Addressing fuel pressure uncertainty during startup of a direct injection engine

• US 7,832,375 B2
• Filed: 11/06/2008
• Issued: 11/16/2010
• Est. Priority Date: 11/06/2008
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Thomas, Joseph Lyle, Surnilla, Gopichandra, Ulrey, Joseph Norman, Pursifull, Ross Dykstra, Dusa, Daniel
• Primary Examiner(s): Moulis; Thomas N
• Application Number:
  US12/266,104
• Publication Number:
  US 20100108035A1
• Time in Patent Office: 740 Days
• Field of Search: 123/179.16, 123/179.17, 123/446, 123/447, 123/497, 123/494
• US Class Current: 123/446
• CPC Class Codes: F02D 2041/223 Diagnosis of fuel pressure sensors
• CPC Class Codes: F02D 2041/227 Limping Home, i.e. taking specific engine control measures at abnormal conditions
• CPC Class Codes: F02D 2200/0602 Fuel pressure
• CPC Class Codes: F02D 2200/0604 Estimation of fuel pressure
• CPC Class Codes: F02D 41/06 for engine starting or warming up F02D41/0255 takes precedence
• CPC Class Codes: F02D 41/3836 Controlling the fuel pressure
• CPC Class Codes: F02D 41/3845 by controlling the flow into the common rail, e.g. the amount of fuel pumped
• CPC Class Codes: F02M 63/0225 Fuel-injection apparatus having a common rail feeding several injectors F02M63/0003 takes precedence; Means for varying pressure in common rails; Pumps feeding common rails

Abstract

An engine system and a method of starting an internal combustion engine of the engine system are described. In one embodiment, the method includes adjusting a fuel pressure within a fuel rail to exceed a pressure of a pressure relief valve. The method may be particularly useful during degradation of a fuel pressure sensor.

Claims

1. A method of starting an internal combustion engine, comprising:

adjusting a fuel pressure within a fuel rail to a first value by operating a high pressure fuel pump to provide pressurized fuel to a high pressure regulation device that exceeds a pressure relief setting of the high pressure regulation device, the high pressure regulation device in fluid communication with the fuel rail;

after the fuel pressure within the fuel rail attains the first value, initiating delivery of fuel to the internal combustion engine from the fuel rail by successively injecting fuel directly into combustion chambers of the internal combustion engine; and

reducing the fuel pressure within the fuel rail from the first value to a second value over subsequent successive fuel injection events after at least a first fuel injection event by adjusting an operating parameter of the high pressure fuel pump.

2. The method of claim 1, where operating the high pressure fuel pump to provide pressurized fuel to the high pressure regulation device that exceeds the pressure relief setting of the high pressure regulation device is performed if a state of a fuel rail pressure sensor is degraded;

and

where the method further comprises, adjusting an operating parameter of the high pressure fuel pump to provide pressurized fuel to the high pressure regulation device that does not exceed the pressure relief setting responsive to feedback from the fuel rail pressure sensor if the state of the fuel rail pressure sensor is non-degraded.

3. The method of claim 1, where the operating parameter includes a pump stroke volume of the high pressure fuel pump, and where adjusting the operating parameter of the high pressure fuel pump includes reducing a pump stroke volume of the high pressure fuel pump.

4. The method of claim 3, where reducing the pump stroke volume of the high pressure fuel pump includes reducing the pump stroke volume to a minimum pump stroke volume of the high pressure fuel pump.

5. The method of claim 1, where operating the high pressure fuel pump to provide pressurized fuel to the high pressure regulation device that exceeds the pressure relief setting of the high pressure regulation device includes setting a pump stroke volume of the high pressure fuel pump to a maximum pump stroke volume.

6. The method of claim 5, where setting the pump stroke volume of the high pressure fuel pump to the maximum pump stroke volume is performed responsive to a lower temperature state of the fuel rail;

and

where the method further comprises, setting the pump stroke volume of the high pressure fuel pump to a lesser pump stroke volume than the maximum pump stroke volume responsive to a higher temperature state of the fuel rail before the delivery of fuel to the internal combustion engine is initiated.

7. The method of claim 1, further comprising, operating a low pressure fuel pump to provide pressurized fuel to a low pressure regulation device that exceeds a pressure relief setting of the low pressure regulation device, the low pressure regulation device in fluid communication with a fuel passage that fluidly couples the low pressure fuel pump to the high pressure fuel pump.

8. The method of claim 7, where the pressure relief setting of the high pressure regulation device corresponds to the first value and the where the pressure relief setting of the low pressure regulation device corresponds to the second value.

9. The method of claim 1, further comprising:

varying a number of pump strokes performed by the high pressure pump before initiating the delivery of fuel to the internal combustion engine responsive to one or more of a temperature of the internal combustion engine and a period of time since the internal combustion engine has been previously shut-off.

10. The method of claim 1, further comprising, varying an amount of fuel that is directly injected into the combustion chambers over one or more of the subsequent successive fuel injection events after the delivery of fuel to the internal combustion engine is initiated to increase an air-fuel ratio of air and fuel charges formed in the combustion chambers relative to an air-fuel ratio of the first fuel injection event.

11. The method of claim 1, where reducing the fuel pressure within the fuel rail from the first value to the second value is performed responsive to degradation of a fuel rail pressure sensor;

and

where the method further comprises adjusting the fuel pressure within the fuel rail after at least the first fuel injection event to a third value that is greater than the second value responsive to a non-degraded state of the fuel rail pressure sensor.

12. The method of claim 11, further comprising limiting performance of the internal combustion engine responsive to degradation of the fuel rail pressure sensor if the fuel pressure is reduced to the second value.

13. An engine system, comprising:

an internal combustion engine including one or more combustion chambers, each of the one or more combustion chambers including a direct fuel injector;

a fuel rail configured to supply fuel to the direct fuel injector of each of the one or more combustion chambers;

a fuel rail pressure sensor configured to provide an indication of a fuel rail pressure;

a fuel tank configured to store fuel;

a fuel passage fluidly coupling the fuel tank to the fuel rail;

a low pressure fuel pump arranged along the fuel passage;

a high pressure fuel pump arranged along the fuel passage between the low pressure fuel pump and the fuel rail;

a high pressure regulation device fluidly coupled with the fuel passage between the high pressure fuel pump and the fuel rail;

a low pressure regulation device fluidly coupled with the fuel passage between the low pressure fuel pump and the fuel tank; and

a control system configured to, before delivering fuel to the internal combustion engine at start-up, assess a state of the fuel rail pressure sensor, and if the fuel rail sensor is in a degraded state, the control system is further configured to;

adjust a fuel rail pressure to a first value by operating the low pressure fuel pump to provide pressurized fuel to the low pressure regulation device that exceeds a pressure relief setting of the low pressure regulation device and by operating the high pressure fuel pump to provide pressurized fuel to the high pressure regulation device that exceeds a pressure relief setting of the high pressure regulation device;

initiate delivery of fuel to the internal combustion engine from the fuel rail by successively injecting fuel directly into the one or more combustion chambers of the internal combustion engine via the one or more direct fuel injectors after the fuel rail pressure attains the first value;

after at least a first fuel injection event, reduce the fuel rail pressure from the first value to a second value over subsequent successive fuel injection events by adjusting an operating parameter of the high pressure fuel pump and by continuing to operate the low pressure fuel pump to provide pressurized fuel to the low pressure regulation device that exceeds a pressure relief setting of the low pressure regulation device.

14. The engine system of claim 13, where the control system is configured to adjust the operating parameter of the high pressure fuel pump by reducing a pump stroke volume of the high pressure fuel pump from a maximum pump stroke volume to a minimum pump stroke volume.

15. The engine system of claim 13, where the control system is further configured to increase an air-fuel ratio of air and fuel charges formed in the one or more combustion chambers over each fuel injection event of the subsequent successive fuel injection events relative to at least the first fuel injection event by varying an amount of fuel that is directly injected into the combustion chambers.

16. The engine system of claim 13, where the control system is configured to operate the high pressure fuel pump at a higher pump stroke volume responsive to a lower temperature state of the fuel rail to provide pressurized fuel to the high pressure regulation device that exceeds a pressure relief setting of the high pressure regulation device before the delivery of the fuel to the internal combustion engine is initiated;

and

where the control system is configured to operate the high pressure fuel pump at a lower pump stroke volume responsive to a higher temperature state of the fuel rail before the delivery of fuel to the internal combustion engine is initiated.

17. A method of starting an internal combustion engine, comprising:

adjusting a fuel pressure within a fuel rail to a first value by operating a high pressure fuel pump at a first pump stroke volume to provide pressurized fuel to a high pressure regulation device that exceeds a pressure relief setting of the high pressure regulation device, the high pressure regulation device in fluid communication with the fuel rail;

initiating delivery of fuel to the internal combustion engine from the fuel rail by successively injecting fuel directly into combustion chambers of the internal combustion engine; and

after at least a first fuel injection event, reducing the fuel pressure within the fuel rail to a reduced value over one or more subsequent successive fuel injection events by operating the high pressure fuel pump at a second pump stroke volume that is less than first pump stroke volume while operating a low pressure fuel pump to provide pressurized fuel to a low pressure regulation device that exceeds a pressure relief setting of the low pressure regulation device, the low pressure regulation device in fluid communication with a fuel passage that fluidly couples the low pressure fuel pump to the high pressure fuel pump.

18. The method of claim 17, further comprising:

increasing an air-fuel ratio of air and fuel charges formed in the combustion chambers over the one or more subsequent successive fuel injection events relative to at least the first fuel injection event by varying an amount of fuel that is directly injected into the combustion chambers responsive to an amount of fuel that was previously delivered to the internal combustion engine from the fuel rail since the delivery of fuel was initiated.

19. The method of claim 17, further comprising, before initiating the delivery of fuel to the internal combustion engine:

adjusting an operating parameter of the high pressure fuel pump responsive to a temperature state of the fuel rail to vary a pressure at which fuel is supplied to the fuel rail via the high pressure fuel pump;

where the operating parameter of the high pressure fuel pump is adjusted to provide a greater pressure increase across the high pressure fuel pump responsive to a lower temperature state of the fuel rail; and

where the operating parameter of the high pressure fuel pump is adjusted to provide a lower pressure increase across the high pressure fuel pump responsive to a higher temperature state of the fuel rail.

20. The method of claim 17, further comprising:

initiating the delivery of fuel to the internal combustion engine after a minimum number of pump strokes are performed by the high pressure fuel pump; and

selecting the minimum number of pump strokes based on one or more of;

a temperature of the internal combustion engine and a period of time since the internal combustion engine was previously shut-off.