Apparatus and method for diagnosis of catalyst performance

• US 6,026,639 A
• Filed: 11/03/1997
• Issued: 02/22/2000
• Est. Priority Date: 11/03/1997
• Status: Expired due to Fees

• Current Assignee: Engelhard Corporation (BASF SE)
• Original Assignee: Engelhard Corporation (BASF SE)
• Inventors: Kumar, Sanath V.
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): TRAN, BINH Q
• Application Number:
  US08/963,171
• Time in Patent Office: 841 Days
• Field of Search: 60/274, 60/285, 60/286, 60/277, 60/276, 60/302, 701/103, 701/109, 422/168, 422/169, 422/170, 422/171
• US Class Current: 60/274
• CPC Class Codes: F01N 11/007 the diagnostic devices measuring oxygen or air concentration downstream of the exhaust apparatus
• CPC Class Codes: F01N 2550/02 Catalytic activity of catalytic converters
• CPC Class Codes: F01N 2550/20 Monitoring artificially aged exhaust systems
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A method and apparatus that converts time-resolved sensor signals into frequency domain signals using Fast Fourier Transforms and power spectral densities. A signal, as a means to assess catalyst performance such as a signal based on sensing oxygen concentration in motor vehicle exhaust in accordance with the present invention is in the time domain and has multiple components at different frequencies. The use of Fast Fourier Transforms isolates the various spectral density which arise from different frequency components of the complex time domain signal. The analysis has been found to be substantially independent of operating conditions. The power spectral density has found to be a precise indication of oxygen storage and release of the catalyst and catalyst performance. The catalyst performance can be signaled to the vehicle operator for on board diagnostics (OBD) of the catalyst.

Claims

1. A method comprising the steps of:

passing a stream of fluid containing at least one fluctuating parameter through a unit operation comprising at least one of a catalyst, a reactor and an absorber, said unit operation affecting the one fluctuating parameter;

sensing, downstream of said unit operation, at least one parameter value as a function of time of said at least one fluctuating parameter having a frequency in the fluid stream;

determining at least one frequency parameter as a function of said at least one parameter value and the frequency, and a first control value based on said frequency parameter;

determining a second control value correlated to the frequency of said fluctuating parameter independently of said first control value; and

generating a control signal based on a comparison of the first and second control values.

2. The method of claim 1 wherein the downstream frequency parameter is determined as a downstream cumulative spectral density corresponding to a set range of frequencies and said second control value is correlated to a cumulative spectral density corresponding to the same range of frequencies used to determine said downstream frequency parameter.

3. The method of claim 2 wherein said second control is a preset value.

4. The method of claim 2 further including the step of sensing upstream of said unit operation said at least one parameter value and determining said second control value as an upstream cumulative spectral density corresponding to said set range of frequencies.

5. A method comprising the steps of:

sensing a parameter value as a function of time of a fluctuating parameter having a frequency in a gaseous stream;

determining a cumulative spectral density for a frequency range, and a control value based on the frequency parameter;

comparing the cumulative spectral density to a preset value to obtain a control value; and

generating a control signal based on the control value, wherein the gaseous stream is a stream comprising hydrocarbons and oxygen and the fluctuating parameter is the concentration of oxygen.

6. The method as recited in claim 5 wherein the control value is a function of hydrocarbon concentration.

7. A method comprising the steps of:

sensing an upstream parameter value as a function of time of an upstream fluctuating parameter having an upstream frequency in a gaseous stream upstream of a unit operation;

determining an upstream cumulative spectral density of the upstream fluctuating parameter for an upstream frequency range, and an upstream control value based on the upstream cumulative parameter value;

generating an upstream control signal based on the upstream control value;

sensing the downstream parameter value as a function of time of a downstream fluctuating parameter having a downstream frequency in the gaseous stream downstream of a unit operation;

determining a downstream cumulative spectral density for a downstream frequency range, and a downstream control value based on the downstream cumulative spectral density;

generating a downstream control signal based on the downstream control value; and

adjusting the downstream control signal as a function of the upstream control signal, wherein the gaseous stream is a stream comprising hydrocarbons and oxygen and the upstream fluctuating parameter is the concentration of oxygen at an upstream location and the downstream fluctuating parameter is the concentration of oxygen at a downstream location downstream of the upstream location.

8. The method as recited in claim 7 wherein the upstream control value is a function of upstream hydrocarbon concentration and the downstream control value is a function of downstream hydrocarbon concentration.

9. The method as recited in claim 7 wherein the downstream control signal is normalized based on the upstream control signal.

10. A method comprising the steps of:

sensing a downstream gas component, selected from oxygen and hydrocarbon concentration as a function of time and said gas component concentration having a downstream frequency in a gaseous exhaust stream, comprising hydrocarbons and oxygen, in an exhaust conduit downstream of a hydrocarbon oxidation catalyst located in the exhaust conduit;

determining a downstream frequency parameter as a function of anyone of the downstream oxygen and hydrocarbon concentration and downstream frequency;

comparing the downstream frequency parameter to an downstream preset value to obtain an downstream control value;

generating a downstream control signal based on the downstream control value;

assessing the performance of the hydrocarbon oxidation catalyst as a function of the downstream control signal; and

signaling, with the control signal, the performance of the hydrocarbon oxidation catalyst.

11. The method as recited in claim 10 wherein the downstream frequency parameter is the spectral density.

12. The method as recited in claim 11 wherein the downstream frequency parameter is the cumulative spectral density.

17. The method as recited in claims 7, 10, 13, 14, 15 or 16 over a frequency range of from 0 up to about 1.5 Hz.

18. The method as recited in claim 17 over a frequency range of from 0 to 0.5 Hz.

13. A method comprising the steps of:

sensing an upstream gas component, selected from oxygen and hydrocarbon concentration, as a function of time and said gas component concentration, the gas component concentration having an upstream frequency in a gaseous exhaust stream comprising hydrocarbons and oxygen, in an exhaust conduit upstream of a hydrocarbon oxidation catalyst located in the exhaust conduit;

determining an upstream frequency parameter as a function of anyone of the upstream oxygen and hydrocarbon concentration and upstream frequency, and an upstream control value based on the upstream frequency parameter;

generating an upstream control signal based on the upstream control value;

sensing a downstream gas component, selected from oxygen and hydrocarbon concentration as a function of time and said gas component concentration having a downstream frequency in the gaseous exhaust stream, in the exhaust conduit downstream of the hydrocarbon oxidation catalyst;

determining a downstream frequency parameter as a function of anyone of the downstream oxygen and hydrocarbon concentration and downstream frequency, and a downstream control value based on the downstream frequency parameter;

generating a downstream control signal based on the downstream control value;

adjusting the downstream control signal as a function of the upstream control signal;

assessing the performance of the hydrocarbon oxidation catalyst as a function of the adjusted downstream control signal; and

signaling the performance of the hydrocarbon oxidation catalyst.

14. The method as recited in claim 13 further comprising the steps of:

comparing the upstream frequency parameter to an upstream preset frequency parameter value to obtain the upstream control value; and

comparing the downstream frequency parameter to a downstream preset frequency parameter value to obtain the downstream control value.

15. The method as recited in claim 13 wherein the upstream frequency parameter is the upstream spectral density and the downstream frequency parameter is the downstream spectral density.

16. The method as recited in claim 13 wherein the upstream frequency parameter is the upstream cumulative spectral density and the downstream frequency parameter is the downstream cumulative spectral density.

19. An apparatus comprising:

a conduit;

a unit operation in communication with the conduit;

a sensor located downstream of the unit operation, the sensor comprising a means to measure a downstream parameter value as a function of time of a fluctuating downstream parameter having a downstream frequency in a gaseous or liquid stream;

means to determine a frequency parameter as a function of the downstream parameter value and downstream frequency;

means to compare the downstream frequency parameter to a preset downstream frequency parameter value to obtain a downstream control value; and

means to generate a downstream control signal based on the downstream control value wherein the unit operation is selected from the group of a catalyst, reactor and adsorber.

20. An apparatus comprising:

a conduit;

a catalyst in communication with the conduit;

an upstream sensor located upstream of the catalyst, the upstream sensor comprising a means to measure an upstream parameter value as a function of time of a fluctuating upstream parameter having an upstream frequency in anyone of a gaseous and liquid stream;

means to determine an upstream frequency parameter as a function of the upstream parameter value and upstream frequency, and an upstream control value;

means to generate an upstream control signal based on an upstream control value;

a downstream sensor located downstream of the catalyst, the downstream sensor comprising a means to measure a downstream parameter value as a function of time of a fluctuating downstream parameter having a downstream frequency in a anyone of gaseous and liquid stream;

means to determine a downstream frequency parameter as a function of the downstream parameter value and frequency, and a downstream control value, based on the downstream frequency parameter;

means to generate a downstream control signal based on a downstream control value; and

means to adjust the downstream control signal as a function of the upstream control signal.

21. The apparatus as recited in claim 20 further comprising:

means to compare the upstream frequency parameter to an upstream preset frequency parameter value to obtain an upstream control value; and

means to compare the downstream frequency parameter to a downstream preset frequency parameter value to obtain a downstream control value.

22. The apparatus as recited in claim 20 when the upstream frequency control parameter is the upstream spectral density, and the downstream frequency control parameter is the downstream spectral density.

23. The apparatus as recited in claim 20 when the upstream frequency control parameter is the upstream cumulative spectral density, and the downstream frequency control parameter is the downstream cumulative spectral density.

28. The apparatus of claims 23 or 27 wherein the cumulative spectral density is the sum of the power spectral densities over a frequency range of from 0 to 1.5 (Hz).

29. The apparatus as recited in claims 20 or 24 wherein the catalyst comprises at least one catalytic component and at least one oxygen storage component.

30. The apparatus as recited in claim 29 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first inner layer and a second outer layer:

the first layer comprising;

a first support;

a first palladium component;

optionally a first platinum group component;

optionally at least one first stabilizer;

optionally at least one first rare earth metal component; and

optionally a zirconium compound; and

the second layer comprising;

a second support;

a second platinum component;

a rhodium component;

an oxygen storage composition comprising a diluted second oxygen storage component; and

optionally a zirconium component;

where

the total amount of platinum component of the composite comprises from 50 to 100 weight percent based on platinum metal of the second platinum component based on the total of the first and second platinum components.

31. The apparatus as recited in claim 29 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first inner layer and a second outer layer:

the first layer comprising;

a first support;

a palladium component;

optionally a first platinum component;

at least one first stabilizer;

at least one first rare earth metal component; and

optionally a zirconia compound; and

the second layer comprising;

a second support;

a second platinum component;

a rhodium component;

an oxygen storage composition comprising a diluted second oxygen storage component; and

where

the total amount of platinum components of the composite comprising from 0 to less than fifty weight percent based on the platinum metal of the first platinum component based on the total of the first and second platinum group components.

32. The apparatus as recited in claim 29 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first layer and a second layer:

the first layer comprising;

a first support;

at least one first platinum group metal component; and

an oxygen storage component in intimate contact with the platinum group metal component; and

the second layer comprising;

a second support; and

at least one second platinum group metal component.

33. The apparatus as recited in claim 32 wherein the first layer further comprises:

a first zirconium component;

at least one first alkaline earth metal component; and

at least one first rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components; and

the second layer further comprises;

a second zirconium component;

at least one second alkaline earth metal component; and

at least one second rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components.

34. The apparatus as recited in claim 29 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first layer and a second layer:

the first layer comprising;

a first support;

at least one first palladium component; and

a first oxygen storage component in intimate contact with the palladium component; and

the second layer comprising;

a second support; and

at least one second palladium component.

35. The apparatus as recited in claim 29 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first layer and a second layer:

the first layer comprising;

a first support;

at least one palladium component, wherein the first palladium component is substantially the only platinum group metal component in the first layer;

a first oxygen storage component in intimate contact with the first palladium component;

optionally a first zirconium component;

optionally at least one first alkaline earth metal component; and

optionally at least one first rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components, wherein the first layer requires at least one first alkaline earth metal component and at least one first rare earth metal component; and

the second layer comprising;

a second support;

at least one second palladium component, wherein the second palladium component is substantially the only platinum group metal component in the second layer;

optionally a second zirconium component;

optionally at least one second alkaline earth metal component; and

optionally at least one second rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components, wherein the second layer requires at least one of the second alkaline earth metal component and at least one second rare earth metal component.

36. The apparatus as recited in claim 29 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises and further comprising:

a gasoline engine having an exhaust outlet;

a close coupled catalyst in communication with the exhaust outlet, the close coupled catalyst comprising a close coupled catalyst composition having substantially no oxygen storage components selected from the group consisting of cerium components and praseodymium components, the catalyst composition comprising;

a support;

a palladium component;

optionally, at least one alkaline metal oxide selected from the group consisting of strontium oxide, calcium oxide and barium oxide;

optionally, at least one platinum group metal component selected from the group consisting of platinum, rhodium, ruthenium and iridium components;

optionally, at least one rare earth oxide selected from the group consisting of neodymium oxide and lanthanum oxide; and

optionally, a second zirconium oxide; and

a downstream catalyst located downstream of and in communication with the close-coupled catalyst, the downstream catalyst comprising an oxygen storage component selected from the group consisting of cerium components and praseodymium components.

37. The apparatus as recited in claims 20 or 24 wherein there is a means to determine the frequency parameter over a range of from 0 to 1.5 Hz.

38. The apparatus as recited in claim 37 wherein there is a means to determine the frequency parameter over a range of from 0 to 0.5 Hz.

24. An apparatus comprising:

a conduit;

a hydrocarbon oxidation catalyst located in the conduit catalyst;

an upstream sensor selected from an oxygen sensor and a hydrocarbon sensor located in communication with the conduit upstream of the catalyst, the upstream sensor comprising means to sense upstream gas component, selected from oxygen and hydrocarbon concentration as a function of time and said gas component having an upstream frequency, in the exhaust conduit upstream of the upstream of the hydrocarbon oxidation catalyst;

means to determine an upstream frequency parameter as a function of the upstream gas component concentration and upstream frequency, and an upstream control value, based on the upstream frequency parameter value;

means to generate an upstream control signal based on an upstream control value;

a downstream sensor selected from an oxygen sensor and a hydrocarbon sensor located downstream of the catalyst, the downstream sensor comprising means to sense a downstream gas component, selected from oxygen and hydrocarbon concentration as a function of time and said gas component having a downstream frequency, in the exhaust conduit downstream of the hydrocarbon oxidation catalyst;

means to determine a downstream frequency parameter as a function of the downstream gas component concentration and downstream frequency, and a control value based on the downstream frequency parameter value;

means to generate a downstream control signal based on a downstream control value;

means to adjust the downstream control signal as a function of the upstream control signal;

means to assess the performance of the hydrocarbon oxidation catalyst as a function of the adjusted downstream control signal and generate a performance signal; and

an indicator to indicate catalyst performance.

25. The apparatus as recited in claim 24 further comprising:

means to compare the upstream frequency parameter to an upstream preset value to obtain an upstream control value; and

means to compare the downstream frequency parameter to a downstream preset value to obtain a downstream control value.

26. The apparatus as recited in claim 24 when the upstream frequency control parameter is the upstream spectral density, and the downstream frequency control parameter is the downstream spectral density.

27. The apparatus as recited in claim 24 when the upstream frequency control parameter is the upstream cumulative spectral density, and the downstream frequency control parameter is the downstream cumulative spectral density.

39. An apparatus comprising:

a conduit;

a unit operation in communication with the conduit, the unit operation including a catalyst which comprises at least one catalytic component and at least one oxygen storage component;

a sensor located downstream of the unit operation, the sensor comprising a means to measure a downstream parameter value as a function of time of a fluctuating downstream parameter having a downstream frequency in a gaseous or liquid stream;

means to determine a frequency parameter as a function of the downstream parameter value and downstream frequency;

means to compare the downstream frequency parameter to a preset downstream frequency parameter value to obtain a downstream control value; and

means to generate a downstream control signal based on the downstream control value.

40. The apparatus as recited in claim 39 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first inner layer and a second outer layer:

the first layer comprising;

a first support;

a first palladium component;

optionally a first platinum group component;

optionally at least one first stabilizer;

optionally at least one first rare earth metal component; and

optionally a zirconium compound; and

the second layer comprising;

a second support;

a second platinum component;

a rhodium component;

an oxygen storage composition comprising a diluted second oxygen storage component; and

optionally a zirconium component;

where

the total amount of platinum component of the composite comprises from 50 to 100 weight percent based on platinum metal of the second platinum component based on the total of the first and second platinum components.

41. The apparatus as recited in claim 39 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first inner layer and a second outer layer:

the first layer comprising;

a first support;

a palladium component;

optionally a first platinum component;

at least one first stabilizer;

at least one first rare earth metal component; and

optionally a zirconia compound; and

the second layer comprising;

a second support;

a second platinum component;

a rhodium component;

an oxygen storage composition comprising a diluted second oxygen storage component; and

where

the total amount of platinum components of the composite comprising from 0 to less than fifty weight percent based on the platinum metal of the first platinum component based on the total of the first and second platinum group components.

42. The apparatus as recited in claim 39 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first layer and a second layer:

the first layer comprising;

a first support;

at least one first platinum group metal component; and

an oxygen storage component in intimate contact with the platinum group metal component; and

the second layer comprising;

a second support; and

at least one second platinum group metal component.

43. The apparatus as recited in claim 42 wherein the first layer further comprises:

a first zirconium component;

at least one first alkaline earth metal component; and

at least one first rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components; and

the second layer further comprises;

a second zirconium component;

at least one second alkaline earth metal component; and

at least one second rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components.

44. The apparatus as recited in claim 39 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first layer and a second layer;

the first layer comprising;

a first support;

at least one first palladium component; and

a first oxygen storage component in intimate contact with the palladium component; and

the second layer comprising;

a second support; and

at least one second palladium component.

45. The apparatus as recited in claim 39 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises a layered catalyst composite comprising a first layer and a second layer:

the first layer comprising;

a first support;

at least one palladium component, wherein the first palladium component is substantially the only platinum group metal component in the first layer;

a first oxygen storage component in intimate contact with the first palladium component;

optionally a first zirconium component;

optionally at least one first alkaline earth metal component; and

optionally at least one first rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components, wherein the first layer requires at least one first alkaline earth metal component and at least one first rare earth metal component; and

the second layer comprising;

a second support;

at least one second palladium component, wherein the second palladium component is substantially the only platinum group metal component in the second layer;

optionally a second zirconium component;

optionally at least one second alkaline earth metal component; and

optionally at least one second rare earth metal component selected from the group consisting of lanthanum metal components and neodymium metal components, wherein the second layer requires at least one of the second alkaline earth metal component and at least one second rare earth metal component.

46. The apparatus as recited in claim 39 further comprises a catalyst substrate wherein the catalyst is supported on the substrate and comprises and further comprising:

a gasoline engine having an exhaust outlet;

a close coupled catalyst in communication with the exhaust outlet, the close coupled catalyst comprising a close coupled catalyst composition having substantially no oxygen storage components selected from the group consisting of cerium components and praseodymium components, the catalyst composition comprising;

a support;

a palladium component;

optionally, at least one alkaline metal oxide selected from the group consisting of strontium oxide, calcium oxide and barium oxide;

optionally, at least one platinum group metal component selected from the group consisting of platinum, rhodium, ruthenium and iridium components;

optionally, at least one rare earth oxide selected from the group consisting of neodymium oxide and lanthanum oxide; and

optionally, a second zirconium oxide; and

a downstream catalyst located downstream of and in communication with the close-coupled catalyst, the downstream catalyst comprising an oxygen storage component selected from the group consisting of cerium components and praseodymium components.

47. An apparatus comprising:

a conduit;

a unit operation in communication with the conduit;

a sensor located downstream of the unit operation, the sensor comprising a means to measure a downstream parameter value as a function of time of a fluctuating downstream parameter having a downstream frequency in a gaseous or liquid stream;

means to determine a frequency parameter as a function of the downstream parameter value and downstream frequency;

means to compare the downstream frequency parameter to a preset downstream frequency parameter value to obtain a downstream control value;

means to generate a downstream control signal based on the downstream control value; and

means to determine the frequency parameter over a range of from 0 to 1.5.

48. The apparatus as recited in claim 47 wherein there is a means to determine the frequency parameter over a range of from 0 to 0.5.

49. A method for controlling at least one of and monitoring a function of a vehicle having an internal combustion engine by sensing a fluctuating parameter of a fluid in a conduit affecting the operation of the engine, said method comprising the steps of:

a) providing a unit operation which affects the fluctuating parameter of the fluid;

b) passing the fluid in the conduit through the unit operation;

c) providing a downstream sensor sensing the fluctuation parameter downstream of the unit operation;

d) obtaining a plurality of time history signals from the downstream sensor;

e) converting each time history sensor signal in the time domain to a plurality of frequency signals in the frequency domain for a set frequency range;

f) summing the signal output for all the frequency signals in the set frequency range for a plurality of sensor signals to generate a first control value;

g) computing a control signal for use by the vehicle based on the relationship of the first control value relative to a second control value correlated to the first control value.

50. The method of claim 49 wherein the second control value is a preset value.

51. The method of claim 49 further including the steps of providing a second sensor upstream of the unit operation for obtaining a plurality of upstream time history sensor signals converted in the frequency domain at the set frequency ranges to generate the second control value for a like plurality of sensor signals.

52. The method of claim 49 wherein the stream is the vehicle'"'"'s exhaust stream and the frequency range is set over a range corresponding to that at which at least one of the gaseous elements within the exhaust gas is observed to regularly occur.