Control method and apparatus for turbocharged diesel engines having exhaust gas recirculation

• US 6,128,902 A
• Filed: 01/26/1999
• Issued: 10/10/2000
• Est. Priority Date: 01/26/1999
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Kolmanovsky, IIya V., Van Nieuwstadt, Michiel J., Moraal, Paul Eduard
• Primary Examiner(s): KOCZO JR, MICHAEL
• Application Number:
  US09/237,742
• Time in Patent Office: 623 Days
• Field of Search: 60/600, 60/601, 60/602, 60/603, 60/605.2
• US Class Current: 60/605.2
• CPC Class Codes: F02B 37/24 by using pumps or turbines with adjustable guide vanes
• CPC Class Codes: F02D 2041/1409 using at least a proportional, integral or derivative controller
• CPC Class Codes: F02D 2041/141 using a feed-forward control element
• CPC Class Codes: F02D 2041/1422 Variable gain or coefficients
• CPC Class Codes: F02D 2041/2027 Control of the current by pulse width modulation or duty cycle control
• CPC Class Codes: F02D 2200/0406 Intake manifold pressure
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/0072 Estimating, calculating or determining the EGR rate, amount or flow sensors in EGR systems F02M26/45
• CPC Class Codes: F02D 41/1448 the characteristics being an exhaust gas pressure
• CPC Class Codes: F02M 26/05 High pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust system upstream of the turbine and reintroduced into the intake system downstream of the compressor
• CPC Class Codes: F02M 26/10 having means to increase the pressure difference between the exhaust and intake system, e.g. venturis, variable geometry turbines, check valves using pressure pulsations or throttles in the air intake or exhaust system
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A method and apparatus of controlling the airflow into a compression ignition engine having an exhaust gas recirculation (EGR) system and a variable geometry turbocharger (VGT). The control strategy includes the steps of measuring the intake manifold pressure and exhaust manifold pressure, and using these values, estimating the EGR flow fraction. The EGR flow fraction is then used in a proportional plus integral feedback control loop to generate position commands for the EGR valve. Similarly, the intake manifold pressure signal is used in a proportional plus integral feedback control loop to generate position commands for the VGT. In this way, the EGR valve is used to regulate the EGR flow fraction to a desired value and the VGT turbine is used to regulate the intake manifold pressure to a desired value.

Claims

1. A method of controlling the airflow into a compression ignition engine having an exhaust gas recirculation (EGR) passage including a EGR valve connecting an intake manifold and exhaust manifold of the engine, said EGR valve responsive to an EGR valve control signal for regulating the flow of exhaust gas into said intake manifold, and a variable geometry turbocharger (VGT) including a compressor connected to a turbine, the compressor in communication with the intake manifold and the turbine in communication with the exhaust manifold, said turbine responsive to a turbocharger signal for regulating the intake manifold pressure, the method comprising the steps of:

determining a desired intake manifold pressure (p_1d) and desired EGR flow fraction (r_d);

detecting the intake manifold pressure (p₁);

generating a first deviation (e_p1) between the desired and detected intake manifold pressure;

detecting the exhaust manifold pressure (p₂),

estimating the EGR flow fraction (r);

generating a second deviation (e_r) between the desired and estimated EGR flow fraction;

determining an open loop EGR valve control value (V_egr) and an open loop turbocharger value (V_vgt) as a function of the current engine speed and fueling rate;

generating proportional and integral feedback gains for the EGR valve (K_p,egr, K_i,egr) and turbocharger turbine (K_p,vgt, K_i,vgt);

generating said EGR valve control signal (U_egr) as a function of V_egr, K_p,egr, K_i,egr and e_r ;

generating said turbocharger signal (U_vgt) as a function of V_vgt, K_p,vgt, K_i,vgt and e_p1 ;

controlling the EGR valve in accordance with U_egr to regulate r; and

controlling the turbocharger turbine in accordance with U_vgt to regulate p₁.

2. The method as set forth in claim 1 wherein the step of determining a desired intake manifold pressure (p_1d) and desired EGR flow fraction (r_d) includes the step of retrieving p_1d and r_d from a table of values indexed by the requested fueling rate (W_f,req) and current engine speed (N).

3. The method as set forth in claim 1 wherein the step of estimating the EGR flow fraction (r) further comprises the steps of estimating the EGR mass flow rate (W₂₁) and compressor mass flow rate (W_c1) based on p₁ and p₂, and calculating the EGR flow fraction according to the following equation:

space="preserve" listing-type="equation">r=W.sub.21 /(W.sub.21 +W.sub.c1)

4. The method as set forth in claim 1 wherein the step of estimating the EGR flow fraction (r) further comprises the steps of measuring the compressor flow rate (W_c1), estimating the EGR mass flow rate (W₂₁) as a function of p₁ and p₂, and calculating the EGR flow fraction according to the following equation:

space="preserve" listing-type="equation">r=W.sub.21 /(W.sub.21 +W.sub.c1)

5. The method as set forth in claim 1 wherein the step of generating proportional and integral feedback gains for the EGR valve (K_p,egr, K_i,egr) and turbocharger turbine (K_p,vgt, K_i,vgt) includes the step of retrieving K_p,egr, K_i,egr, K_p,vgt, and K_i,vgt from a table of values indexed by the current fueling rate (W_f) and engine speed (N).

6. The method as set forth in claim 1 wherein the steps of generating said EGR valve control signal (U_egr) and said turbocharger signal (U_vgt) includes the step of calculating U_egr according to the following equation:

space="preserve" listing-type="equation">U.sub.egr =V.sub.egr +K.sub.p,egr e.sub.r +K.sub.i,egr Z.sub.r

wherein Z_r represents the accumulated error and calculating U_vgt according to the following equation;

space="preserve" listing-type="equation">U.sub.vgt =V.sub.vgt +K.sub.p,vgt e.sub.p1 +K.sub.i,vgt Z.sub.p1

wherein Z_p1 represents the integrator state.

7. A compression ignition engine system comprising:

an exhaust gas recirculation (EGR) passage including a EGR valve connecting an intake manifold and exhaust manifold of the engine, said EGR valve responsive to an EGR valve control signal for regulating the fraction of exhaust gas flowing into said intake manifold;

a variable geometry turbocharger (VGT) including a compressor connected to a turbine, the compressor in communication with the intake manifold and the turbine in communication with the exhaust manifold, said turbine responsive to a turbocharger signal for regulating the intake manifold pressure;

an exhaust manifold pressure sensor located in said exhaust manifold for providing an exhaust manifold pressure signal;

an intake manifold pressure sensor located in said intake manifold for providing an intake manifold pressure signal;

an engine control unit including memory and a microprocessor, said engine control adapted to receive as inputs said intake and exhaust manifold pressure signals and transmit as outputs the EGR valve control signal for regulating the EGR flow fraction and the turbocharger signal for regulating the intake manifold pressure.

8. In a compression ignition engine system having an exhaust gas recirculation (EGR) passage including an EGR valve connecting an intake manifold and exhaust manifold of the engine, said EGR valve responsive to an EGR valve control signal for regulating the flow of exhaust gas into said intake manifold, and a variable geometry turbocharger (VGT) including a compressor connected to a turbine, the compressor in communication with the intake manifold and the turbine in communication with the exhaust manifold, said turbine responsive to a turbocharger signal for regulating the intake manifold pressure, an engine control unit for regulating the airflow into said engine, said engine control unit comprising:

memory for storing feedback gains and desired engine operating values; and

a microprocessor for generating said EGR valve control signal and said turbocharger signal, said microprocessor programmed to;

retrieve from said memory a desired intake manifold pressure value (p_1d) and a desired EGR flow fraction value(r_d);

receive a first pressure signal (p₁) indicative of the actual intake manifold pressure;

generate a first deviation value (e_p1) between the desired and actual intake manifold pressure;

receive a second pressure signal (p₂) indicative of the actual exhaust manifold pressure;

estimate the EGR flow fraction (r) based on p₁ and p₂ ;

generate a second deviation value (e_r) between the desired and estimated EGR flow fraction;

retrieve from said memory an open loop EGR valve value (V_egr) and an open loop turbocharger value (V_vgt) from a table of values indexed as a function of engine speed and fueling rate;

calculate proportional and integral feedback gains for the EGR valve (K_p,egr /K_i,egr) and turbocharger turbine (K_p,vgt, K_i,vgt);

generate said EGR valve control signal (U_egr) as a function of V_egr, K_p,egr, K_i,egr and e_r ;

generate said turbocharger signal (U_vgt) as a function of V_vgt, K_p,vgt, K_i,vgt and e_p1 ;

transmit U_egr to said EGR valve to regulate r; and

transmit U_vgt to said turbocharger turbine to regulate p₁.

9. The engine control unit of claim 8 wherein said microprocessor is programmed to generate said EGR valve control signal (U_egr) and said turbocharger signal (U_vgt) according to the following equations:

space="preserve" listing-type="equation">U.sub.egr =V.sub.egr +K.sub.p,egr e.sub.r +K.sub.i,egr Z.sub.r

space="preserve" listing-type="equation">U.sub.vgt =V.sub.vgt +K.sub.p,vgt e.sub.p1 +K.sub.i,vgt Z.sub.p1

wherein Z_r represents the integrator state of r, and Z_p1 represents the integrator state of p₁.