Evaporative emissions leak tester and leak test method

• US 9,476,792 B2
• Filed: 05/09/2013
• Issued: 10/25/2016
• Est. Priority Date: 05/10/2012
• Status: Expired due to Fees

• Current Assignee: MAHLE Powertrain, LLC (MAHLE-STIFTUNG GmbH)
• Original Assignee: MAHLE Powertrain, LLC (MAHLE-STIFTUNG GmbH)
• Inventors: Gearhart, Raymond D., Bolt, Louis Scott, Bhargava, Sumit
• Primary Examiner(s): LARKIN, DANIEL SEAN
• Application Number:
  US13/890,328
• Publication Number:
  US 20130298643A1
• Time in Patent Office: 1,265 Days
• US Class Current: 1/1
• CPC Class Codes: F02M 25/0809 Judging failure of purge control system
• CPC Class Codes: G01M 3/025 Details with respect to the testing of engines or engine parts
• CPC Class Codes: G01M 3/04 by detecting the presence of fluid at the leakage point
• CPC Class Codes: Y10T 29/49718 Repairing

Abstract

A tester and method for testing for a leak in an evaporative-emissions system of a motor vehicle comprise a/an power supply, computer, display communicating with the computer, analog-to-digital board communicating with the power supply and computer, pressure sensor communicating with the board, housing into which the power supply, board, and sensor are integrated, stationary enclosure, and test connection including a hose to the enclosure. A fuel-vapor pressure-rise rate is recorded with an engine of a motor vehicle turned “off.” A value is recorded that directly correlates with an out-gassing effect created by a volume, blend, and temperature of fuel. A “purge” cycle occurs at idling of the vehicle within a short period of time. The engine applies a vacuum to a fuel-delivery system of the vehicle. Vacuum decay is recorded. A leak rate is determined by off-setting the recorded fuel-vapor pressure-rise rate with the recorded vacuum decay.

Claims

1. A method for testing for a leak in an evaporative-emissions system of a motor vehicle using an evaporative-emissions-leak tester, the method comprising steps of:

recording a fuel-vapor pressure-rise rate with an engine of the vehicle turned “

off”

;

recording a value that directly correlates with an out-gassing effect created by a volume, blend, and temperature of fuel;

applying a vacuum to a fuel-delivery system of the vehicle;

recording vacuum decay; and

determining a leak rate by offsetting the recorded fuel-vapor pressure-rise rate with the recorded decay.

2. The method as set forth in claim 1, wherein the method further comprises the steps of:

an operator connecting the tester to the fuel-delivery system of the vehicle;

recording a pressure “

A”

of the fuel-delivery system;

detecting whether there is a resident pressure and/or vacuum at a start of the test;

deter determining if the tester has been erroneously left connected for a predetermined time; and

ending the method if it is determined that the tester has been so connected.

3. The method as set forth in claim 1, wherein the method further comprises the steps of:

using the tester on a natural vacuum-leak detection “

NVLD”

system;

an operator connecting the tester to the fuel-delivery system of the vehicle;

recording a pressure “

A”

of the fuel-delivery system;

detecting whether seating of either of a gravity- and spring-controlled valve has occurred on a canister-vent port to ensure integrity of the NVLD system; and

ending the method if it is detected that the seating has not occurred.

4. The method as set forth in claim 1, Wherein the method further comprises the steps of:

detecting whether excess vapor boil-off has occurred; and

ending the method if it is detected that the excess boil-off has occurred.

5. The method as set forth in claim 1, wherein the method further comprises the steps of:

the tester waiting a “

vapor-rise sample”

time;

recording a pressure “

B”

of the fuel-delivery system;

performing a “

vapor rise”

calculation of [(pressure “

B”

−

pressure “

A”

)/“

vapor-rise sample”

time=vapor-pressure change/second];

prompting an operator to start the engine;

starting a “

purge cycle”

timer;

recording a pressure “

C”

of the fuel-delivery system;

recording a pressure “

D”

of the fuel-delivery system within a predetermined time;

determining whether pressure “

D”

changes more than about −

50% of pressure “

C”

within a predetermined time;

determining, if it is determined that pressure “

D”

so changes, whether the “

purge cycle”

timer has expired;

concluding, if it is determined that the “

purge cycle”

timer has expired, that the test fails for either a large leak or an inoperative or disconnected purge line;

re-recording pressure “

C”

if it is determined that the “

purge cycle”

timer has not expired; and

concluding, if it is determined that pressure “

D”

does not change more than about −

50% of pressure C, that a purge cycle of the fuel-delivery system has been detected and waiting a predetermined amount of time.

6. The method as set forth in claim 5, wherein the method further comprises the steps of:

recording a pressure “

E”

the fuel-delivery system;

requesting the operator to turn off the engine;

determining whether current pressure of the fuel-delivery system is greater than pressure “

E”

;

requesting, if it is determined that the current pressure is not greater than pressure “

E,”

the operator to keep off the engine; and

concluding, if it is determined that the current pressure is greater than pressure “

E,”

that “

engine off”

/“

purge off”

is detected.

7. The method as set forth in claim 6, wherein the method further comprises the steps of:

waiting for the pressure in the fuel-delivery system to become greater than a predetermined pressure;

waiting for a predetermined time;

checking if the current pressure is greater than the predetermined pressure;

concluding, if the current pressure is greater than the predetermined pressure, that the test fails for a medium leak; and

recording, if the current pressure is not greater than the predetermined pressure, a fuel-system pressure “

F”

.

8. The method as set forth in claim 7, wherein the method further comprises the steps of:

the tester waiting a “

leak-rate sample”

time;

checking if the current pressure is greater than a predetermine pressure;

returning, if the current pressure is not greater than the predetermined pressure, to the tester waiting the “

leak-rate sample”

time; and

recording, if the current pressure is greater than the predetermined pressure, a pressure “

G”

of the fuel-delivery system.

9. The method as set forth in claim 8, wherein the method further comprises steps of:

performing a “

raw leak rate”

calculation of [(pressure “

G”

−

pressure “

F”

)/“

leak-rate sample”

time=raw leak rate/second];

performing an “

adjusted leak rate”

calculation of [(raw leak rate/second)−

(vapor-pressure change/second)=adjusted leak rate];

determining whether the adjusted leak rate exceeds a predetermined leak-rate limit;

concluding, if it is determined that the adjusted leak rate exceeds the predetermined leak-rate limit, that the test fails for a small leak; and

concluding, if it is determined that the adjusted leak rate does not exceed the predetermined leak-rate limit, that the test passes.

10. The method as set forth in claim 1, wherein the method further comprises the steps of:

an operator, once the vehicle is flagged with a leak, identifying and fixing a source of the leak by steps of;

connecting a hand-operated pressure pump with a fuel-cap connector and hose line to a fuel cap of the vehicle;

pressurizing the fuel-delivery system by pumping a regulated predetermined amount of pressure;

scanning, once the fuel-delivery system is pressurized, evaporative-system lines with a hand-held hydrocarbon sniffer to look for small leaks, wherein resident pressure forces sufficient leakage flow, thereby causing the hydrocarbon sniffer to beep within a predetermined distance of the leak source on the evaporative-emissions system;

depressurizing, if the hydrocarbon sniffer beeps, the evaporative-emissions system; and

tagging the vehicle for repair.