Catalyst monitoring in a diesel engine

• US 6,502,386 B1
• Filed: 08/02/2000
• Issued: 01/07/2003
• Est. Priority Date: 08/02/2000
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Laing, Paul Matthew, Adams, Karen M, Hammerle, Robert Henry, Mazur, Christopher John
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): TRAN, DIEM T
• Application Number:
  US09/631,135
• Time in Patent Office: 888 Days
• Field of Search: 602/74, 602/77, 602/85, 602/76
• US Class Current: 60/277
• 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 11/005 the temperature or pressure being estimated, e.g. by means of a theoretical model
• CPC Class Codes: F01N 2550/02 Catalytic activity of catalytic converters
• CPC Class Codes: F01N 9/005 using models instead of sensors to determine operating characteristics of exhaust systems, e.g. calculating catalyst temperature instead of measuring it directly
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A carbon monoxide sensor placed downstream of the catalytic converter and a temperature sensor placed upstream of the converter in a diesel engine provide information to build a real time CO conversion efficiency versus catalyst temperature curve to determine whether a catalyst has deteriorated beyond a predetermined point with respect to On-Board Diagnostic (OBD) requirements. Pre catalyst CO concentration is inferred from the engine operating conditions, and catalyst temperature is determined using the temperature sensor output and the engine exhaust flow heat transfer model. The real time curve is compared to a reference curve to determine catalyst performance. Catalyst performance with respect to CO conversions can then be correlated to that for HC and NO_x to meet OBD requirements.

Claims

1. A method for monitoring a performance of a catalytic converter, comprising:

determining a conversion efficiency of the catalytic converter based on an amount of a carbon and oxygen carrying component in an exhaust gas mixture entering the converter and on an amount of said carbon and oxygen carrying component in an exhaust gas mixture exiting the converter;

generating a first measure of the catalytic converter performance based on not less than two of said conversion efficiency calculations performed at different operating temperatures of the converter, such temperatures extending to a predetermined temperature, such predetermined temperature being a temperature where the conversion efficiency for an aged catalytic converter and a new catalytic converter are substantially the same; and

comparing said first measure to a second measure indicative of a threshold performance of the catalytic converter.

2. The method as set forth in claim 1 wherein said catalytic converter is coupled to a diesel engine.

3. The method as set forth in claim 2 wherein said carbon and oxygen carrying exhaust gas component is a carbon monoxide.

4. The method as set forth in claim 3 wherein said amount of carbon and oxygen carrying component of said exhaust gas mixture entering the converter is estimated based on operating conditions.

5. The method as set forth in claim 4 wherein estimation is based on engine speed and engine load.

6. The method as set forth in claim 1 wherein said amount of carbon and oxygen carrying component of said exhaust gas mixture entering the converter is determined based on an output of a sensor coupled upstream of the converter.

7. The method as set forth in claim 1 wherein said amount of carbon and oxygen carrying component of said exhaust gas mixture exiting the converter is determined based on an output of a sensor coupled downstream of the converter.

8. The method as set forth in claim 1 wherein said conversion efficiency is calculated as a ratio of a difference between said amount of said carbon and oxygen carrying component in said exhaust gas mixture entering the converter and said amount of said carbon and oxygen carrying component in said exhaust gas mixture exiting the converter, and said amount of said carbon and oxygen carrying component in said exhaust gas mixture entering the converter.

9. The method as set forth in claim 1 further comprising indicating that the performance of the catalytic converter is degraded based on a result of said comparing of said first measure to said second measure.

10. The method as set forth in claim 9 further comprising setting a diagnostic code in response to said indicating.

11. The method as set forth in claim 10 further comprising lighting an indicator light if said diagnostic code is set.

12. A system for monitoring a performance of a catalytic converter, the system comprising:

a diesel engine having the converter disposed in its exhaust passage;

a sensor coupled downstream of the converter, said sensor providing a signal indicative of an amount of carbon monoxide in an exhaust gas mixture exiting the catalytic converter; and

a controller estimating an amount of carbon monoxide in an exhaust gas mixture entering the catalytic converter, and performing at least two calculations of a catalytic converter efficiency based on said estimating and said sensor signal, said calculations performed at different operating temperatures of the converter, such temperatures extending to a predetermined temperature, such predetermined temperature being a temperature where the conversion efficiency for an aged catalytic converter and a new catalytic converter are substantially the same.

13. The system as set forth in claim 12 wherein said controller further compares said calculations to a set of predetermined values indicative of threshold catalytic converter efficiencies at said operating temperatures.

14. The system as set forth in claim 13 wherein said controller further provides an indication of a converter degradation based on a result of said comparing.

15. The system as set forth in claim 12 wherein said controller estimates said carbon monoxide amount based on engine speed and engine load.

16. A system for monitoring a performance of a catalytic converter, the system comprising:

a diesel engine having the catalytic converter coupled downstream;

a sensor coupled upstream of the converter, said sensor providing a first signal indicative of a concentration of carbon monoxide in an exhaust gas mixture entering the catalytic converter;

a sensor coupled downstream of the converter, said sensor providing a second signal indicative of a concentration of carbon monoxide in an exhaust gas mixture exiting the catalytic converter; and

a controller for calculating a catalyst conversion efficiency based on said first and said second signals and;

wherein said controller further generates a measure of converter performance based on not less than two said efficiency calculations performed at different operating temperatures of the converter, such temperatures extending to a predetermined temperature, such predetermined temperature being a temperature where the conversion efficiency for an aged catalytic converter and a new catalytic converter are substantially the same.

17. The system as set forth in claim 16 wherein said controller further provides an indication of converter degradation based on a comparison of said measure of converter performance and a baseline measure of converter performance.

18. The system as set forth in claim 17 wherein said controller further sets a diagnostic code in response to said indication.