System and method for safe valve activation in a dynamic skip firing engine

• US 9,175,613 B2
• Filed: 09/16/2014
• Issued: 11/03/2015
• Est. Priority Date: 09/18/2013
• Status: Active Grant

• Current Assignee: Tula Technology, Incorporated
• Original Assignee: Tula Technology, Incorporated
• Inventors: Parsels, John W., Younkins, Matthew A., Chen, Shikui Kevin
• Primary Examiner(s): Low, Lindsay
• Assistant Examiner(s): AMICK, JACOB M
• Application Number:
  US14/487,563
• Publication Number:
  US 20150075458A1
• Time in Patent Office: 413 Days
• US Class Current: 1/1
• CPC Class Codes: F02D 13/06 Cutting-out cylinders
• CPC Class Codes: F02D 17/02 Cutting-out cutting-out engines in multiple engine arrangements F02D25/04
• CPC Class Codes: F02D 2041/001 for engines with variable valve actuation
• CPC Class Codes: F02D 41/0087 Selective cylinder activation, i.e. partial cylinder operation deceleration cut-off F02D41/123
• CPC Class Codes: F02D 41/1498 measuring engine roughness
• CPC Class Codes: F02D 41/22 Safety or indicating devices for abnormal conditions in air/fuel ratio feedback systems F02D41/1495, in electric control linkage F02D11/107, in purge control systems F02M25/0809
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A variety of methods and devices for controlling the operation of the intake and exhaust valves in an internal combustion engine during skip fire operation are described. In various embodiments, an exhaust valve monitor or other suitable mechanism is used to detect exhaust valve actuation faults. When an exhaust valve actuation fault is detected for a particular cylinder, the corresponding intake valve is deactivated (or not activated) in circumstances when it would otherwise be activated in order to prevent the intake valve from opening into a cylinder that contains high pressure combustion gases. The described approach is particularly beneficial when skip fire operation is combined with cylinder deactivation so that air is not pumped through the cylinders during the skipped working cycles.

Claims

1. A method of controlling the operation of an internal combustion engine having at least one cylinder, each cylinder having an associated intake valve and an associated exhaust valve, the method comprising:

directing skip fire operation of the engine;

determining whether an exhaust valve actuation failure has occurred in which the exhaust valve associated with a selected cylinder fails to open properly during a selected working cycle during the skip fire operation of the engine; and

when it is determined that an exhaust valve actuation failure has occurred, deactivating the intake valve associated with the selected cylinder during a subsequent working cycle in which the intake valve would otherwise have been actuated in response to the detection of the exhaust valve actuation failure.

3. A method as recited in claim 1 wherein the exhaust valve actuation failure is detected at least in part based on an analysis of at least one of the rotational speed of the crankshaft, angular acceleration of the crankshaft and angular jerk of the crankshaft.

4. A method as recited in claim 1 wherein the exhaust valve actuation failure is detected at least in part based on an analysis of the output of a proximity sensor that senses movement of the exhaust valve.

5. A method as recited in claim 1 wherein the exhaust valve actuation failure is detected at least in part based on an analysis of at least one selected from the group consisting of:

angular speed, acceleration or jerk of a camshaft that drives the exhaust valve;

electrical properties of gases within the selected cylinder;

the output of an accelerometer, microphone or knock sensor that monitors the engine;

exhaust manifold pressure;

exhaust flow rate; and

exhaust gas oxygen content.

6. A method as recited in claim 1 wherein the subsequent working cycle in which the intake valve would otherwise have been actuated is the working cycle that immediately follows the working cycle for which the exhaust valve actuation failure was detected.

7. A method as recited in claim 1 wherein the subsequent working cycle in which the intake valve would otherwise have been actuated is the second working cycle following the working cycle for which the exhaust valve actuation failure was detected.

8. A method as recited in claim 1 wherein the intake valve associated with the selected cylinder is deactivated during each subsequent working cycle in which the intake valve would otherwise open into a cylinder containing high pressure combustion gases.

12. A method as recited in claim 1 wherein the intake and exhaust valves are deactivated during most skipped working cycles to prevent air from being pumped through the associated cylinders during such skipped working cycles.

2. A method of controlling the intake valve of an internal combustion engine operating in skip fire mode having at least one cylinder, each cylinder having at least one intake valve and one exhaust valve, the method comprising:

operating the engine in a skip fire mode having active working cycles and skipped working cycles, wherein during at least some of the skipped working cycle the associated cylinder is deactivated such that air is not pumped through the associated cylinder during the skipped working cycle; and

during skip fire operation, opening the intake valve associated with each cylinder only after ensuring or verifying that the exhaust valve associated with such cylinder has been opened in a previous working cycle to ensure that the intake valve does not open when the cylinder contains high pressure combustion gases.

9. A method as recited in claim 2 wherein the intake valve is deactivated after each intake event and must be reactivated to initiate a subsequent intake event.

10. A method as recited in claim 9 wherein the intake valve is activated for an active working cycle only after an exhaust actuation event has been detected in association with the immediately previous active working cycle in the associated cylinder to help ensure that the intake valve to not open into a cylinder containing high pressure combustion gases.

11. A method as recited in claim 2 wherein the intake valve is affirmatively deactivated after detection of an exhaust valve actuation failure.

13. A valve control system for use in an internal combustion engine operating in skip fire mode, the engine including a plurality of deactivatable cylinders and a camshaft, each cylinder having an associated intake valve and an associated exhaust valve, the camshaft being arranged to actuate the intake and exhaust valves, wherein for each deactivatable cylinder, the valve control system includes:

a collapsible lifter arranged to activate and deactivate the cylinder by activating and deactivating the intake and exhaust valves associated with the cylinder, the collapsible lifter being hydraulically actuatable;

a solenoid valve arranged to control the application of a high pressure hydraulic fluid to the collapsible lifter;

wherein the solenoid valve and collapsible lifter are arranged to allow opening of the intake valve only after opening of the exhaust valve.

14. A valve control system as recited in claim 13 wherein for each deactivatable cylinder, the activation of the cylinder is prohibited during an associated designated portion of an engine cycle.

15. A valve control system as recited in claim 13 further comprising an exhaust valve motion verification module arranged to detect opening of the exhaust valve to vent combustion gases.

16. A valve control system as recited in claim 15 wherein the exhaust valve motion verification module is required to detect opening of the exhaust valve before activation of the intake valve.

17. A valve control system as recited in claim 15 wherein the exhaust valve motion verification module uses crankshaft rotation speed or time derivatives thereof to detect exhaust valve opening.