System and method for relieving engine back-pressure by selectively bypassing a stage of a two-stage turbocharger during non-use of EGR

• US 7,000,393 B1
• Filed: 04/14/2005
• Issued: 02/21/2006
• Est. Priority Date: 04/14/2005
• Status: Active Grant

• Current Assignee: International Engine Intellectual Property Company, LLC (Volkswagen AG)
• Original Assignee: International Engine Intellectual Property Company, LLC (Volkswagen AG)
• Inventors: Wood, Terry G., Siuchta, Grzegorz, Terry, Wesley J.
• Primary Examiner(s): Richter, Sheldon J
• Application Number:
  US11/106,994
• Time in Patent Office: 313 Days
• Field of Search: 606/02, 606/052, 606/12, 123/562, 701/100, 701/108
• US Class Current: 60/605.2
• CPC Class Codes: F02B 29/0406 Layout of the intake air cooling or coolant circuit
• CPC Class Codes: F02B 37/004 with exhaust drives arranged in series
• CPC Class Codes: F02B 37/013 with exhaust-driven pumps arranged in series
• CPC Class Codes: F02B 37/18 by bypassing exhaust from the inlet to the outlet of turbine or to the atmosphere
• CPC Class Codes: F02B 47/08 the substances including exhaust gas
• CPC Class Codes: F02D 2041/141 using a feed-forward control element
• CPC Class Codes: F02D 23/00 Controlling engines characterised by their being supercharged
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/0065 Specific aspects of external EGR control constructional details of EGR system F02M26/00
• CPC Class Codes: F02D 41/2422 Selective use of one or more tables
• CPC Class Codes: F02M 26/08 for engines having two or more intake charge compressors or exhaust gas turbines, e.g. a turbocharger combined with an additional compressor
• CPC Class Codes: F02M 26/23 Layout, e.g. schematics
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A valve (50) selectively shunts exhaust gas around a stage (20T) of a turbocharger turbine (20) under control of a control system that selectively renders an EGR system (38) active and inactive and that develops a value for a set-point of operation for the valve. The control system comprises a first map set (60, 142) containing data that the control system uses to the exclusion of data in a second map set (80, 148) to develop the set-point value when the EGR system is active. When the EGR system is inactive, the control system uses the data in the second map set to the exclusion of the data in the first map set to develop the set-point value.

Claims

1. A control system for an internal combustion engine that has an intake system including a turbocharger compressor for developing combustion charge air for the engine, combustion chambers where charge air and fuel are combusted to operate the engine, an exhaust system through which exhaust gas resulting from combustion pass from the combustion chambers, including a turbocharger turbine that uses exhaust gas to operate the turbocharger compressor, an EGR system for recirculating some exhaust gas from the exhaust system to the intake system, and a valve for selectively shunting exhaust gas around a stage of the turbine, the control system comprising:

a processor for processing data to selectively render the EGR system active and inactive and to develop a value for a set-point of operation for the valve defining the extent to which the valve shunts exhaust gas around the turbine stage, a first map set containing set-point data based on the EGR system being active and a second map set containing set-point data based on the EGR system being inactive, wherein the processor processes data selected from the first map set and not from the second map set to develop the set-point value when the EGR system is active, and processes data selected from the second map set and not from the first map set to develop the set-point value when the EGR system is inactive.

2. A control system as set forth in claim 1 wherein the data in both maps sets are measured by a parameter comprising one of exhaust back-pressure, manifold absolute pressure, and manifold gauge pressure, and the control system comprises a closed-loop control that closes a control loop by feedback measured in the same parameter as the parameter in which the map data is measured.

3. A control system as set forth in claim 1 wherein the first map set comprises a first map containing data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, the second map set comprises a second map containing data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, and when the EGR system is active, the processor selects for further processing to develop the set-point value a data value from the first map based on current engine speed and current engine fueling, and when the EGR system is inactive, the processor selects for further processing to develop the set-point value a data value from the second map based on current engine speed and current engine fueling.

4. A control system as set forth in claim 3 wherein the processor processes data to develop a closed-loop control component for control of the valve, and when the EGR system is active, processes the selected data value from the first map as a command input for closed-loop control, and when the EGR system is inactive, processes the selected data value from the second map as a command input for closed-loop control.

5. A control system as set forth in claim 4 wherein the processor also processes data to develop a feed-forward control component for control of the valve, the first map set comprises a third map containing feed-forward data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, the second map set comprises a fourth map containing data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, and when the EGR system is active, the processor selects for further processing to develop the feed-forward control component a data value from the third map based on current engine speed and current engine fueling, and when the EGR system is inactive, the control system selects for further processing to develop the feed-forward control component a data value from the fourth map based on current engine speed and current engine fueling.

6. An internal combustion engine comprising:

an intake system including a turbocharger compressor for developing combustion charge air for the engine;

combustion chambers where charge air and fuel are combusted to operate the engine;

an exhaust system through which exhaust gas resulting from combustion pass from the combustion chambers, including a turbocharger turbine that uses exhaust gas to operate the turbocharger compressor;

an EGR system for recirculating some exhaust gas from the exhaust system to the intake system;

a valve for selectively shunting exhaust gas around a stage of the turbine; and

a control system for selectively rendering the EGR system active and inactive and for developing a value for a set-point of operation for the valve defining the extent to which the valve shunts exhaust gas around the turbine stage, wherein the control system comprises a first map set containing data that the control system uses to the exclusion of data in a second map set to develop the set-point value when the EGR system is active and the control system uses the data in the second map set to the exclusion of the data in the first map set to develop the set-point value when the EGR system is inactive.

7. An engine as set forth in claim 6 wherein the data in both maps sets are measured by a parameter comprising one of exhaust back-pressure, manifold absolute pressure, and manifold gauge pressure, and the control system comprises a closed-loop control that closes a control loop by feedback measured in the same parameter as the parameter in which the map data is measured.

8. An engine as set forth in claim 6 wherein the turbocharger comprises a high-pressure stage in upstream flow relation to a low-pressure stage, and the valve shunts the high-pressure stage.

9. An engine as set forth in claim 6 wherein the first map set comprises a first map containing data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, the second map set comprises a second map containing data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, and when the EGR system is active, the control system selects for further processing to develop the set-point value a data value from the first map based on current engine speed and current engine fueling, and when the EGR system is inactive, the control system selects for further processing to develop the set-point value a data value from the second map based on current engine speed and current engine fueling.

10. An engine as set forth in claim 9 wherein the control system comprises a closed-loop control portion that when the EGR system is active, processes the selected data value from the first map for closed-loop control of the valve, and that when the EGR system is inactive, processes the selected data value from the second map for closed-loop control of the valve.

11. An engine as set forth in claim 10 wherein the control system further comprises a feed-forward control portion coacting with the closed-loop control portion to control the valve, the first map set comprises a third map containing feed-forward data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, the second map set comprises a fourth map containing data values each correlated both with a particular span of engine fueling within a range of engine fueling and with a particular span of engine speed within a range of engine speeds, and when the EGR system is active, the control system selects for further processing to develop a feed-forward component for control of the valve a data value from the third map based on current engine speed and current engine fueling, and when the EGR system is inactive, the control system selects for further processing to develop a feed-forward component for control of the valve a data value from the fourth map based on current engine speed and current engine fueling.

12. A method for control of a turbocharger in an internal combustion engine that has an intake system including a compressor of the turbocharger for developing combustion charge air for the engine, combustion chambers where charge air and fuel are combusted to operate the engine, an exhaust system through which exhaust gas resulting from combustion pass from the combustion chambers, including a turbine of the turbocharger operated by exhaust gas to operate the compressor, an EGR system for recirculating some exhaust gas from the exhaust system to the intake system, and a device for selectively utilizing exhaust gas to operate the turbine, the method comprising:

processing data to selectively render the EGR system active and inactive and to develop a value for a set-point of operation for the turbocharger defining the extent to which exhaust gas is utilized to operate the turbine;

processing data to select from a first map set containing set-point data based on the EGR system being active, a set-point data value correlated with current engine speed and engine load and further processing the selected set-point data value from the first map when the EGR system is active to develop the set-point of operation for the turbocharger; and

processing data to select from a second map set containing set-point data based on the EGR system being inactive, a set-point data value correlated with current engine speed and engine load and further processing the selected set-point data value from the second map when the EGR system is inactive to develop the set-point of operation for the turbocharger.

13. A method as set forth in claim 12 further including using the value for set-point of operation for the turbocharger to set the extent to which a valve shunts exhaust gas flow around a stage of the turbine.

14. A method as set forth in claim 12 further comprising processing data to develop a closed-loop control component for the set-point of operation for the turbocharger, and when the EGR system is active, processing the selected set-point data value from a map of the first map set as a command input for closed-loop control, and when the EGR system is inactive, processing the selected set-point data value from a map of the second map set as a command input for closed-loop control.

15. A method as set forth in claim 14 further comprising processing data to develop a feed-forward control component for the set-point of operation for the turbocharger, and when the EGR system is active, processing a selected data value from a second map of the first map set to develop the feed-forward control component, and when the EGR system is inactive, processing s selected data value from a second map of the second map to develop the feed-forward control component.