Method and apparatus for controlling micro pilot fuel injection to minimize NOxand UHC emissions

• US 7,007,661 B2
• Filed: 01/27/2004
• Issued: 03/07/2006
• Est. Priority Date: 01/27/2004
• Status: Active Grant

• Current Assignee: Woodward Governor Company
• Original Assignee: Woodward Governor Company
• Inventors: Warlick, Tim
• Primary Examiner(s): Yuen, Henry C.
• Assistant Examiner(s): Benton, Jason
• Application Number:
  US10/765,803
• Publication Number:
  US 20050161017A1
• Time in Patent Office: 770 Days
• Field of Search: 123/276.E, 123/526, 123/525, 123/299, 123/27.R
• US Class Current: 123/27.0GE
• CPC Class Codes: F02D 19/061 by controlling fuel injectors
• CPC Class Codes: F02D 19/0631 by estimation, i.e. without using direct measurements of a corresponding sensor
• CPC Class Codes: F02D 19/10 peculiar to compression-ignition engines in which the main fuel is gaseous
• CPC Class Codes: F02D 2200/1015 Engines misfires
• CPC Class Codes: F02D 35/021 using an ionic current sensor
• CPC Class Codes: F02D 35/023 by determining the cylinder pressure
• CPC Class Codes: F02D 35/027 using knock sensors
• CPC Class Codes: F02D 35/028 by determining the combustion timing or phasing
• CPC Class Codes: F02D 41/0025 Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures
• CPC Class Codes: F02D 41/0027 the fuel being gaseous non-electrical control F02D19/02
• CPC Class Codes: F02D 41/403 with pilot injections
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

The present invention provides a system that controls the amount and timing of pilot fuel injection to obtain minimum NO_x and UHC emissions. The system senses if combustion occurs, when combustion occurs, and/or the quality of combustion in the combustion chamber of each cylinder of the gaseous fuel engine and adjusts the amount and/or timing of the pilot fuel injected. The minimum amount of pilot fuel needed to ignite gaseous fuel in a combustion chamber is determined and injected into the prechamber or the combustion chamber of the engine. The actual start of combustion location is determined and the injection timing is adjusted if the start of combustion location is not approximately equal to a desired location. The amount of pilot fuel or injection timing is adjusted if a knock or a misfire has occurred or if the combustion quality measure is not approximately equal to a desired quality measure.

Claims

1. A method to minimize NOx and UHC emissions in a pilot fuel ignited gaseous fuel engine comprising the steps:

determining a minimum amount of pilot fuel needed to ignite gaseous fuel in a combustion chamber;

injecting the pilot fuel into at least one of a prechamber and the combustion chamber;

determining a start of combustion location from one of an ionization signal and a cylinder pressure of the combustion chamber;

comparing the start of combustion location to a desired start of combustion location; and

adjusting a pilot fuel injection timing if the start of combustion location is not approximately equal to the desired start of combustion location.

2. The method of claim 1 further comprising the step of measuring at least one of the ionization signal and the cylinder pressure of the combustion chamber.

3. The method of claim 1 wherein the pilot fuel is one of diesel fuel and engine oil.

4. The method of claim 1 further comprising the step of determining the desired start of combustion location.

5. The method of claim 1 further comprising the step of determining a pilot fuel injection timing.

6. The method of claim 5 wherein the step of determining the pilot fuel injection timing comprises determining the pilot fuel injection timing as a function of air/fuel ratio, engine speed, knock level, and exhaust gas oxygen concentration level.

7. The method of claim 1 further comprising the step of measuring the one of the ionization signal and the cylinder pressure.

8. The method of claim 1 further comprising the step of adjusting one of the pilot fuel amount and a pilot fuel injection timing if a misfire has occurred.

9. The method of claim 1 further comprising the step of adjusting one of the pilot fuel amount and a pilot fuel injection timing if a knock has occurred.

10. The method of claim 1 further comprising the steps of:

comparing a combustion quality measure to a desired value; and

adjusting the pilot fuel amount if the combustion quality measure is not approximately equal to the desired value.

11. A pilot fuel injection system controller comprising:

means for determining a minimum amount of pilot fuel needed to initiate combustion of gaseous fuel in a combustion chamber;

means for controlling a pilot fuel injector to inject the pilot fuel into at least one of a prechamber and the combustion chamber;

means for determining a start of combustion location from one of an ionization signal and a cylinder pressure;

means for comparing the start of combustion location to a desired start of combustion location; and

means for adjusting a pilot fuel injection timing if the start of combustion location is not approximately equal to the desired start of combustion location.

12. The pilot fuel injection system controller of claim 11 further comprising means for adjusting at least one of the pilot fuel amount and a pilot fuel injection timing if at least one of a knock has occurred and a misfire has occurred.

13. The pilot fuel injection system controller of claim 11 further comprising means for comparing a combustion quality measure to a desired value and adjusting the pilot fuel amount if the combustion quality measure is not approximately equal to the desired value.

14. A natural gas combustion engine comprising:

at least one cylinder having a combustion chamber;

a pilot fuel injector system comprising;

a pilot fuel injector in communication with the combustion chamber;

a controller for controlling the pilot fuel injector to minimize NOx and UHC emissions, the controller including

means for determining a minimum amount of pilot fuel needed to initiate combustion of gaseous fuel in a combustion chamber;

means for controlling a pilot fuel injector to inject the pilot fuel into at least one of a prechamber and the combustion chamber;

means for determining a start of combustion location from one of an ionization signal and a cylinder pressure;

means for comparing the start of combustion location to a desired start of combustion location; and

means for adjusting a pilot fuel injection timing if the start of combustion location is not approximately equal to the desired start of combustion location.

15. The natural gas combustion engine of claim 14 wherein the controller further comprises means for adjusting the pilot fuel amount if at least one of a knock has occurred and a misfire has occurred.

16. The natural gas combustion engine of claim 14 wherein the controller further comprises means for adjusting a pilot fuel injection timing if at least one of a knock has occurred and a misfire has occurred.

17. The natural gas combustion engine of claim 14 wherein the controller further comprises means for adjusting the pilot fuel amount if the combustion quality measure is not approximately equal to a desired combustion quality.