Crankcase integrity breach detection

• US 9,416,694 B2
• Filed: 09/14/2012
• Issued: 08/16/2016
• Est. Priority Date: 09/14/2012
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Jentz, Robert Roy, Rollinger, John Eric, Pursifull, Ross Dykstra
• Primary Examiner(s): Gimie, Mahmoud
• Assistant Examiner(s): HAMAOUI, DAVID E
• Application Number:
  US13/619,751
• Publication Number:
  US 20140081550A1
• Time in Patent Office: 1,432 Days
• Field of Search: 701/101, 701/113, 123/572
• US Class Current: 1/1
• CPC Class Codes: F01M 1/18 Indicating or safety devices concerning lubricant level F01M11/06, F01M11/12
• CPC Class Codes: F01M 1/20 concerning lubricant pressure
• CPC Class Codes: F01M 1/22 rendering machines or engines inoperative or idling on pressure failure
• CPC Class Codes: F01M 13/00 Crankcase ventilating or breathing
• 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: F02M 35/10222 Exhaust gas recirculation [EGR]; Positive crankcase ventilation [PCV]; Additional air admission, lubricant or fuel vapour admission
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

Methods and systems are provided for using a crankcase vent tube pressure or flow sensor for diagnosing a location and nature of crankcase system integrity breach. The same sensor can also be used for diagnosing air filter plugging and PCV valve degradation. Use of an existing sensor to diagnose multiple engine components provides cost reduction and sensor compaction benefits.

Claims

1. An engine method, comprising:

via an electronic controller coupled with engine sensors and actuators;

identifying a location of crankcase ventilation system breach based on an amplitude of a transient dip in crankcase vent tube pressure during cranking and a change in crankcase vent tube pressure during steady-state engine airflow, wherein identifying the location of the crankcase ventilation system breach includes indicating whether the breach is at a first side or a second side;

setting a different diagnostic code based on whether the breach is detected at the first side or the second side of a crankcase vent tube,

sending a message to notify a vehicle operator about the location of the crankcase system breach; and

taking mitigating action including adjusting engine operating parameters to limit engine power responsive to the identified location.

2. The method of claim 1, wherein the crankcase ventilation system includes the crankcase vent tube, the first side of the vent tube mechanically connected to an air intake passage, the second, opposite side of the vent tube mechanically connected to a crankcase.

3. The method of claim 2, wherein the indicating includes,

in response to the transient dip in crankcase vent tube pressure during cranking being lower than a threshold amplitude and a decrease in crankcase vent tube pressure during a steady-state increase in manifold airflow being lower than a threshold rate, indicating crankcase ventilation system breach at the first side;

and

in response to the transient dip in crankcase vent tube pressure during cranking being lower than the threshold amplitude and the decrease in crankcase vent tube pressure during the steady-state increase in manifold airflow being higher than the threshold rate, indicating crankcase ventilation system breach at the second side.

4. The method of claim 3, wherein determining crankcase ventilation system breach at the first side includes determining disconnection of the crankcase vent tube from the air intake passage at the first side, the electronic controller taking the mitigating action based on the determined first side or second side of crankcase breach.

5. The method of claim 3, wherein crankcase ventilation system breach at the second side includes determining one of disconnection of the crankcase vent tube from the crankcase at the second side, detachment of a crankcase oil fill port cap, detachment of a crankcase oil level dipstick, and blockage of the crankcase vent tube at the second side, the electronic controller taking the mitigating action based on the determination.

6. The method of claim 5, further comprising determining an orifice size of the crankcase ventilation system breach at the second side, and indicating detachment of the crankcase oil fill port cap in response to the orifice size being larger than a threshold.

7. The method of claim 1, wherein the crankcase vent tube pressure is estimated by one of a pressure sensor, a flow sensor, and a venturi coupled in the crankcase vent tube.

8. The method of claim 7, wherein the crankcase vent tube includes a venturi, and wherein the indicating includes, in response to the amplitude of the transient dip in crankcase vent tube pressure during cranking being lower than a threshold amplitude and a decrease in crankcase vent tube pressure during a steady-state increase in manifold airflow being higher than a threshold rate, indicating crankcase ventilation system breach at the second side due to detachment of a crankcase oil fill port cap or detachment of a crankcase oil level dipstick.

9. The method of claim 1, wherein indicating based on a transient dip in crankcase vent tube pressure during cranking includes monitoring a change in crankcase vent tube pressure while engine speed is below a threshold, and wherein indicating based on a change in crankcase vent tube pressure during a steady-state increase in manifold airflow includes comparing a decrease in crankcase vent tube pressure with an increase in manifold airflow while engine speed is above the threshold.

10. The method of claim 2, wherein the crankcase vent tube is coupled to the air intake passage and the crankcase at a location outside of the engine'"'"'s manifold.

11. The method of claim 1 wherein the transient dip includes a decrease in pressure followed by a rise creating the amplitude.

12. The method of claim 1 further comprising prompting the vehicle operator to check the identified breach location.

13. The method of claim 1 wherein the amplitude of the transient dip is determined and compared relative to a threshold amplitude, the threshold amplitude determined based on manifold vacuum during the engine cranking, the threshold increased as expected flow through a PCV valve changes such that during a first condition, the threshold amplitude increases with increasing manifold vacuum, and during a second condition, the threshold amplitude decreases with increasing manifold vacuum.

14. A method for a crankcase ventilation system coupled to an engine, comprising:

distinguishing, via an electronic controller, a breach located on a first side of a crankcase vent tube from a breach located on a second, opposite side of the crankcase vent tube based on a sensed crankcase vent tube pressure dip during engine cranking and a sensed rate of crankcase vent tube vacuum generation during engine run-up with a pressure sensor, the distinguishing including determining a location of the breach; and

taking mitigating action responsive to the determined location including limiting an engine boost, and where the engine progresses from engine cranking to engine run-up, and then to idling where air flow and crankcase vent tube pressure are at steady-state levels.

15. The method of claim 14, wherein the crankcase ventilation system includes the pressure sensor coupled in the vent tube for sensing the crankcase vent tube pressure, and wherein the distinguishing includes,

in response to an amplitude of the pressure dip during engine cranking being lower than a threshold amplitude and the rate of vacuum generation being lower than a first threshold rate but greater than a second threshold rate during engine run-up, indicating breach on the second side;

and

in response to the amplitude of the pressure dip during engine cranking being lower than the threshold amplitude and the rate of vacuum generation being lower than the first and second threshold rates, indicating breach on the first side, wherein the second threshold rate is lower than the first threshold rate.

16. The method of claim 14, wherein the crankcase ventilation system includes a venturi coupled in the vent tube and the pressure sensor coupled to the venturi for sensing the crankcase vent tube pressure, and wherein the distinguishing includes,

in response to a pressure drop across the venturi being smaller than a first threshold during engine cranking and higher than a second threshold during engine run-up, indicating breach on the second side;

and

in response to the pressure drop across the venturi being smaller than the first threshold during engine cranking and smaller than the second threshold during engine run-up, indicating breach on the first side.

17. The method of claim 14, further comprising, in response to determining a breach located on the second side, estimating an orifice size of the breach, and indicating that the breach is due to a cap of an oil fill port being detached from the port based on the orifice size being larger than a threshold size.

18. An engine crankcase ventilation system, comprising:

an engine including an intake passage and a crankcase;

a crankcase vent tube wherein a first side of the tube is mechanically connected to the intake passage upstream of a compressor and a second, opposite side of the tube is mechanically connected to the crankcase via an oil separator, the vent tube located external to the engine;

a sensor coupled in the crankcase vent tube for estimating a vent tube pressure and/or air flow; and

a control system with computer readable instructions for,

indicating a location of crankcase vent tube disconnection based on an amplitude of a transient dip in vent tube pressure during engine cranking and a rate of change in vent tube pressure during engine run-up; and

adjusting engine operation in response to the indication of the location.

19. The system of claim 18, wherein the indicating includes,

indicating that the vent tube is disconnected at the first side if the amplitude of the transient dip in vent tube pressure during engine cranking is lower than a threshold amplitude and the rate of change in vent tube pressure during engine run-up is lower than a threshold rate;

and

indicating that the vent tube is disconnected at the second side if the amplitude of the transient dip in vent tube pressure during engine cranking is lower than the threshold amplitude and the rate of change in vent tube pressure during engine run-up is higher than the threshold rate.

20. The system of claim 19, wherein the controller includes further instructions for,

setting a first diagnostic code to indicate that the vent tube is disconnected at the first side;

setting a second, different diagnostic code to indicate that the vent tube is disconnected at the second side; and

limiting an engine power if the vent tube is disconnected at either the first or second side.