the instantaneous midbed temperature of said converter;

calculating the exothermic temperature at the trap entrance;

estimating the temperature at the sensor location in the trap based on said midbed temperature and said exothermic temperature;

calculating the temperature error between the estimated output of the sensor and the actual output of the sensor;

learning a catalyst midbed temperature correction term based on said temperature error; and

correcting said estimated midbed temperature using said midbed correction term.

12. A method of correcting the estimated temperature of a catalytic converter located in an exhaust passage of an engine, said converter including a sensor for measuring the temperature of the converter, said method comprising a sequence of the steps of:

estimating the instantaneous midbed temperature of said converter;

estimating temperature output of said sensor based on a previous estimate of said sensor output, said instantaneous midbed temperature of said converter, and a predetermined temperature rate of change of said sensor as a function of engine air mass flow;

calculating the temperature error between the said estimated sensor output and the actual output of the sensor;

learning a catalyst midbed temperature correction term based on said temperature error; and

correcting said estimated midbed temperature using said midbed correction term.