System for diagnosing and controlling high-pressure fuel system for in-cylinder fuel injection engine

• US 6,138,638 A
• Filed: 09/01/1998
• Issued: 10/31/2000
• Est. Priority Date: 09/03/1997
• Status: Expired due to Fees

• Current Assignee: Fuji Jukogyo KK (Subaru Corp.)
• Original Assignee: Fuji Jukogyo KK (Subaru Corp.)
• Inventors: Morikawa, Koji
• Primary Examiner(s): Dolinar, Andrew M.
• Application Number:
  US09/144,980
• Time in Patent Office: 791 Days
• Field of Search: 123/305, 123/690, 123/479, 123/295, 73/119 A, 73/117.3
• US Class Current: 123/295
• CPC Class Codes: F02D 2041/224 Diagnosis of the fuel system
• CPC Class Codes: F02D 2041/389 for injecting directly into the cylinder
• CPC Class Codes: F02D 2200/0602 Fuel pressure
• CPC Class Codes: F02D 41/061 the corrections being time dependent
• CPC Class Codes: F02D 41/221 relating to the failure of actuators or electrically driven elements
• CPC Class Codes: F02D 41/3029 further comprising a homogeneous charge spark-ignited mode
• CPC Class Codes: F02D 41/3076 with special conditions for selecting a mode of combustion, e.g. for starting, for diagnosing
• CPC Class Codes: F02D 41/3863 by controlling the flow out of the common rail, e.g. using pressure relief valves

Abstract

A system for controlling an in-cylinder fuel injection engine determines that a high-pressure fuel system is abnormal, when meeting at least one of conditions that the fuel pressure Pf of the high-pressure fuel system does not reach a preset pressure PFS (S24) even if a predetermined period of time elapses after the engine start-up (S22), that the fuel pressure Pf of the high-pressure fuel system is not within an ordinary fuel pressure range defined by the lower limit PFL and the upper limit PFH after the engine start-up (S27, S28), and that the fuel injection pulse width Ti continues to exceed the upper limit TiNGMAX, which can not usually be obtained, for a predetermined period of time at a lean air-fuel ratio (S30˜S33). Thus, the abnormality of the high-pressure fuel system of the in-cylinder fuel injection engine can be accurately diagnosed.

Claims

1. A system for controlling an in-cylinder fuel injection engine, wherein a low pressure fuel fed from a low pressure pump is regulated to a predetermined fuel pressure by a low pressure regulator to be fed to a high pressure pump, the pressure of said fuel being raised by said high pressure pump and regulated to a predetermined controlled fuel pressure by a high pressure regulator to feed a high pressure fuel to an injector, and wherein a fuel injection quantity is set on the basis of an engine operating condition, said fuel injection quantity of said fuel being injected directly into a cylinder by the injector, said control system comprising:

opening/closing valve means provided in a fuel by-pass passage provided for by passing said high pressure regulator to establish a communication between a high-pressure fuel system and a low-pressure fuel system;

diagnosing means for monitoring at least one of the behavior of a fuel pressure of said high-pressure fuel system and the relationship between an air-fuel ratio and a fuel injection pulse width for the injector, said diagnosing means determining that said high-pressure fuel system is abnormal when meeting at least one of conditions that said behavior of the fuel pressure is abnormal and that said air-fuel ratio is incompatible with said fuel injection pulse width;

opening/closing valve control means for closing said opening/closing valve means when said high-pressure fuel system is normal and for opening said opening/closing valve means when said high-pressure fuel system is abnormal;

fuel injection control means for setting a fuel injection pulse width defining a fuel injection quantity for the injector on the basis of the engine operating condition in accordance with the controlled fuel pressure regulated by said high pressure regulator when said high-pressure fuel system is normal, said fuel injection control means setting the fuel injection pulse width on the basis of the engine operating condition in accordance with the pressure of a low pressure fuel regulated by said low pressure regulator when said high-pressure fuel system is abnormal;

a fuel pressure correction factor table which uses a fuel pressure in a practical use range of said high-pressure fuel system as a parameter for storing therein a fuel pressure correction factor for correcting the variation in fuel injection quantity based on said fuel pressure; and

an abnormal period fuel pulse width table which uses an engine speed and an engine load as parameters for storing therein a fuel injection pulse width suited to obtain a required fuel injection quantity at the pressure of a low pressure fuel regulated by said low pressure regulator,

wherein when said high-pressure fuel system is normal, said fuel injection control means sets a basic fuel injection quantity on the basis of the engine operating condition to set a basic fuel injection pulse width, which is used for obtaining said basic fuel injection quantity at a predetermined controlled fuel pressure regulated by said high-pressure regulator or said electromagnetic high-pressure regulator and which defines a basic valve opening period for said injector, on the basis of said basic fuel injection quantity, and said fuel injection control means makes reference to said fuel pressure correction factor table on the basis of the fuel pressure of said high-pressure fuel system to set a fuel pressure correction factor to correct said basic fuel injection pulse width by said fuel pressure correction factor to set a final fuel injection pulse width for the injector, and

wherein when said high-pressure fuel system is abnormal, said fuel injection control means makes reference to said abnormal period fuel injection pulse width table on the basis of the engine speed and the engine load to set a final fuel injection pulse width for the injector.

2. A system for controlling an in-cylinder fuel injection engine, wherein a low pressure fuel fed from a low pressure pump is regulated to a predetermined fuel pressure by a low pressure regulator to be fed to a high pressure pump, the pressure of said fuel being raised by said high pressure pump and regulated to a predetermined controlled fuel pressure by a high pressure regulator to feed a high pressure fuel to an injector, and wherein during low engine speeds with low loads, a stratified combustion based on a late injection is selected to set a fuel injection quantity, a fuel injection timing and an ignition timing, which are adapted to the stratified combustion, on the basis of the engine operating condition, and during high engine speeds with high loads, a uniform premixed combustion based on an early injection is selected to set a fuel injection quantity, a fuel injection timing and an ignition timing, which are adapted to the uniform premixed combustion, on the basis of the engine operating condition, said injection quantity of fuel being injected directly into a cylinder by the injector to ignite the injected fuel by a spark plug at said ignition timing to achieve the stratified combustion or the uniform premixed combustion, said system control comprising:

opening/closing valve means provided in a fuel by-pass passage provided for by-passing said high pressure regulator to establish a communication between a high-pressure fuel system and a low-pressure fuel system;

diagnosing means for monitoring at least one of the behavior of a fuel pressure of said high-pressure fuel system and the relationship between an air-fuel ratio and a fuel injection pulse width for the injector, said diagnosing means determining that said high-pressure fuel system is abnormal when meeting at least one of conditions that said behavior of the fuel pressure is abnormal and that said air-fuel ratio is incompatible with said fuel injection pulse width;

opening/closing valve control means for closing said opening/closing valve means when said high-pressure fuel system is normal and for opening said opening/closing valve means when said high-pressure fuel system is abnormal; and

combustion system selecting means for selecting the stratified combustion based on the late injection during low engine speeds with low loads, and the uniform premixed combustion based on the early injection during high engine speeds with high loads, on the basis of the engine operating condition;

fuel injection control means for setting a fuel injection pulse width for the injector, which defines a fuel injection quantity adapted to the stratified combustion, on the basis of the engine operating condition in accordance with the controlled fuel pressure regulated by said high pressure regulator and for setting a fuel injection timing in a compression stroke of a cylinder to be injected when said high-pressure fuel system is normal and when the stratified combustion is selected, said fuel injection control means setting a fuel injection pulse width for the injector, which is adapted to the uniform premixed combustion, on the basis of the engine operating condition in accordance with the controlled fuel pressure regulated by said high pressure regulator and setting a fuel injection timing in an exhaust stroke end or intake stroke of a cylinder to be injected when said high pressure fuel system is normal and when the uniform premixed combustion is selected, and said fuel injection control means setting a fuel injection pulse width adapted to the uniform premixed combustion on the basis of said engine operating condition in accordance with the pressure of a low pressure fuel regulated by said low pressure regulator and setting a fuel injection timing adapted to the uniform premixed combustion when said high-pressure fuel system is abnormal; and

ignition timing control means for setting an ignition timing adapted to the stratified combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the stratified combustion is selected, and for setting an ignition timing adapted to the uniform premixed combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the uniform premixed combustion is selected or when said high-pressure fuel system is abnormal.

3. A system for controlling an in-cylinder fuel injection engine as set forth in claim 2, which further comprises:

a fuel pressure correction factor table which uses a fuel pressure in a practical use range of said high-pressure fuel system as a parameter for storing therein a fuel pressure correction factor for correcting the variation in fuel injection quantity based on said fuel pressure; and

an abnormal period fuel pulse width table which uses an engine speed and an engine load as parameters for storing therein a fuel injection pulse width suited to obtain a required fuel injection quantity adapted to the uniform premixed combustion at the pressure of a low pressure fuel regulated by said low pressure regulator;

said fuel injection control means setting a basic fuel injection quantity adapted to the stratified combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the stratified combustion is selected and setting a basic fuel injection quantity adapted to the uniform premixed combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the uniform premixed combustion is selected, said fuel injection control means setting a basic fuel injection pulse width, which is used for obtaining said basic fuel injection quantity at a predetermined controlled fuel pressure regulated by said high-pressure regulator or said electromagnetic high-pressure regulator and which defines a basic valve opening period for the injector, on the basis of said basic fuel injection quantity, and said fuel injection control means making reference to said fuel pressure correction factor table on the basis of the fuel pressure of said high-pressure fuel system to set a fuel pressure correction factor to correct said basic fuel injection pulse width by said fuel pressure correction factor to set a final fuel injection pulse width for the injector, and

said fuel injection control means making reference to said abnormal period fuel injection pulse width table on the basis of the engine speed and the engine load to set a final fuel injection pulse width for the injector when said high-pressure fuel system is abnormal.

4. A system for controlling an in-cylinder fuel injection engine as set forth in claim 2, which further comprises:

a fuel pressure correction factor table which uses a fuel pressure in a practical use range of said high-pressure fuel system as a parameter for storing therein a fuel pressure correction factor for correcting the variation in fuel injection quantity based on said fuel pressure,

said fuel injection control means setting a basic fuel injection quantity adapted to the stratified combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the stratified combustion is selected and setting a basic fuel injection quantity adapted to the uniform premixed combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the uniform premixed combustion is selected or when said high-pressure fuel system is abnormal, said fuel injection control means setting a basic fuel injection pulse width, which is used for obtaining said basic fuel injection quantity at a predetermined controlled fuel pressure regulated by said high-pressure regulator or said electromagnetic high-pressure regulator and which defines a basic valve opening period for the injector, on the basis of said basic fuel injection quantity, said fuel injection control means making reference to said fuel pressure correction factor table on the basis of the fuel pressure of said high-pressure fuel system to set a fuel pressure correction factor,

said fuel injection control means setting an abnormal period correction factor for correcting to increase said basic fuel injection pulse width in accordance with the pressure of a low pressure fuel regulated by said low pressure regulator when at least said high-pressure fuel system is abnormal, and

said fuel injection control means correcting said basic fuel injection pulse width by said fuel pressure correction factor and said abnormal period correction factor to set a final fuel injection pulse width for the injector.

5. A system for controlling an in-cylinder fuel injection engine as set forth in claim 2, which further comprises:

a fuel pressure correction factor table which uses the pressure of a low pressure fuel related by said low pressure regulator and a fuel pressure in a practical use range of said high-pressure fuel system as parameters for storing therein a fuel pressure correction factor for correcting the variation in fuel injection quantity based on said fuel pressure,

said fuel injection control means setting a basic fuel injection quantity adapted to the stratified combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the stratified combustion is selected and setting a basic fuel injection quantity adapted to the uniform premixed combustion on the basis of the engine operating condition when said high-pressure fuel system is normal and when the uniform premixed combustion is selected or when said high-pressure fuel system is abnormal, said fuel injection control means setting a basic fuel injection pulse width, which is used for obtaining said basic fuel injection quantity at a predetermined controlled fuel pressure regulated by said high-pressure regulator or said electromagnetic high-pressure regulator and which defines a basic valve opening period for the injector, on the basis of said basic fuel injection quantity, and said fuel injection control means making reference to said fuel pressure correction factor table on the basis of the fuel pressure of said high-pressure fuel system to set a fuel pressure correction factor to correct said basic fuel injection pulse width by said fuel pressure correction factor to set a final fuel injection pulse width for the injector.

6. A system for controlling an in-cylinder fuel injection engine as set forth in claim 2, wherein said fuel injection control means carries out an upper limitation of the fuel injection pulse width which is set when said high-pressure fuel system is abnormal.

7. A system for controlling an in-cylinder fuel injection engine as set forth in claim 2, wherein said diagnosing means determines that said high-pressure fuel system is abnormal, when meeting at least one of conditions that the fuel pressure of said high-pressure fuel system does not reach a predetermined pressure even if a predetermined period of time elapses after the engine start-up, that the fuel pressure of said high-pressure fuel system is not within an ordinary fuel pressure range after the engine start-up, and that the fuel injection pulse width continues to exceed a predetermined value for a predetermined period of time at a lean air-fuel ratio.

8. A system for controlling an in-cylinder fuel injection engine having a high pressure fuel system including a high pressure pump provided to supply a regulated high pressure fuel to an injector, a low pressure fuel system including a low pressure pump provided to feed a regulated low pressure fuel to said high pressure pump and a control unit including diagnosing means for determining whether said high pressure fuel system is normal or abnormal and pressure reducing means for reducing the pressure of said high pressure fuel when said high pressure fuel system is abnormal, said control unit comprising:

combustion control means for controlling a combustion state of said engine between a stratified combustion and a uniform premixed combination in accordance with engine operating conditions when said high pressure fuel system is normal, and for fixing the combustion state to said uniform premixed combustion when said high pressure fuel system is abnormal.

9. The system according to claim 8, further comprising a valve provided in a passage by passing said high pressure fuel system and being opened by said pressure reducing means to reduce the pressure in said high pressure fuel system when said high pressure fuel system is abnormal.

10. The system according to claim 8, further comprising an electromagnetic high pressure regulator provided to variably set the pressure of said high pressure fuel and lower the pressure in said high pressure fuel system when said high pressure fuel system is abnormal.

11. The system according to claim 8, wherein said control unit further comprises fuel injection control means for setting, when said high pressure fuel system is abnormal, a fuel injection pulse width longer than that at a normal state of said high pressure fuel system.

12. The system according to claim 11, wherein said fuel injection control means is adapted to apply an upper limit to the fuel injection pulse width when said high pressure fuel system is abnormal.

13. The system according to claim 8, wherein said diagnosing means is adapted to determine an abnormality of said high pressure fuel system when the pressure in said high pressure fuel system does not reach a predetermined level even if a predetermined period of time elapses after the engine start-up.

14. The system according to claim 8, wherein said diagnosing means is adapted to determine an abnormality of said high pressure fuel system when the pressure in said high pressure fuel system exceeds a predetermined level.

15. The system according to claim 8, wherein said diagnosing means is adapted to determine an abnormality of said high pressure fuel system when the fuel injection pulse width continues to exceed a predetermined value for a predetermined period of time under an engine operation at a lean air-fuel ratio.