Apparatus and method for determining component fault conditions as a function of primary coil voltage in a capacitive discharge ignition system

• US 6,492,818 B1
• Filed: 11/06/2000
• Issued: 12/10/2002
• Est. Priority Date: 11/06/2000
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Downs, Robert A.
• Primary Examiner(s): Le, N.
• Assistant Examiner(s): Deb, Anjan K.
• Application Number:
  US09/707,125
• Time in Patent Office: 764 Days
• Field of Search: 324/382, 324/391, 324/392, 324/399, 324/388, 324/379, 324/380, 340/662, 701/114
• US Class Current: 324/382
• CPC Class Codes: F02D 2041/2051 using voltage control
• CPC Class Codes: F02D 2041/2089 detecting open circuits
• CPC Class Codes: F02D 2041/2093 detecting short circuits
• CPC Class Codes: F02P 17/12 Testing characteristics of the spark, ignition voltage or current testing of sparking plugs H01T13/60
• CPC Class Codes: F02P 3/0838 with semiconductor devices F02P3/0861, F02P3/0884, F02P3/093 take precedence

Abstract

An apparatus for determining component fault conditions associated with a capacitive discharge ignition system for an internal combustion engine includes a number of AC coupling circuits connected to a spark detection circuit, wherein the combination is responsive to a corresponding number of primary coil voltage signals to produce digital pulses indicative of reflected spark events from the various secondary coils to the respective primary coils of the ignition system. A number of level shifting circuits are also included and provide a pulse width circuit with a corresponding number of level-shifted primary coil voltage signals. A pulse width circuit is responsive to the number of level-shifted primary coil voltage signals to produce appropriate digital pulses timed to match the non-zero voltage times of the various primary coil voltage signals. A signal processing circuit is responsive to the digital signals produced by the spark detection circuit and the pulse width circuit to determine spark breakdown voltage, shorted ignition coils, worn ignition plugs, shorted ignition plugs, ignition control module faults and external arcing conditions. These faults are communicated to a service technician via a display and/or by logging such faults in memory.

Claims

1. In a capacitive discharge ignition system for an internal combustion engine, a method of diagnosing ignition system fault conditions comprising the steps of:

measuring a first time difference between an onset of capacitive discharge and occurrence of a reflected spark event in a primary coil voltage of a capacitive discharge ignition system for an internal combustion engine; and

determining at least one ignition system fault condition as a function of said first time difference.

2. The method of claim 1 wherein the determining step includes:

computing a peak spark voltage as a function of said first time difference;

comparing said peak spark voltage to a voltage threshold; and

detecting an indicator of an ignition system fault condition based on a comparison between said peak spark voltage and a voltage threshold.

3. The method of claim 2 wherein the computing step includes computing said peak spark voltage as a function of said first time difference and a characteristic signal rise time of a primary ignition coil of said capacitive discharge ignition system.

4. The method of claim 3 wherein the computing step includes computing said peak spark voltage as an average of peak voltage values over a number of engine cycles.

5. The method of claim 2 wherein the detecting step includes incrementing a fault counter if said peak spark voltage exceeds said voltage threshold.

6. The method of claim 5 wherein the determining step further includes concluding existence of said ignition system fault condition if said fault counter exceeds a count threshold.

7. The method of claim 6 wherein the concluding step includes:

computing a ratio of said fault counter and a current number of engine cycles;

providing said count threshold as a percentage threshold; and

identifying said ignition system fault condition if said ratio exceeds said percentage threshold.

8. The method of claim 7 wherein said identifying step includes displaying said ignition system fault condition.

9. The method of claim 7 wherein said identifying step includes logging said ignition system fault condition.

10. The method of claim 2 wherein said capacitive discharge system includes an ignition plug, and wherein said ignition system fault condition corresponds to a worn condition of said ignition plug.

11. The method of claim 1 wherein the determining step includes:

computing a peak spark voltage as a function of said first time difference for each of a number of cylinders of said engine;

learning a maximum peak spark voltage for one of said engine cylinders;

calculating an average difference between said maximum peak spark voltage and peak spark voltages of remaining ones of said engine cylinders; and

detecting an indicator of an ignition system fault condition based on a comparison between said average difference and a difference threshold.

12. The method of claim 11 wherein the computing step includes computing said peak spark voltage as a function of said first time difference and a characteristic signal rise time of a primary ignition coil of said capacitive discharge ignition system.

13. The method of claim 12 wherein the computing step includes computing said peak spark voltage as an average of peak voltage values over a number of engine cycles.

14. The method of claim 11 wherein the detecting step includes incrementing a fault counter if said difference value exceeds said difference threshold.

15. The method of claim 14 wherein the determining step further includes concluding existence of said ignition system fault condition if said fault counter exceeds a count threshold.

16. The method of claim 15 wherein the concluding step includes:

computing a ratio of said fault counter and a current number of engine cycles;

providing said count threshold as a percentage threshold; and

identifying said ignition system fault condition if said ratio exceeds said percentage threshold.

17. The method of claim 16 wherein said identifying step includes displaying said ignition system fault condition.

18. The method of claim 16 wherein said identifying step includes logging said ignition system fault condition.

19. The method of claim 11 wherein said ignition system fault condition corresponds to an external arc fault.

20. The method of claim 1 further including the step of measuring a second time difference between said onset of capacitive discharge and an end of said capacitive discharge;

and wherein the determining step includes determining said at least one ignition fault condition as a function of said second time difference if said first time difference exceeds said second time difference.

21. The method of claim 20 wherein the determining step includes:

comparing said second time difference with a first time threshold; and

detecting an indicator of a first ignition system fault condition based on said comparison.

22. The method of claim 21 wherein said capacitive discharge ignition system includes an ignition control module (ICM) responsive to a control signal to implement said onset and said end of said capacitive discharge, and wherein said first ignition system fault condition corresponds to a fault condition associated with said ICM.

23. The method of claim 22 wherein the determining step further includes:

comparing said second time difference with a second time threshold, said second time threshold greater than said first time threshold; and

detecting an indicator of a second ignition system fault condition based on said comparison of said second time difference with said first and second time thresholds.

24. The method of claim 23 wherein said capacitive discharge system includes an ignition plug, and wherein said second ignition system fault condition corresponds to an electrically shorted condition of said ignition plug.

25. The method of claim 24 wherein the detecting step includes incrementing a fault counter if said second time difference exceeds said first time threshold but does not exceed said second time threshold.

26. The method of claim 25 wherein the determining step further includes concluding existence of said second ignition system fault condition if said fault counter exceeds a count threshold.

27. The method of claim 26 wherein the concluding step includes:

computing a ratio of said fault counter and a current number of engine cycles;

providing said count threshold as a percentage threshold; and

identifying said second ignition system fault condition if said ratio exceeds said percentage threshold.

28. The method of claim 27 wherein said identifying step includes displaying said second ignition system fault condition.

29. The method of claim 27 wherein said identifying step includes logging said second ignition system fault condition.

30. The method of claim 24 wherein the determining step further includes:

comparing said second time difference with a third time threshold, said third time threshold greater than said second time threshold; and

detecting an indicator of a third ignition system fault condition based on said comparison of said second time difference with said second and third time thresholds.

31. The method of claim 30 wherein said capacitive discharge system includes an ignition coil, and wherein said third ignition system fault condition corresponds to an electrically shorted condition of said ignition coil.

32. The method of claim 31 wherein the detecting step includes incrementing a fault counter if said second time difference exceeds said second time threshold but does not exceed said third time threshold.

33. The method of claim 32 wherein the determining step further includes concluding existence of said third ignition system fault condition if said fault counter exceeds a count threshold.

34. The method of claim 33 wherein the concluding step includes:

computing a ratio of said fault counter and a current number of engine cycles;

providing said count threshold as a percentage threshold; and

identifying said third ignition system fault condition if said ratio exceeds said percentage threshold.

35. The method of claim 34 wherein said identifying step includes displaying said third ignition system fault condition.

36. The method of claim 34 wherein said identifying step includes logging said third ignition system fault condition.

37. The method of claim 31 wherein the determining step further includes detecting an indicator of a fourth ignition system fault condition based on said comparison of said second time difference with said third time threshold.

38. The method of claim 37 wherein said fourth ignition system fault condition corresponds to a worn condition of said ignition plug.

39. The method of claim 38 wherein the detecting step includes incrementing a fault counter if said second time difference exceeds said third time threshold.

40. The method of claim 39 wherein the determining step further includes concluding existence of said fourth ignition system fault condition if said fault counter exceeds a count threshold.

41. The method of claim 40 wherein the concluding step includes:

computing a ratio of said fault counter and a current number of engine cycles;

providing said count threshold as a percentage threshold; and

identifying said fourth ignition system fault condition if said ratio exceeds said percentage threshold.

42. The method of claim 41 wherein said identifying step includes displaying said fourth ignition system fault condition.

43. The method of claim 41 wherein said identifying step includes logging said fourth ignition system fault condition.

44. The method of claim 20 wherein the detecting step includes incrementing a fault counter if said second time difference does not exceed said first time threshold.

45. The method of claim 44 wherein the determining step further includes concluding existence of said first ignition system fault condition if said fault counter exceeds a count threshold.

46. The method of claim 45 wherein the concluding step includes:

computing a ratio of said fault counter and a current number of engine cycles;

providing said count threshold as a percentage threshold; and

identifying said first ignition system fault condition if said ratio exceeds said percentage threshold.

47. The method of claim 46 wherein said identifying step includes displaying said first ignition system fault condition.

48. The method of claim 46 wherein said identifying step includes logging said first ignition system fault condition.

49. The method of claim 46 wherein said capacitive discharge ignition system includes an ignition control module (ICM) responsive to a control signal to implement said onset and said end of said capacitive discharge, and wherein said first ignition system fault condition corresponds to a fault condition associated with said ICM.

50. The method of claim 46 wherein said capacitive discharge system includes an ignition plug, and wherein said first ignition system fault condition corresponds to an electrically shorted condition of said ignition plug.

51. The method of claim 46 wherein said capacitive discharge system includes an ignition coil, and wherein said first ignition system fault condition corresponds to an electrically shorted condition of said ignition coil.

52. Apparatus for determining component fault conditions as a function of primary coil voltage in a capacitive discharge ignition system, comprising:

an ignition coil including a primary coil electrically connected to a capacitor and a secondary coil electrically connected to an ignition plug;

means for discharging said capacitor through said primary coil;

a spark detection circuit responsive to a primary voltage across said primary coil to compute a first time difference between a beginning of discharge of said capacitor and occurrence of a reflected spark event in said primary voltage; and

a processing circuit responsive to said first time difference to determine at least one ignition system fault condition.

53. The apparatus of claim 52 further including a pulse width detection circuit responsive to said primary voltage to compute a second time difference between said beginning of discharge of said capacitor and an end of discharge of said capacitor;

and wherein said processing circuit is further responsive to said second time difference to determine a number of ignition system fault conditions.