OBD calorimetric sensor system with offset error correction

• US 6,003,307 A
• Filed: 02/06/1998
• Issued: 12/21/1999
• Est. Priority Date: 02/06/1998
• Status: Expired due to Term

• Current Assignee: Engelhard Corporation (BASF SE), Continental Automotive Systems, Inc. (Continental AG)
• Original Assignee: Engelhard Corporation (BASF SE), Motorola, Inc. (Motorola Solutions, Inc.)
• Inventors: Price, David Richard, Balko, Edward N., Naber, Jeffrey Donald, Blosser, Patrick Wayne
• Primary Examiner(s): Lopez, F. Daniel
• Assistant Examiner(s): TRAN, BINH Q
• Application Number:
  US09/019,085
• Time in Patent Office: 683 Days
• Field of Search: 60/274, 60/276, 60/277, 60/285, 60/278, 60/286
• US Class Current: 60/274
• 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 11/007 the diagnostic devices measuring oxygen or air concentration downstream of the exhaust apparatus
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 2550/02 Catalytic activity of catalytic converters
• CPC Class Codes: F02D 2041/1432 the system including a filter, e.g. a low pass or high pass filter
• CPC Class Codes: F02D 2041/288 for performing a transformation into the frequency domain, e.g. Fourier transformation
• CPC Class Codes: F02D 41/0055 Special engine operating conditions, e.g. for regeneration of exhaust gas treatment apparatus
• CPC Class Codes: F02D 41/1408 Dithering techniques
• CPC Class Codes: F02D 41/1444 characterised by the characteristics of the combustion gases
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

An on-board catalytic monitoring system uses an intrusive technique to cause the vehicle'"'"'s engine to cycle between first and second operating conditions. The first and second operating conditions are chosen such that different concentrations of emissions with different chemistries are present at the first and second operating conditions. A calorimetric sensor with a selective catalyst senses exothermic oxidation reactions produced by the emissions in the exhaust gas passing over the sensor. By matching the catalyst activity with the emission concentrations occurring at the operating conditions, the difference between the heat release sensor signals detected between the first and second operating conditions is indicative of the actual concentration of specific emissions in the exhaust gas stream. The difference or delta signal, obtained without reference to a zero point, provides an excellent correlation to the efficiency of the vehicle'"'"'s catalytic converter for converting the sensed emission, i.e., hydrocarbons.

Claims

1. An on-board diagnostic method for determining if the emissions of an internal combustion engine in a vehicle with a catalytic converter comply with regulatory standards comprising the steps of:

a) providing a calorimetric sensor downstream of said catalytic converter developing electrical sensor signals indicative of the concentration of at least one, specific regulated gaseous emission in the vehicle'"'"'s exhaust gases;

b) cyclically operating said engine between a first operating condition producing exhaust gases having a first composition of gaseous emissions and a second operating condition producing exhaust gases having a second, composition of gaseous emissions with different concentrations of specific emissions than said first mixture;

c) determining a delta signal indicative of the difference between said calorimetric signals generated for said first and second gas mixtures in any given cycle; and

,

d) comparing said delta signal to a stored value correlated to the efficiency of said catalytic converter to convert said specific gaseous emissions to harmless gaseous emissions to satisfy said regulatory standards whereby a relative sensor signal, independent of an absolute value, senses concentrations of specific regulated gaseous emissions to determine compliance with said regulatory standards.

2. The method of claim 1 wherein said operating condition is lambda, defined as the combustion air to fuel ratio supplied to the combustion chambers of the engine divided by the combustion air to fuel ratio supplied to said chambers to produce stoichiometric combustion.

3. The method of claim 2 wherein lambda is varied at a set frequency causing said operating conditions to cyclically occur at said set frequency.

4. The method of claim 2 wherein lambda is set at a fixed number establishing a lambda bias and cyclically varied from said lambda bias between a set higher and a set lower number to cause said operating conditions to cyclically occur.

5. The method of claim 4 wherein said variation from said lambda bias establishes lambda amplitude, said lambda amplitude fixed at a set value.

6. The method of claim 2 wherein said first operating condition is defined as a lean condition in which lambda is greater than one and said second condition is defined as a rich condition in which lambda is less than one.

7. The method of claim 2 wherein said first operating condition is defined as a lean condition in which lambda is greater than one by a set amount and said second operating condition is defined as a more lean condition in which lambda is greater than one by a second set amount, said second set amount greater than said first set amount.

8. The method of claim 2 wherein said first operating condition is defined as a rich condition in which lambda is less than one by a first set fractional amount and said second operating condition is defined as a more rich condition in which lambda is less than one by a second set fractional amount, said second set fractional amount greater than said first fractional amount.

9. The method of claim 2 wherein the time of said cycle does not exceed more than about five seconds, and lambda is not less than 0.98 in said first condition and not more than about 1.02 in said second condition whereby said vehicle may be driven in a fuel efficient manner without adversely affecting vehicular driveability and/or tail pipe emission while said monitoring method is active.

10. The method of claim 1 wherein said specific gaseous emission is one or more emissions selected from the group consisting of hydrocarbons, carbon monoxide, NO_x and hydrogen within the exhaust stream.

11. The method of claim 1 wherein said sensor'"'"'s electrical signal is proportional to the exothermic oxidation reactions of the gaseous emissions sensed by said sensor;

said operating conditions being selected such that at one of said operating conditions at least one specific gaseous emission is caused to be present at minimal concentration levels producing exothermic oxidation reactions which cause said sensor'"'"'s electrical signal generated at said one operating condition to approximate a baseline value while said specific emission is present at a higher concentration at the other one of said operating conditions to produce an exothermic oxidation reaction causing said sensor'"'"'s electrical signal to exceed said baseline value and thus constitute at least a portion of said delta signal and a measure of catalyst efficiency for said specific emission.

12. The method of claim 11 wherein said baseline value is approximately zero and said minimal concentration of said specific emission is insignificant.

13. The method of claim 11 further including the steps of accumulating a plurality of said sensor'"'"'s electrical signals for a plurality of cycles produced at said operating condition whereat said specific emission concentration level is at minimal concentration levels and detrending said data at said condition producing minimal concentrations whereby said baseline is established, said delta signal being the difference between said baseline and said signals produced at the other one of said operating conditions.

14. The method of claim 11 wherein said step of detrending includes the steps of fitting the data to a linear line and calculating the slope of said line to define said baseline.

15. The method of claim 11 further including the additional steps of a) performing a first plurality of cycles to generate a first plurality of normal delta signals until one or more normal delta signals indicate a failure of said catalytic converter;

b) additionally varying one or more parameters selected from the group consisting of i) space velocity of said exhaust gases, ii) the temperature of said exhaust gas sensed by said sensor and iii) air/fuel ratio and/or cycling thereof by a set amount from the value said parameter had during the time said first plurality of delta signals were collected;

c) performing a second plurality of operating condition cycles with said selected parameter present to generate a second plurality of stressed delta signals and d) comparing said stressed delta signals to a second threshold to determine if said normal delta signals are valid so that a failure established by said normal delta signals is attributed to a failure of the catalytic converter.

16. The method of claim 15 wherein said selected parameter is caused to cyclically change while said second plurality of delta signals are generated.

17. The method of claim 15 wherein said parameter is temperature, said method further including the step of changing the power inputted to the heater of said sensor during the time said stressed delta signals are generated so that the temperature of said exhaust gases sensed by said sensor is increased.

18. The method of claim 15 wherein said parameter is space velocity of said exhaust gas and said method further includes the additional step of changing one or more of said engine'"'"'s operating conditions selected from the group consisting of i) mass combustion air flow;

ii) manifold air pressure; and

, iii) engine operating speed from the value said selected condition had during the time said first plurality of signals were generated.

19. The method of claim 15 wherein said parameter is said A/F ratio, said method further including the step of changing said A/F ratio and/or period during the time said stressed delta signals are obtained to values different than that present during the initial time period during which said normal delta signals were generated.

20. The method of claim 11 wherein one of said operating conditions is selected so that the principal limiting reagent producing said reaction detected by said calorimetric sensor is a reductant at one of said operating conditions while the principal limiting reagent producing said reaction detected by said calorimetric sensor at the other operating condition is an oxidant.

21. The method of claim 20 wherein said reductant is HC and said oxidant is O₂ and NO.

22. The method of claim 11 wherein said sensor has a catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said surface;

said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO is substantially not present in said exhaust gas at said sensor; and

said second operating condition causing said engine to operate at a rich air/fuel ratio such that the exothermic reaction of CO and/or H₂ with NO changes said electrical signal from said first operating condition to produce said delta signal indicative of the concentration of NO_x emissions at said second operating condition.

23. The method of claim 11 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions with HC, NO, CO and H₂ emissions contained in said exhaust gas passing over said catalyst surface;

said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present in said exhaust gas at said sensor while said catalyst promotes exothermic oxidation reactions with HC whereby said electrical signal generated by said sensor is indicative of the HC concentrations in the exhaust gas at said first operating condition and said second operating condition causing said engine to operate at a rich air/fuel ratio such that CO and H₂ exothermic oxidation reactions with NO principally causes a heat release sensed by sensor whereby said electrical signal generated by said sensor at said second condition is indicative of the NO_x concentration in said exhaust gas.

24. The method of claim 23 further including the steps of providing a second sensor having a second catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said second surface;

said second sensor signal substantially unaffected by HC when said engine is operating in said lean first condition and producing an electrical signal indicative of NO_x resulting from the exothermic oxidation reaction of CO and/or H₂ with NO at said second operating condition whereby said second sensor produces a second delta signal indicative of NO_x concentration in said exhaust gas, and subtracting said second delta signal from said first delta signal to produce a signal indicative of the concentration of HC in said exhaust gas.

25. The method of claim 24 further including the step of providing said second catalyst surface area and said first catalyst surface area in one sensor housing whereby the same exhaust stream passes over both said first and second catalyst areas.

26. The method of claim 1 further including the steps of storing and detrending said signals occurring at one of said operating conditions for a set number of cycles to determine a baseline signal for said one of said operating conditions, said baseline signal subtracted from said sensor signal at the other one of said operating conditions to produce said delta signal.

27. The method of claim 11 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions for HC, CO, NO and H₂ emissions;

said vehicle has an exhaust gas recirculation system for metering a portion of said exhaust gas with combustion air injected with fuel into the combustion chambers of said vehicle;

said method further including the steps of regulating the vehicle'"'"'s exhaust gas recirculation system to inject a set percentage of exhaust gas into said combustion chambers;

said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present at said sensor while said catalyst surface area promotes exothermic oxidation reactions with said HC causing said sensor'"'"'s electrical signal to be indicative of said HC concentration in said exhaust gas at said first operating condition and said second operating condition causing said air/fuel ratio to operate at a rich condition whereat substantially insignificant exothermic oxidation reactions occur with said gaseous emissions whereby said delta signal is indicative of the HC concentration in said exhaust gas.

28. The method of claim 27 wherein said set percentage of exhaust gas recirculated to said combustion chambers is about ten percent.

29. The method of claim 1 wherein said operating condition is timing of said engine, said first operating condition being selected at one timing condition and said second operating condition being selected at a second advanced timing condition.

30. The method of claim 29 wherein said timing operating condition is selected from the group consisting of i) spark timing;

ii) valve timing; and

iii) injection timing.

31. The method of claim 30 wherein said operating condition is spark timing, said timing being advanced in said first operating condition and retarded in said second operating condition.

32. The method of claim 1 wherein said vehicle has an exhaust gas recirculation system for metering exhaust gas with combustion air injected with fuel into the combustion chambers of said engine, said first operating condition occurring when a set percentage of exhaust gas is metered into said combustion chamber and said second operating condition occurring when a different set percentage of exhaust gas is metered into said combustion chamber.

33. The method of claim 1 wherein said method is operative only for a set time period during steady state conditions of a drive cycle of said vehicle whereby said vehicle may operate at rapid air to fuel perturbations during other modes of operations.

34. The method of claim 1 further including the step of filtering said delta signal before comparing said delta signal to said stored value to ascertain that said delta signal is a valid signal for comparison.

35. An on-board monitoring system for detecting a failure of the catalytic converter in the exhaust system of a vehicle equipped with an internal combustion engine to control concentrations of certain gaseous emissions of said vehicle within regulatory standards, said system comprising:

a calorimetric sensor downstream of said catalytic converter for generating, when activated, electrical sensor signals indicative of at least one regulated gaseous emission in said vehicle'"'"'s exhaust gas;

means for cyclically operating said engine between a first operating condition producing a first exhaust gas composition of gaseous emissions within a first range of concentrations and a second operating condition producing a composition of gaseous emissions within a second range of concentrations, said first and second emissions concentration ranges being different from one another to produce different heat releases resulting from exothermic oxidation reactions of certain gaseous emissions sensed by said calorimetric sensor;

means for generating a delta signal resulting from the difference between said calorimetric sensor signals of said first composition and said second composition sensed in the same cycle;

means for comparing said delta signal to a stored signal, said stored signal correlated to said first and second operating conditions for determining the efficiency of said catalyst converter to convert said at least one regulated sensed emission to harmless emissions without reference to a specific value assigned the sensor signal at any specific condition; and

,

means for actuating an alarm indicator should said stored value be exceeded.

36. The system of claim 35 wherein said means for cyclically operating said engine includes an air to fuel regulating means regulating the ratio of the amount of combustion air and the amount of fuel supplied to the engine'"'"'s combustion chambers.

37. The system of claim 36 wherein said at least one gaseous emission being sensed are hydrocarbons, said means for cyclically operating further including means for controlling the amount of said exhaust gas being recirculated to said combustion chambers by a set amount whereby emissions forming NO_x are significantly reduced in one of said compositions to minimize exothermic oxidation reactions for that composition and produce a near zero sensor signal at one of said operating conditions while the other operating condition produces HC exothermic oxidant reactions resulting in a delta signal indicative of HC concentration in said exhaust gas.

38. The system of claim 35 wherein said means for cyclically operating includes means for varying the timing of said engine.

39. The system of claim 35 further including means for introducing a portion of said exhaust gases with combustion air metered with fuel into the combustion chambers of said engine and wherein said means for cyclically operating said engine including cyclically varying the amount of exhaust gases metered with said combustion air into said combustion chambers from a first set percentage to a second set percentage.

40. The system of claim 35 wherein said means for comparing includes means for storing and detrending said signals occurring at one of said operating conditions for a set number of cycles to determine a baseline signal for said one of said operating conditions, said baseline signal subtracted from said sensor signal at the other one of said operating conditions to produce said delta signal.

41. The system of claim 35 wherein said means for cyclically operating said engine establishes a set operating cycle having a period of about five seconds.

42. The system of claim 35 further including means for verifying that said engine is operating at one or more set values selected from the group consisting of i) exhaust gas temperature, ii) exhaust gas volume flow, iii) engine timing;

and, iv) mass air flow and/or pressure, before said means for cyclically operating said vehicle occurs.

43. The system of claim 35 wherein said catalytic converter includes a close-coupled catalyst spaced closely adjacent said engine and having a washcoat substantially lacking ceria, said catalytic converter effective to reduce HC concentrations in said exhaust gas.

44. The system of claim 35 wherein said operating condition is lambda, said lambda being the combustion air to fuel ratio supplied to the combustion chambers of the engine divided by the combustion air to fuel ratio supplied to said chambers to produce stoichiometric combustion.

45. The system of claim 44 wherein said means for cyclically operating causes said lambda to be varied at a set frequency whereby said operating conditions cyclically occur at said set frequency.

46. The system of claim 44 wherein said means for cyclically operating causes said lambda to be set at a fixed number establishing a lambda bias and cyclically varied from said lambda bias between a set higher and a set lower number whereby said operating conditions cyclically occur.

47. The system of claim 46 wherein said variation from said lambda bias establishes a lambda amplitude, said lambda amplitude being at a set value.

48. The system of claim 35 wherein said sensor'"'"'s electrical signal being proportional to the exothermic oxidation reactions of the gaseous emissions sensed by said sensor;

said means for cyclically operating causing said operating conditions to be selected such that at one of said operating conditions at least one specific gaseous emission is caused to be present at minimal concentration levels producing exothermic oxidation reactions which cause said sensor'"'"'s electrical signal generated at said one operating condition to approximate a baseline value while said specific emission is present at a higher concentration at the other one of said operating conditions to produce an exothermic oxidation reaction causing said sensor'"'"'s electrical signal to exceed said baseline value and thus constitute at least a portion of said delta signal and a measure of catalyst efficiency for said specific emission.

49. The system of claim 48 wherein said baseline value being approximately zero and said minimal concentration of said specific emission being insignificant.

50. The system of claim 48 further including means for accumulating a plurality of said sensor'"'"'s electrical signals for a plurality of cycles produced at said operating condition whereat said specific emission concentration level is at minimal concentration levels and means for detrending said data at said condition producing said minimal concentrations whereby said baseline is established, said delta signal being the difference between said baseline and said signals produced at the other one of said operating conditions.

51. The system of claim 50 wherein said means for detrending includes the means for fitting the data to a linear line and calculating the slope of said line to define said baseline.

52. The system of claim 48 wherein said means for cycling producing a first plurality of cycles generating a first plurality of normal delta signals until said means for comparing indicates that one or more normal delta signals exceeded said stored value, said system further including means for;

b) additionally varying one or more parameters selected from the group consisting of i) space velocity of said exhaust gases, ii) the temperature of said exhaust gas sensed by said sensor and iii) air/fuel ratio and/or cycling thereof by a set amount from the value said parameter had during the time said first plurality of delta signals were collected;

means for additionally producing a second plurality of operating condition cycles with said selected parameter present to generate a second plurality of stressed delta signals;

said comparing means additionally comparing said stressed delta signals to a second threshold to determine if said normal delta signals are valid, said actuating means activated when a stressed signal exceeds said second threshold.

53. The system of claim 52 wherein said selected parameter being cyclically change while said second plurality of delta signals are generated.

54. The system of claim 52 wherein said parameter being temperature, said system further including means for changing the power inputted to the heater of said sensor during the time said stressed delta signals are generated so that the temperature of said exhaust gases sensed by said sensor is increased.

55. The system of claim 52 wherein said parameter being space velocity of said exhaust gas and said system further includes means for changing one or more of said engine'"'"'s operating conditions selected from the group consisting of i) mass combustion air flow;

ii) manifold air pressure; and

, iii) engine operating speed from the value said selected condition had during the time said first plurality of signals were generated.

56. The system of claim 52 wherein said parameter being A/F ratio, said system further including means for changing said A/F ratio and/or period during the time said stressed delta signals are obtained to values different than that present during the initial time period during which said normal delta signals were generated.

57. The system of claim 52 wherein one of said operating conditions being such that the principal limiting reagent producing said reaction detected by said calorimetric sensor is a reductant at one of said operating conditions while the principal limiting reagent producing said reaction detected by said calorimetric sensor at the other operating condition is an oxidant.

58. The system of claim 57 wherein said reductant being HC and said oxidant being O₂ and NO.

59. The system of claim 35 wherein said sensor has a catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said surface;

said means for cyclically operating at said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO is substantially not present in said exhaust gas at said sensor; and

said means for cyclically operating at said second operating condition causing said engine to operate at a rich air/fuel ratio such that the exothermic reaction of CO and/or H₂ with NO changes said electrical signal from said first operating condition to produce said delta signal indicative of the concentration of NO_x emissions at said second operating condition.

60. The system of claim 35 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions with HC, NO, CO and H₂ emissions contained in said exhaust gas passing over said catalyst surface;

said means for cyclically operating at said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present in said exhaust gas at said sensor while said catalyst promotes exothermic oxidation reactions with HC whereby said electrical signal generated by said sensor is indicative of the HC concentrations in the exhaust gas at said first operating condition and said means for cyclically operating at said second operating condition causing said engine to operate at a rich air/fuel ratio such that CO and H₂ exothermic oxidation reactions with NO principally causes a heat release sensed by sensor whereby said electrical signal generated by said sensor at said second condition is indicative of the NO_x concentration in said exhaust gas.

61. The system of claim 60 further including a second sensor having a second catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said second surface;

said second sensor signal being substantially unaffected by HC when said engine is operating in said lean first condition and producing an electrical signal indicative of NO_x resulting from the exothermic oxidation reaction of CO and/or H₂ with NO at said second operating condition whereby said second sensor produces a second delta signal indicative of NO_x concentration in said exhaust gas, and said means for generating subtracting said second delta signal from said first delta signal to produce a delta signal indicative of the concentration of HC in said exhaust gas.

62. The system of claim 35 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions for HC, CO, NO and H₂ emissions;

said vehicle has an exhaust gas recirculation means for metering a portion of said exhaust gas with combustion air injected with fuel into the combustion chambers of said vehicle;

means for regulating said exhaust gas recirculation system to inject a set percentage of exhaust gas into said combustion chambers;

said means for cyclically operating at said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present at said sensor while said catalyst surface area promotes exothermic oxidation reactions with said HC causing said sensor'"'"'s electrical signal to be indicative of said HC concentration in said exhaust gas at said first operating condition and said means for cyclically operating at said second operating condition causing said air/fuel ratio to operate at a rich condition whereat substantially insignificant exothermic oxidation reactions occur with said gaseous emissions whereby said delta signal is indicative of the HC concentration in said exhaust gas.

63. The system of claim 62 wherein said set percentage of exhaust gas recirculated to said combustion chambers being about ten percent.

64. The system of claim 35 wherein said means for cyclically operating including means for varying the operating condition is timing of said engine, said first operating condition being selected at one timing condition and said second operating condition being selected at a second advanced timing condition.

65. In an on-board monitoring method to determine if the catalytic converter has deteriorated to the extent that a vehicle equipped with an internal combustion engine exhausts certain gaseous emissions to the atmosphere in excess of regulatory standards, said vehicle having an ECU controlling the ratio of combustion air to fuel supplied said engine in accordance with a plurality of sensor signals including those generated by an exhaust gas sensor located upstream of said catalytic converter and by a plurality of systems utilizing any given sensor signal including an EGR system to meter and mix a portion of the exhaust gases with said combustion air, said ECU cycling said ratio of combustion air to fuel supplied to said engine between a first rich mixture and a second lean mixture during certain operating conditions of said vehicle, the improvement comprising the steps of:

a) providing a calorimetric sensor downstream of said catalytic converter for generating electrical signals corresponding to the thermal energy in the concentration of at least one regulated, specific gaseous emission within said exhaust stream;

b) recording said calorimetric sensor signal when said engine is operating at one of said air to fuel mixtures to produce a first sensor signal and immediately recording said calorimetric signal when said engine switches to and is operating at the other one of said air to fuel mixtures to produce a second sensor signal; and

,

c) comparing the difference between said first and second recorded signals to a stored value indicative of the efficiency of said catalytic converter to determine whether said vehicle is in compliance with said regulatory standards.

66. The improvement of claim 65 wherein said catalytic converter includes a light off catalytic converter spaced closely adjacent said engine, said light off catalytic converter having a washcoat lacking ceria and operable to reduce the concentration of HC in said exhaust gas.

67. The improvement of claim 65 further including the step, before said ECU commences cycling of said air to fuel ratio, of verifying that said engine is programmed to operate at set values for one or more conditions selected from the group consisting of i) exhaust gas temperature;

ii) exhaust gas volume flow;

iii) engine timing; and

, iv) mass air flow and/or pressure.

68. The improvement of claim 65 wherein said ECU cycles said first and second mixtures at periods of about five seconds during said monitoring only whereby driveability and/or tailpipe emissions of said vehicle during any drive cycle are not adversely affected.

69. The improvement of claim 65 wherein said sensor'"'"'s electrical signal is proportional to the exothermic oxidation reactions of the gaseous emissions sensed by said sensor;

said operating conditions being selected such that at one of said operating conditions at least one specific gaseous emission is caused to be present at minimal concentration levels producing exothermic oxidation reactions which cause said sensor'"'"'s electrical signal generated at said one operating condition to approximate a baseline value while said specific emission is present at a higher concentration at the other one of said operating conditions to produce an exothermic oxidation reaction causing said sensor'"'"'s electrical signal to exceed said baseline value and thus constitute at least a portion of said delta signal and a measure of catalyst efficiency for said specific emission.

70. The improvement of claim 69 wherein said baseline value is approximately zero and said minimal concentration of said specific emission is insignificant.

71. The improvement of claim 69 further including the steps of accumulating a plurality of said sensor'"'"'s electrical signals for a plurality of cycles produced at said operating condition whereat said specific emission concentration level is at minimal concentration levels and detrending said data at said condition producing minimal concentrations whereby said baseline is established, said delta signal being the difference between said baseline and said signals produced at the other one of said operating conditions.

72. The improvement of claim 71 wherein said step of detrending includes the steps of fitting the data to a linear line and calculating the slope of said line to define said baseline.

73. The improvement of claim 69 further including the additional steps of a) performing a first plurality of cycles to generate a first plurality of normal delta signals until one or more normal delta signals indicate a failure of said catalytic converter;

b) additionally varying one or more parameters selected from the group consisting of i) space velocity of said exhaust gases, ii) the temperature of said exhaust gas sensed by said sensor and iii) air/fuel ratio and/or cycling thereof by a set amount from the value said parameter had during the time said first plurality of delta signals were collected;

c) performing a second plurality of operating condition cycles with said selected parameter present to generate a second plurality of stressed delta signals and d) comparing said stressed delta signals to a second threshold to determine if said normal delta signals are valid so that a failure established by said normal delta signals is attributed to a failure of the catalytic converter.

74. The improvement of claim 73 wherein said selected parameter is caused to cyclically change while said second plurality of delta signals are generated.

75. The improvement of claim 73 wherein said parameter is temperature, said method further including the step of changing the power inputted to the heater of said sensor during the time said stressed delta signals are generated so that the temperature of said exhaust gases sensed by said sensor is increased.

76. The improvement of claim 73 wherein said parameter is space velocity of said exhaust gas and said method further includes the additional step of changing one or more of said engine'"'"'s operating conditions selected from the group consisting of i) mass combustion air flow;

ii) manifold air pressure; and

, iii) engine operating speed from the value said selected condition had during the time said first plurality of signals were generated.

77. The improvement of claim 73 wherein said parameter is said A/F ratio, said method further including the step of changing said A/F ratio and/or period during the time said stressed delta signals are obtained to values different than that present during the initial time period during which said normal delta signals were generated.

78. The improvement of claim 69 wherein one of said operating conditions is selected so that the principal limiting reagent producing said reaction detected by said calorimetric sensor is a reductant at one of said operating conditions while the principal limiting reagent producing said reaction detected by said calorimetric sensor at the other operating condition is an oxidant.

79. The improvement of claim 78 wherein said reductant is HC and said oxidant is O₂ and NO.

80. The improvement of claim 69 wherein said sensor has a catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said surface;

said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO is substantially not present in said exhaust gas at said sensor; and

said second operating condition causing said engine to operate at a rich air/fuel ratio such that the exothermic reaction of CO and/or H₂ with NO changes said electrical signal from said first operating condition to produce said delta signal indicative of the concentration of NO_x emissions at said second operating condition.

81. The improvement of claim 69 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions with HC, NO, CO and H₂ emissions contained in said exhaust gas passing over said catalyst surface;

said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present in said exhaust gas at said sensor while said catalyst promotes exothermic oxidation reactions with HC whereby said electrical signal generated by said sensor is indicative of the HC concentrations in the exhaust gas at said first operating condition and said second operating condition causing said engine to operate at a rich air/fuel ratio such that CO and H₂ exothermic oxidation reactions with NO principally causes a heat release sensed by sensor whereby said electrical signal generated by said sensor at said second condition is indicative of the NO_x concentration in said exhaust gas.

82. The improvement of claim 81 further including the steps of providing a second sensor having a second catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said second surface;

said second sensor signal substantially unaffected y HC when said engine is operating in said lean first condition and producing an electrical signal indicative of NO_x resulting from the exothermic oxidation reaction of CO and/or H₂ with NO at said second operating condition whereby said second sensor produces a second delta signal indicative of NO_x concentration in said exhaust gas, and subtracting said second delta signal from said first delta signal to produce a signal indicative of the concentration of HC in said exhaust gas.

83. The improvement of claim 69 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions for HC, CO, NO and H₂ emissions;

said vehicle has an exhaust gas recirculation system for metering a portion of said exhaust gas with combustion air injected with fuel into the combustion chambers of said vehicle;

said method further including the steps of regulating the vehicle'"'"'s exhaust gas recirculation system to inject a set percentage of exhaust gas into said combustion chambers;

said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present at said sensor while said catalyst surface area promotes exothermic oxidation reactions with said HC causing said sensor'"'"'s electrical signal to be indicative of said HC concentration in said exhaust gas at said first operating condition and said second operating condition causing said air/fuel ratio to operate at a rich condition whereat substantially insignificant exothermic oxidation reactions occur with said gaseous emissions whereby said delta signal is indicative of the HC concentration in said exhaust gas.

84. The improvement of claim 83 wherein said set percentage of exhaust gas recirculated to said combustion chambers is bout ten percent.

85. A system for controlling and monitoring the exhaust emissions produced by an internal combustion engine in a vehicle comprising:

a) a light off catalytic converter having a wash cost substantially devoid of ceria and containing a precious metal coating;

b) an exhaust gas sensor upstream of said catalytic converter developing electrical signals indicative of the oxygen content in exhaust gases produced by said vehicle;

c) a sensor downstream of said catalytic converter developing signals indicative of specific gaseous emissions in said exhaust gases;

d) ECU means for controlling the operation of said engine in response to said oxygen signals to cyclically produce an exhaust gas having first and second exhaust gas mixtures with different concentrations of gaseous emissions;

e) said ECU means having means i) to record said emission sensor signals developed by said emission sensor for said first and second mixtures in each signal, ii) generate a delta signal indicative of the difference in said emission signals for said first and second mixtures and iii) compare said delta signal to a stored signal indicative of the efficiency of said catalytic converter.

86. The system of claim 85 wherein said downstream sensor is a calorimetric sensor.

87. The system of claim 86 wherein said sensor'"'"'s electrical signal being proportional to the exothermic oxidation reactions of the gaseous emissions sensed by said sensor;

said means for cyclically operating causing said operating conditions to be selected such that at one of said operating conditions at least one specific gaseous emission is caused to be present at minimal concentration levels producing exothermic oxidation reactions which cause said sensor'"'"'s electrical signal generated at said one operating condition to approximate a baseline value while said specific emission is present at a higher concentration at the other one of said operating conditions to produce an exothermic oxidation reaction causing said sensor'"'"'s electrical signal to exceed said baseline value and thus constitute at least a portion of said delta signal and a measure of catalyst efficiency for said specific emission.

88. The system of claim 87 wherein said baseline value being approximately zero and said minimal concentration of said specific emission being insignificant.

89. The system of claim 87 further including means for accumulating a plurality of said sensor'"'"'s electrical signals for a plurality of cycles produced at said operating condition whereat said specific emission concentration level is at minimal concentration levels and means for detrending said data at said condition producing said minimal concentrations whereby said baseline is established, said delta signal being the difference between said baseline and said signals produced at the other one of said operating conditions.

90. The system of claim 87 wherein said means for detrending includes the means for fitting the data to a linear line and calculating the slope of said line to define said baseline.

91. The system of claim 87 wherein said means for cycling producing a first plurality of cycles generating a first plurality of normal delta signals until said means for comparing indicates that one or more normal delta signals exceeded said stored value, said system further including means for;

b) additionally varying one or more parameters selected from the group consisting of i) space velocity of said exhaust gases, ii) the temperature of said exhaust gas sensed by said sensor and iii) air/fuel ratio and/or cycling thereof by a set amount from the value said parameter had during the time said first plurality of delta signals were collected;

means for additionally producing a second plurality of operating condition cycles with said selected parameter present to generate a second plurality of stressed delta signals;

said comparing means additionally comparing said stressed delta signals to a second threshold to determine if said normal delta signals are valid, said actuating means activated when a stressed signal exceeds said second threshold.

92. The system of claim 91 wherein said selected parameter being cyclically changed while said second plurality of delta signals are generated.

93. The system of claim 91 wherein said parameter being temperature, said system further including means for changing the power inputted to the heater of said sensor during the time said stressed delta signals are generated so that the temperature of said exhaust gases sensed by said sensor is increased.

94. The system of claim 91 wherein said parameter being space velocity of said exhaust gas and said system further includes means for changing one or more of said engine'"'"'s operating conditions selected from the group consisting of i) mass combustion air flow;

ii) manifold air pressure; and

, iii) engine operating speed from the value said selected condition had during the time said first plurality of signals were generated.

95. The system of claim 91 wherein said parameter being A/F ratio, said system further including means for changing said A/F ratio and/or period during the time said stressed delta signals are obtained to values different than that present during the initial time period during which said normal delta signals were generated.

96. The system of claim 87 wherein one of said operating conditions being such that the principal limiting reagent producing said reaction detected by said calorimetric sensor is a reductant at one of said operating conditions while the principal limiting reagent producing said reaction detected by said calorimetric sensor at the other operating condition is an oxidant.

97. The system of claim 96 wherein said reductant being HC and said oxidant being O₂ and NO.

98. The system of claim 87 wherein said sensor has a catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said surface;

said means for cyclically operating at said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO is substantially not present in said exhaust gas at said sensor; and

said means for cyclically operating at said second operating condition causing said engine to operate at a rich air/fuel ratio such that the exothermic reaction of CO and/or H₂ with NO changes said electrical signal from said first operating condition to produce said delta signal indicative of the concentration of NO_x emissions at said second operating condition.

99. The system of claim 87 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions with HC, NO, CO and H₂ emissions contained in said exhaust gas passing over said catalyst surface;

said means for cyclically operating at said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present in said exhaust gas at said sensor while said catalyst promotes exothermic oxidation reactions with HC whereby said electrical signal generated by said sensor is indicative of the HC concentrations in the exhaust gas at said first operating condition and said means for cyclically operating at said second operating condition causing said engine to operate at a rich air/fuel ratio such that CO and H₂ exothermic oxidation reactions with NO principally causes a heat release sensed by sensor whereby said electrical signal generated by said sensor at said second condition is indicative of the NO_x concentration in said exhaust gas.

100. The system of claim 99 further including a second sensor having a second catalyst surface promoting CO and/or H₂ exothermic oxidation reactions with exhaust gases passing over said second surface;

said second sensor signal being substantially unaffected by HC when said engine is operating in said lean first condition and producing an electrical signal indicative of NO_x resulting from the exothermic oxidation reaction of CO and/or H₂ with NO at said second operating condition whereby said second sensor produces a second delta signal indicative of NO_x concentration in said exhaust gas, and said means for subtracting said second delta signal from said first delta signal to produce a delta signal indicative of the concentration of HC in said exhaust gas.

101. The system of claim 87 wherein said sensor has a catalyst surface promoting exothermic oxidation reactions for HC, CO, NO and H₂ emissions;

said vehicle has an exhaust gas recirculation means for metering a portion of said exhaust gas with combustion air injected with fuel into the combustion chambers of said vehicle;

means for regulating said exhaust gas recirculation system to inject a set percentage of exhaust gas into said combustion chambers;

said means for cyclically operating at said first operating condition causing said engine to operate at a lean air/fuel ratio such that CO and H₂ is substantially not present at said sensor while said catalyst surface area promotes exothermic oxidation reactions with said HC causing said sensor'"'"'s electrical signal to be indicative of said HC concentration in said exhaust gas at said first operating condition and said means for cyclically operating at said second operating condition causing said air/fuel ratio to operate at a rich condition whereat substantially insignificant exothermic oxidation reactions occur with said gaseous emissions whereby said delta signal is indicative of the HC concentration in said exhaust gas.

102. The system of claim 101 wherein said set percentage of exhaust gas recirculated to said combustion chambers being about ten percent.