Exhaust emission control system for internal combustion engine

• US 6,539,707 B2
• Filed: 10/03/2001
• Issued: 04/01/2003
• Est. Priority Date: 10/03/2000
• Status: Expired due to Fees

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Iida, Hisashi, Yamashita, Yukihiro, Ikemoto, Noriaki, Shimizu, Kouichi
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): TRAN, DIEM T
• Application Number:
  US09/968,837
• Publication Number:
  US 20020038544A1
• Time in Patent Office: 545 Days
• Field of Search: 602/74, 602/76, 602/85, 123/674, 123/679
• US Class Current: 60/285
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F02D 41/123 the fuel injection being cut-off
• CPC Class Codes: F02D 41/1441 Plural sensors
• CPC Class Codes: F02D 41/1456 with sensor output signal being linear or quasi-linear with the concentration of oxygen
• CPC Class Codes: F02D 41/1474 by detecting the commutation time of the sensor
• CPC Class Codes: F02D 41/1483 Proportional component
• CPC Class Codes: F02D 41/1495 Detection of abnormalities in the air/fuel ratio feedback system

Abstract

An upstream catalyst and a downstream catalyst are disposed in series in an exhaust pipe, and first through third sensors for detecting the air-fuel ratio or an adsorption amount of hazardous components on the rich/lean side of exhaust gases are disposed on the upstream and downstream sides of the upstream catalyst and the downstream side of the downstream catalyst, respectively. An ECU for controlling an engine controls the air-fuel ratio so that when the adsorption amount of the hazardous components on the rich side of the downstream catalyst is large, that of the hazardous components on the lean side of the upstream catalyst is large. Similarly, the ECU controls the air-fuel ratio so that when the adsorption amount of the hazardous components on the lean side of the downstream catalyst is large, that of the hazardous components on the rich side of the upstream catalyst is large.

Claims

1. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

an upstream catalyst state detector for detecting or estimating a state of said upstream catalyst;

a downstream catalyst state detector for detecting or estimating a state of said downstream catalyst; and

an air-fuel ratio controller for controlling an air-fuel ratio so that one of the states of said upstream and downstream catalysts is rich and the other of the states of said upstream and downstream catalysts is lean;

wherein at a time of controlling the state of said upstream catalyst to rich or lean in accordance with the state of said downstream catalyst, the air-fuel ratio controller limits a degree of rich/lean of said upstream catalyst to be within a predetermined range so that catalytic conversion efficiency of said upstream catalyst is more than a predetermined value.

2. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of exhaust gases flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gases flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gases flowing from said downstream catalyst;

an air-fuel ratio closed loop controller for setting a target air-fuel ratio based on at least one of an output of said second sensor and an output of said third sensor, and closed loop controlling an air-fuel ratio based on a deviation between the target air-fuel ratio and an output of said first sensor; and

a target air-fuel ratio limiter for limiting the target air-fuel ratio in a predetermined control range, wherein

said target air-fuel ratio limiter shifts the control range based on an output of said second sensor and an output of said third sensor.

3. An exhaust emission control system according to claim 2, wherein at a time of shifting the control range, said target air-fuel ratio limiter sets a change value in accordance with at least one of the output of said second sensor and the output of the third sensor.

4. An exhaust emission control system according to claim 2, further comprising a control gain changer for changing a control gain of a second closed loop control for setting the target air-fuel ratio based on the output of said second sensor and the output of said third sensor.

5. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of exhaust gases flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gases flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gases flowing from said downstream catalyst;

an air-fuel ratio closed loop controller for setting a target air-fuel ratio based on at least one of an output of said second sensor and an output of said third sensor, and closed loop controlling an air-fuel ratio based on a deviation between the target air-fuel ratio and an output of said first sensor; and

a target air-fuel ratio limiter for limiting the target air-fuel ratio in a predetermined control range,

wherein said target air-fuel ratio limiter shifts the control range based on an output of said second sensor and an output of said third sensor;

said target air-fuel ratio limiter changes at least a rich-side limit value of the control range to a limit value having a lower degree of richness when both of the outputs of said second and third sensors are rich, and

the target air-fuel ratio limiter changes at least a lean-side limit value of the control range to a limit value having a lower degree of leanness when both of the outputs of said second and third sensors are lean.

6. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of exhaust gases flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gases flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gases flowing from said downstream catalyst;

an air-fuel ratio closed loop controller for setting a target air-fuel ratio based on at least one of an output of said second sensor and an output of said third sensor, and closed loop controlling the air-fuel ratio based on a deviation between the target air-fuel ratio and the output of said first sensor; and

a control gain changer for changing a control gain of a second closed loop control for setting the target air-fuel ratio based on the outputs of said second and third sensors.

7. An exhaust emission control system according to claim 6, wherein at a time of changing the control gain, said control gain changer sets a change value in accordance with at least one of the output of said second sensor and the output of said third sensor.

8. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of said second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor;

a sensor diagnosing means for determining whether an output of said third sensor is normal or not; and

a fail-safe means, when it is determined by said sensor diagnosing means that the output of said third sensor is not normal, for inhibiting an operation of said downstream-side second closed loop controller and setting the target output of said second sensor to a learn value or a predetermined set value;

wherein even in a case where said third sensor is not abnormal, if a temperature of said third sensor has not increased to an active state, said sensor diagnosing means determines that the output of said third sensor is not normal.

9. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of said second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor;

a sensor diagnosing means for determining whether an output of said third sensor is normal or not; and

a fail-safe means, when it is determined by said sensor diagnosing means that the output of said third sensor is not normal, for inhibiting an operation of said downstream-side second closed loop controller and setting the target output of said second sensor to a learn value or a predetermined set value;

wherein when it is determined by said sensor diagnosing means that the output of said third sensor is not normal, said fail-safe means lowers at least one of a control gain and a control range of a second closed loop control for setting the target output of said first sensor as compared with those in a normal state.

10. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of the second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor;

a sensor diagnosing means for determining whether the output of said second sensor is normal or not; and

a fail-safe means, when it is determined by said sensor diagnosing means that the output of said second sensor is not normal, for inhibiting operations of both said upstream-side and downstream-side second closed loop controller and setting the target output of said first sensor based on an output of said third sensor;

wherein even in a case where said second sensor is not abnormal, if a temperature of said second sensor has not increased to an active state, said sensor diagnosing means determines that the output of said second sensor is not normal.

11. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of the second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor;

a sensor diagnosing means for determining whether the output of said second sensor is normal or not; and

a fail-safe means, when it is determined by said sensor diagnosing means that the output of said second sensor is not normal, for inhibiting operations of both said upstream-side and downstream-side second closed loop controller and setting the target output of said first sensor based on an output of said third sensor;

wherein when it is determined by said sensor diagnosing means that the output of said second sensor is not normal, said fail-safe means lowers at least one of a control gain and a control range of a second closed loop control for setting the target output of said first sensor as compared with those in a normal state.

12. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of said second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor; and

a learning means for learn-correcting the target output of said second sensor based on a deviation between the output of said second sensor and the output of said third sensor.

13. An exhaust emission control system according to claim 12, wherein said learning means compensates deviation of the output characteristics of the second and third sensors due to at least one of manufacture variations and deterioration with time.

14. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of said second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor; and

a learning means for learn-correcting the target output of said second sensor based on a deviation between the output of said second sensor and the output of said third sensor;

wherein said learning means averages the output of said second sensor and the output of said third sensor respectively, and

said learning means learn-corrects the target output of said second sensor based on a deviation between an averaged value of the outputs of said second sensor and an averaged value of the outputs of said third sensor.

15. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of said second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor; and

a learning means for learn-correcting the target output of said second sensor based on a deviation between the output of said second sensor and the output of said third sensor;

wherein said leaning means learns a learn correction amount on a rich side and a learn correction amount on a lean side, independently.

16. An exhaust emission control system according to claim 15, wherein said learning means makes at least one of an updating speed and an updating amount of the learn correction amount on the rich side different from at least one of an updating speed and an updating amount of the learn correction amount on the lean side.

17. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of said second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor; and

a learning means for learn-correcting the target output of said second sensor based on a deviation between the output of said second sensor and the output of said third sensor;

wherein said learning means limits the learn correction amount to be within a predetermined range.

18. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

a downstream-side second closed loop controller for setting a target output of said second sensor based on an output of said third sensor;

an upstream-side second closed loop controller for setting a target output of said first sensor based on a deviation between an output of said second sensor and the target output of said second sensor;

an air-fuel ratio closed loop controller for closed loop controlling an air-fuel ratio based on a deviation between an output of said first sensor and the target output of said first sensor; and

a learning means for learn-correcting the target output of said second sensor based on a deviation between the output of said second sensor and the output of said third sensor;

a learning inhibiting means for inhibiting learning correction by said learning means when an intake air volume is smaller than a predetermined value.

19. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

a first sensor for detecting an air-fuel ratio or a rich/lean state of an exhaust gas flowing into said upstream catalyst;

a second sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said upstream catalyst;

a third sensor for detecting an air-fuel ratio or a rich/lean state of the exhaust gas flowing from said downstream catalyst;

an air-fuel ratio closed loop controlling means for setting a target air-fuel ratio based on at least one of an output of said second sensor and an output of said third sensor, and closed loop controlling an air-fuel ratio based on a deviation between the target air-fuel ratio and an output of said first sensor; and

a rich-side control means for performing a rich-side control for setting the air-fuel ratio temporarily to a rich side when it is estimated that a lean-side component adsorption amount at least one of said upstream catalyst and said downstream catalyst is more than a predetermined amount, wherein

said rich-side control means changes a degree of richness in the air-fuel ratio based on at least one of an output of said second sensor and an output of said third sensor during the rich-side control.

20. An exhaust emission control system according to claim 19, wherein said rich-side control means changes the degree of richness in the air-fuel ratio in accordance with the output of said second sensor and determines a timing of finishing the rich-side control based on the output of said third sensor.

21. An exhaust emission control system according to claim 19, wherein said rich-side control means switches a sensor to be used for the rich-side control in accordance with operating conditions of said internal combustion engine.

22. An exhaust emission control system for an internal combustion engine, comprising:

an upstream catalyst disposed in an exhaust passage;

a downstream catalyst disposed in said exhaust passage, said downstream catalyst disposed at a downstream of and in series with said upstream catalyst;

an upstream catalyst state detecting means for detecting or estimating a state of said upstream catalyst;

a downstream catalyst state detecting means for detecting or estimating a state of said downstream catalyst; and

an air-fuel ratio controlling means for controlling an air-fuel ratio, wherein

when the state of said downstream catalyst is richer than an air-fuel ratio where a catalytic conversion efficiency of said downstream catalyst is maximum, said air-fuel ratio controlling means controls the air-fuel ratio such that the state of said upstream catalyst is leaner than an air-fuel ratio where a catalytic conversion efficiency of said upstream catalyst is maximum, and

when the state of said downstream catalyst is leaner than the air-fuel ratio where the catalytic conversion efficiency of said downstream catalyst is maximum, said air-fuel ratio controlling means controls the air-fuel ratio such that the state of said upstream catalyst is richer than the air-fuel ratio where the catalytic conversion efficiency of said upstream catalyst is maximum.