System and method for estimating EGR mass flow rates

• US 8,201,442 B2
• Filed: 09/25/2009
• Issued: 06/19/2012
• Est. Priority Date: 09/25/2009
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Osburn, Andrew W., Books, Martin T., Reisinger, Richard E., Sisson, Albert E.
• Primary Examiner(s): MCCALL, ERIC SCOTT
• Application Number:
  US12/567,284
• Publication Number:
  US 20110072911A1
• Time in Patent Office: 998 Days
• Field of Search: 731/143.1, 731/143.2, 731/143.3, 731/143.4, 731/143.7, 731/146.9, 731/147.4, 731/147.6
• US Class Current: 73/114.74
• CPC Class Codes: F02D 2041/0067 Determining the EGR temperature
• CPC Class Codes: F02D 2200/0406 Intake manifold pressure
• CPC Class Codes: F02D 41/0072 Estimating, calculating or determining the EGR rate, amount or flow sensors in EGR systems F02M26/45
• CPC Class Codes: G01F 1/36 the pressure or differential pressure being created by the use of flow constriction
• CPC Class Codes: G01F 1/363 with electrical or electro-mechanical indication G01F1/37 and G01F1/38 take precedence
• CPC Class Codes: G01F 1/40 Details of construction of the flow constriction devices
• CPC Class Codes: G01F 1/88 with differential-pressure measurement to determine the volume flow
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A system and method are provided for estimating an instantaneous EGR mass flow rate corresponding to a flow rate of exhaust gas through an exhaust gas recirculation (EGR) conduit fluidly coupled between an exhaust manifold and an intake manifold of an internal combustion engine with an EGR cooler positioned in-line with the EGR conduit. An operating position of the engine is monitored, and the instantaneous EGR mass flow rate is estimated at each of a plurality of fixed increments of the engine position based on EGR cooler outlet temperature, intake manifold pressure and a pressure differential across a flow restriction disposed in-line with the exhaust gas conduit between the EGR cooler and the intake manifold.

Claims

1. A method of estimating an instantaneous flow rate of exhaust gas through an exhaust gas recirculation (EGR) conduit fluidly coupled between an exhaust manifold and an intake manifold of an internal combustion engine, the EGR conduit including an EGR cooler disposed in-line therewith, the method comprising:

monitoring an operating position of the engine, and

executing the following steps at each of a plurality of fixed increments of the engine position,

sampling an EGR cooler outlet temperature corresponding to a temperature of gas exiting a gas outlet of the EGR cooler,

sampling a pressure differential across a flow restriction disposed in-line with the exhaust gas conduit between the EGR cooler and the intake manifold,

sampling an intake manifold pressure corresponding to fluid pressure within the intake manifold,

estimating the instantaneous mass flow rate of exhaust gas through the EGR conduit based on the sampled pressure differential, the EGR cooler outlet temperature and the intake manifold pressure, and

storing the estimated instantaneous mass flow rate of exhaust gas in a memory unit.

2. The method of claim 1 wherein the fixed increments are selected such that the sampling of the EGR cooler outlet temperature, the pressure differential across the flow restriction and the intake manifold pressure occur at least 8-10 times faster than a firing cycle of the engine.

3. The method of claim 1 further comprising determining an average EGR mass flow rate by averaging a number of values of the estimated instantaneous mass flow rate of exhaust gas through the EGR conduit.

4. The method of claim 3 further comprising storing the average EGR mass flow rate in the memory unit.

5. The method of claim 1 further comprising estimating the instantaneous mass flow rate of exhaust gas through the EGR conduit based on an instantaneous EGR mass flow rate model that includes a number of model constants.

6. The method of claim 5 wherein the instantaneous EGR mass flow rate model is:

EGRFR=[C_D*A_FR*sqrt[(2*Δ

P*IMP/(R*COT)]/sqrt[1−

(A_FR/A_U)²],

where EGRFR is the instantaneous mass flow rate of exhaust gas through the EGR conduit, COT is the EGR cooler outlet temperature, Δ

P is the pressure differential across the flow restriction, IMP is the intake manifold pressure, and C_D, A_FR, R and A_U comprise the number of model constants.

7. The method of claim 6 wherein C_D is a charge density value, A_FR is a cross-sectional flow area of the flow restriction, A_U is a cross-sectional area of the EGR conduit and R is a gas constant.

8. The method of claim 5 wherein the instantaneous EGR mass flow rate model is:

EGRFR=[C_D*A_T*(IMP−

Δ

P)/sqrt(R*COT)]*[Δ

P^1/γ

]*sqrt{[2*γ

/(γ

−

1)]*[1−

Δ

P]<sup>(γ

-1)</sup>},

where EGRFR is the instantaneous mass flow rate of exhaust gas through the EGR conduit, COT is the EGR cooler outlet temperature, Δ

P is the pressure differential across the flow restriction, IMP is the intake manifold pressure, and C_D, A_T, R and γ

comprise the number of model constants.

9. The method of claim 8 wherein C_D is a charge density value, A_T is a cross-sectional flow area of the flow restriction, R is a gas constant and γ

is a ratio of specific heat capacity at constant pressure to specific heat capacity at constant volume for a cylinder charge.

10. A system for estimating an instantaneous flow rate of exhaust gas through an exhaust gas recirculation (EGR) conduit fluidly coupled between an exhaust manifold and an intake manifold of an internal combustion engine, the system comprising:

an EGR cooler disposed in-line with the EGR conduit,

a temperature sensor configured to produce a temperature signal corresponding to a temperature of exhaust gas exiting the EGR cooler,

a flow restriction disposed in-line with the EGR conduit between a gas outlet of the EGR cooler and the intake manifold of the engine,

a differential pressure sensor fluidly configured to produce a differential pressure signal corresponding to a differential pressure across the flow restriction,

a pressure sensor configured to produce a pressure signal corresponding to a pressure within the intake manifold of the engine,

an engine position sensor configured to produce an engine position signal that corresponds to engine position relative to a reference position, and

a control circuit including a memory having instructions stored therein that are executable by the control circuit to monitor the engine position signal and estimate at each of a plurality of fixed increments of the engine position the instantaneous mass flow rate of exhaust gas through the EGR conduit based on the temperature signal, the differential pressure signal and the pressure signal.

11. The system of claim 10 wherein the instructions stored in the memory include instructions that are executable by the control circuit to store the estimated instantaneous mass flow rate in the memory.

12. The system of claim 10 wherein the instructions stored in the memory include instructions that are executable by the control circuit to compute an average EGR mass flow rate value based on a number of most recently estimated values of the instantaneous mass flow rate of exhaust gas through the EGR conduit.

13. The system of claim 12 wherein the instructions stored in the memory include instructions that are executable by the control circuit to store the average EGR mass flow rate value in the memory.

14. The system of claim 10 wherein the differential pressure sensor is configured to sample the pressure differential across the flow restriction at a sampling rate that is at least 8-10 times faster than a firing cycle of the engine over a full range of engine rotational speeds.

15. The system of claim 10 wherein the instructions stored in the memory include instructions that are executable by the control circuit to estimate the instantaneous mass flow rate of exhaust gas through the EGR conduit according to the equation:

EGRFR=[C_D*A_FR*sqrt[(2*Δ

P*IMP/(R*COT)]/sqrt[1−

(A_FR/A_U)²],

where EGRFR is the instantaneous mass flow rate of exhaust gas through the EGR conduit, COT is the EGR cooler outlet temperature, Δ

P is the pressure differential across the flow restriction, IMP is the intake manifold pressure, and C_D, A_FR, R and A_U are constants.

16. The system of claim 15 wherein C_D is a charge density value, A_FR is a cross-sectional flow area of the flow restriction, A_U is a cross-sectional area of the EGR conduit and R is a gas constant, and wherein the constants are stored in the memory unit, and wherein the instructions stored in the memory further include instructions that are executable by the control circuit to retrieve the constants from the memory unit prior to estimating the instantaneous flow rate of exhaust gas through the EGR conduit.

17. The system of claim 10 wherein the instructions stored in the memory include instructions that are executable by the control circuit to estimate the instantaneous mass flow rate of exhaust gas through the EGR conduit according to the equation:

EGRFR=[C_D*A_T*(IMP−

Δ

P)/sqrt(R*COT)]*[Δ

P^1/γ

]*sqrt{[2*γ

/(γ

−

1)]*[1−

Δ

P]<sup>(γ

-1)</sup>},

where EGRFR is the instantaneous mass flow rate of exhaust gas through the EGR conduit, COT is the EGR cooler outlet temperature, Δ

P is the pressure differential across the flow restriction, IMP is the intake manifold pressure, and C_D, A_T, R and γ

are constants.

18. The system of claim 17 wherein C_D is a charge density value, A_T is a cross-sectional flow area of the flow restriction, R is a gas constant, and γ

is a ratio of specific heat capacity at constant pressure to specific heat capacity at constant volume for a cylinder charge, and wherein the constants are stored in the memory unit, and wherein the instructions stored in the memory further include instructions that are executable by the control circuit to retrieve the constants from the memory unit prior to estimating the instantaneous flow rate of exhaust gas through the EGR conduit.