Direct-injection spark ignition engine

• US 6,672,277 B2
• Filed: 11/29/2001
• Issued: 01/06/2004
• Est. Priority Date: 03/29/2000
• Status: Expired due to Fees

• Current Assignee: Mazda Motor Corporation
• Original Assignee: Mazda Motor Corporation
• Inventors: Matsumoto, Masakazu, Seto, Masatoshi, Araki, Keiji, Saito, Fumihiko, Ohta, Noriyuki, Yasuoka, Takehiko, Yamashita, Hiroyuki
• Primary Examiner(s): Gimie, Mahmoud
• Application Number:
  US09/995,972
• Publication Number:
  US 20020078919A1
• Time in Patent Office: 768 Days
• Field of Search: 123/295, 123/301, 123/302, 123/305, 123/306, 123/308, 123/430
• US Class Current: 123/295
• CPC Class Codes: F02B 17/005 having direct injection in the combustion chamber
• CPC Class Codes: F02B 2023/106 Tumble flow, i.e. the axis of rotation of the main charge flow motion is horizontal
• CPC Class Codes: F02B 2075/125 Direct injection in the combustion chamber for spark ignition engines, i.e. not in pre-combustion chamber
• CPC Class Codes: F02B 2275/48 Tumble motion in gas movement in cylinder
• CPC Class Codes: F02B 23/104 the injector being placed on a side position of the cylinder
• CPC Class Codes: F02B 31/085 having two inlet valves
• CPC Class Codes: F02D 13/0219 by shifting the phase, i.e. the opening periods of the valves are constant
• CPC Class Codes: F02D 13/0249 changing the valve timing only
• CPC Class Codes: F02D 13/0261 Controlling the valve overlap
• CPC Class Codes: F02D 2041/389 for injecting directly into the cylinder
• CPC Class Codes: F02D 41/3023 a mode being the stratified charge spark-ignited mode
• CPC Class Codes: F02D 41/401 Controlling injection timing F02D41/402 takes precedence
• CPC Class Codes: F02F 1/4214 specially adapted for four or more valves per cylinder
• CPC Class Codes: F02F 2001/245 the valve stems being orientated at an angle with the cylinder axis
• CPC Class Codes: F02P 5/045 combined with electronic control of other engine functions, e.g. fuel injection in general F02D37/02
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

During stratified-charge combustion operation of a direct-injection spark ignition engine, at the cylinder compression stroke, a tumble is generated which flows between a spark plug electrode and a piston crown surface toward an injector. A fuel is injected from the injector in correspondence with the cylinder ignition timing by controlling the penetration of fuel spray from the injector to correspond to the tumble flow rate so that the fuel spray may go against the tumble, become a flammable mixture at the cylinder ignition timing and stay near the spark plug electrode. In the late stage of the compression stroke, diffusion of the flammable mixture is suppressed with squishes. Thus, fuel spray behavior in the combustion chamber is controlled to allow suitable mixture stratification over a wide engine operating condition range. This improves combustion quality and extends a stratified-charge combustion zone thereby providing enhanced fuel economy and power output.

Claims

1. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, said engine comprising:

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for causing the fuel injection nozzle to inject the fuel in correspondence with an ignition timing for the cylinder so that fuel spray from the fuel injection nozzle goes against the tumble and stays in the vicinity of the electrode of the spark plug in the form of a flammable mixture at the time of ignition of the spark plug;

wherein the fuel injection control means controls penetration of fuel spray through the fuel injection nozzle in accordance with the flow rate of the tumble opposed to the fuel spray.

2. The direct-injection spark ignition engine of claim 1, wherein the electrode of the spark plug is disposed closer to the crown surface of the piston than to the nozzle hole of the fuel injection nozzle when viewed in a direction orthogonal to the center line of the cylinder.

3. The direct-injection spark ignition engine of claim 1, wherein the spray cone angle of fuel spray from the fuel injection nozzle during the compression stroke of the cylinder is at a value within the range of approximately 20°

to 60°

.

4. The direct-injection spark ignition engine of claim 1, wherein the fuel injection nozzle is disposed so that the fuel spray impinges substantially oppositely against the tumble flowing along the crown surface of the piston during the compression stroke of the cylinder.

5. The direct-injection spark ignition engine of claim 1, wherein

the crown surface of the piston is formed with a cavity longer in a direction in which the center line of fuel spray extends when viewed along the center line of the cylinder, and

the cavity has such a form that maximizes the distance thereof along the center line of the cylinder from the ceiling of the combustion chamber at the position corresponding to the center line of the cylinder.

6. The direct-injection spark ignition engine of claim 1, wherein the fuel injection control means controls the penetration of fuel spray from the fuel injection nozzle in accordance with the revolving speed of a crank shaft.

7. The direct-injection spark ignition engine of claim 1, wherein

injection pressure regulating means is provided for regulating the fuel injection pressure of the fuel injection nozzle, and

the fuel injection control means is arranged to cause the injection pressure regulating means to increase the fuel injection pressure in increasing the penetration of the fuel spray and to decrease the fuel injection pressure in decreasing the penetration of the fuel spray.

8. The direct-injection spark ignition engine of claim 7, wherein the fuel injection control means is arranged to correctively control the operation of the injection pressure regulating means in accordance with the temperature conditions of the combustion chamber so that the fuel injection pressure becomes larger as the temperature of the combustion chamber is increased even if the fuel injection quantity and the revolving speed of the crank shaft are substantially constant.

9. The direct-injection spark ignition engine of claim 1, wherein the fuel injection nozzle is provided with a variable spray angle mechanism for adjusting the spray cone angle of fuel spray, and the fuel injection control means is arranged to cause the variable spray angle mechanism to decrease the spray cone angle of fuel spray in increasing the penetration of fuel spray and to increase the spray cone angle of fuel spray in decreasing the penetration of fuel spray.

10. The direct-injection spark ignition engine of claim 1, wherein

the fuel injection control means is arranged to increase the penetration of fuel spray through the fuel injection nozzle to correspond to rise in the revolving speed of the crank shaft until the revolving speed of the crank shaft reaches a predetermined value and suppress increase of the penetration when the revolving speed of the crank shaft reaches or exceeds the predetermined value, and

the engine further comprises:

variable tumble means for making the flow rate of the tumble variable; and

tumble control means for operating the variable tumble means to suppress increase in the flow rate of the tumble which corresponds to increase in the revolving speed of the crank shaft when the revolving speed of the crank shaft reaches or exceeds the predetermined value.

11. The direct-injection spark ignition engine of claim 10, wherein the variable tumble means comprises an intake airflow control valve for changing the flowing conditions of the intake air flowing into the combustion chamber.

12. The direct-injection spark ignition engine of claim 10, wherein the variable tumble means is a variable valve timing mechanism for changing the valve timing of at least one of intake and exhaust valves.

13. The direct-injection spark ignition engine of claim 10, wherein the tumble control means correctively controls the operation of the variable tumble means in accordance with the temperature conditions of the combustion chamber so that the flow rate of the tumble is lower as the temperature of the combustion chamber is higher even if the fuel injection quantity and the revolving speed of the crank shaft is substantially constant.

14. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, wherein

the spark plug is disposed so that the electrode thereof protrudes from the ceiling of the combustion chamber in a direction parallel to the center line of the cylinder and the distance e between the ceiling of the combustion chamber and the electrode thereof has a value satisfying the relationship of e≧

0.4d where d is the distance on the center line of the cylinder between the ceiling of the combustion chamber and the crown surface of the piston when the cylinder is at the top dead center during the compression stroke thereof,

the fuel injection nozzle is disposed so that the spray cone angle of fuel spray therefrom has a value within the range of approximately 20°

to 60° and

the center line of fuel spray therefrom has a tilt angle within the range of approximately 25°

to 40°

with respect to an assumed plane orthogonal to the center line of the cylinder, and

the engine comprises;

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for controlling penetration of fuel spray through the fuel injection nozzle in accordance with the flow rate of the tumble and causing the fuel injection nozzle to inject fuel against the tumble.

15. The direct-injection spark ignition engine of claim 14, characterized by further comprising:

variable tumble means for making the flow rate of the tumble variable; and

tumble control means for operating the variable tumble means so that a tumble ratio during the compression stroke of the cylinder falls within the range of approximately 1.1 to 2.3.

16. The direct-injection spark ignition engine of claim 14, wherein

the engine further comprises injection pressure regulating means for regulating the fuel injection pressure of the fuel injection nozzle, and

the fuel injection control means controls the operation of the injection pressure regulating means so that the fuel injection pressure falls within the range of approximately 3 MPa to 13 MPa.

17. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, said engine comprising:

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for causing the fuel injection nozzle to inject the fuel in correspondence with an ignition timing for the cylinder so that fuel spray from the fuel injection nozzle goes against the tumble and stays in the vicinity of the electrode of the spark plug in the form of a flammable mixture at the time of ignition of the spark plug;

wherein the electrode of the spark plug protrudes from the ceiling of the combustion chamber in a direction parallel to the center line of the cylinder, and

the distance e between the ceiling of the combustion chamber and the electrode of the spark plug is set at a value satisfying the relationship of e≧

0.4d where d is the distance on the center line of the cylinder between the ceiling of the combustion chamber and the crown surface of the piston when the cylinder is at the top dead center during the compression stroke thereof.

18. The direct-injection spark ignition engine of claim 17, wherein the distance e between the ceiling of the combustion chamber and the electrode of the spark plug is set at a value satisfying the relationship of e≧

0.2d where d is the distance on the center line of the cylinder between the ceiling of the combustion chamber and the crown surface of the piston when the cylinder is at a 55°

crank angle before the top dead center during the compression stroke thereof.

19. The direct-injection spark ignition engine of claim 17, wherein the electrode of the spark plug is disposed closer to the ceiling of the combustion chamber than to the crown surface of the piston, when viewed along the center line of a geometrical area of fuel spray from the fuel injection nozzle during the compression stroke of the cylinder, with respect to the center line of fuel spray.

20. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, said engine comprising:

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for causing the fuel injection nozzle to inject the fuel in correspondence with an ignition timing for the cylinder so that fuel spray from the fuel injection nozzle goes against the tumble and stays in the vicinity of the electrode of the spark plug in the form of a flammable mixture at the time of ignition of the spark plug

wherein the crown surface of the piston is formed with a cavity longer in a direction in which the center line of fuel spray extends when viewed along the center line of the cylinder with, the deepest portion of the cavity is positioned in correspondence with the center line of the cylinder and

the cavity has such a form that maximizes the distance thereof along the center line of the cylinder from the ceiling of the combustion chamber at the position corresponding to the center line of the cylinder.

21. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, said engine comprising:

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for causing the fuel injection nozzle to inject the fuel in correspondence with an ignition timing for the cylinder so that fuel spray from the fuel injection nozzle goes against the tumble and stays in the vicinity of the electrode of the spark plug in the form of a flammable mixture at the time of ignition of the spark plug

wherein the crown surface of the piston is formed with a cavity longer in a direction in which the center line of fuel spray extends when viewed along the center line of the cylinder with the deepest portion of the cavity is positioned closer to an intake side than the position corresponding to the center line of the cylinder.

22. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, said engine comprising:

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for causing the fuel injection nozzle to inject the fuel in correspondence with an ignition timing for the cylinder so that fuel spray from the fuel injection nozzle goes against the tumble and stays in the vicinity of the electrode of the spark plug in the form of a flammable mixture at the time of ignition of the spark plug;

the crown surface of the piston is formed with a cavity that accommodates the electrode of the spark plug when viewed along the center line of the cylinder, and

squish area sections each for generating a squish flowing toward the inside of the cavity in cooperation with the opposed ceiling of the combustion chamber are formed in an outer portion of the crown surface of the piston, located outside of the cavity, at least both lateral locations thereof from the electrode of the spark plug with respect to the center line of the fuel spray when viewed along the center line of the cylinder.

23. The direct-injection spark ignition engine of claim 22, wherein the opening width of the cavity in the lateral direction when viewed along the center line of the cylinder is maximized in the vicinity of the electrode of the spark plug.

24. The direct-injection spark ignition engine of claim 23, wherein the opening width of the cavity in the lateral direction in the vicinity of the electrode of the spark plug when viewed along the center line of the cylinder is set to include a geometrical area of fuel spray from the fuel injection nozzle during the compression stroke of the cylinder.

25. The direct-injection spark ignition engine of claim 23, wherein

the ceiling of the combustion chamber is formed with a pair of intake ports, and

the opening width of the cavity in the lateral direction in the vicinity of the electrode of the spark plug when viewed along the center line of the cylinder is equal to or more than the center distance between the pair of intake ports.

26. The direct-injection spark ignition engine of claim 22, wherein the squish area sections are provided in the outer portion of the crown surface of the piston to continue from both the lateral locations thereof, which interpose the electrode of the spark plug therebetween, toward the exhaust side.

27. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, said engine comprising:

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for causing the fuel injection nozzle to inject the fuel in correspondence with an ignition timing for the cylinder so that fuel spray from the fuel injection nozzle goes against the tumble and stays in the vicinity of the electrode of the spark plug in the form of a flammable mixture at the time of ignition of the spark plug;

wherein the crown surface of the piston is formed with a squish area section for generating squishes in cooperation with the ceiling of the combustion chamber so that a layer of the flammable mixture residing in the vicinity of the electrode of the spark plug takes on a diametrically diminished form on the side closer to the ceiling of the combustion chamber when viewed along the center line of the fuel spray.

28. The direct-injection spark ignition engine of claim 27, wherein

the crown surface of the piston is formed with a cavity so as to accommodate the electrode of the spark plug and the layer of flammable mixture residing in the vicinity of the electrode of the spark plug when viewed along the center line of the cylinder, and

the squishes act to suppress diffusion of the layer of flammable mixture so that the profile of the layer of flammable mixture is spaced apart from the side walls of the cavity and has a larger distance from each of the side walls as it approaches the ceiling of the combustion chamber.

29. A direct-injection spark ignition engine in which a spark plug is disposed in a cylinder at a ceiling of a combustion chamber opposed to a crown surface of a piston, a fuel injection nozzle is disposed in the combustion chamber to inject a fuel from a peripheral portion of the combustion chamber, and the fuel injected from the fuel injection nozzle is stratified around an electrode of the spark plug during stratified-charge combustion operation, said engine comprising:

tumble generating means capable of generating a tumble which flows between the electrode of the spark plug and the crown surface of the piston toward the fuel injection nozzle during a compression stroke of the cylinder; and

fuel injection control means for causing the fuel injection nozzle to inject the fuel in correspondence with an ignition timing for the cylinder so that fuel spray from the fuel injection nozzle goes against the tumble and stays in the vicinity of the electrode of the spark plug in the form of a flammable mixture at the time of ignition of the spark plug;

wherein the electrode of the spark plug is disposed at the midpoint between a first partial flow of the tumble flowing along the crown surface of the piston and a second partial flow of the tumble flowing along the ceiling of the combustion chamber at a certain point after the start timing of fuel injection during the compression stroke of the cylinder and before the ignition timing for the cylinder.