Methods and systems for real-time compressor surge line adaptation

• US 9,506,474 B2
• Filed: 12/08/2014
• Issued: 11/29/2016
• Est. Priority Date: 12/08/2014
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Xiao, Baitao, Ossareh, Hamid-Reza, Banker, Adam Nathan
• Primary Examiner(s): Trieu, Thai Ba
• Application Number:
  US14/563,749
• Publication Number:
  US 20160160868A1
• Time in Patent Office: 722 Days
• Field of Search: 606/11, 606/051, 605/98, 415/1, 415/17, 415/27
• US Class Current: 1/1
• CPC Class Codes: F02D 2200/602 Pedal position
• CPC Class Codes: F02D 35/00 Controlling engines, dependent on conditions exterior or interior to engines, not otherwise provided for
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/12 for deceleration F02D41/0005, F02D41/107 take precedence
• CPC Class Codes: F04D 17/10 for compressing or evacuating
• CPC Class Codes: F04D 27/001 Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
• CPC Class Codes: F04D 27/0253 by throttling F04D27/0246 takes precedence
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Methods and systems are provided for adapting a compressor surge line in real-time. In one example, a method may include retarding a surge line in response to a number of surge events greater than a threshold number of surge events, and advancing the surge line in response to a number of aggressive tip-out events, that do not result in surge, greater than a threshold number of tip-out events.

Claims

1. A method for operating an engine including a compressor, comprising:

detecting a surge event of the compressor based on a frequency content of a signal from a throttle inlet pressure sensor located downstream of the compressor; and

adapting a surge line of a compressor map stored in a memory of a controller of the engine based on an operating point of the compressor during the surge event;

wherein the operating point includes an estimated and/or a measured compressor pressure ratio and a corrected compressor flow during the surge event.

2. The method of claim 1, further comprising:

in response to a tip-out greater than a threshold amount and not detecting a surge during the tip-out, advancing a region of the surge line, wherein advancing the region of the surge line includes adjusting the region of the surge line to left of the surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow, the region of the surge line corresponding to a region on the compressor map, and the region on the map including a tip-out operating point corresponding to an estimated and/or a measured compressor pressure ratio and a corrected compressor flow at which the tip-out occurred; and

advancing the region of the surge line by a first selected amount of advancement.

3. The method of claim 2, further comprising advancing the region of the surge line in response to a number of tip-outs greater than a threshold number and not detecting surge at each of the number of the tip-outs;

and wherein said each of the number of the tip-outs is greater than the threshold number and occurring in the region on the compressor map.

4. The method of claim 3, further comprising advancing the region of the surge line to left of the surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow in response to the region on the compressor map located to the left of the surge line.

5. The method of claim 2, wherein the first selected amount is based on an amount of tip-out.

6. The method of claim 1, further comprising retarding a region of the surge line corresponding to the compressor pressure ratio and corrected compressor flow at which surge occurred by a second selected amount of retard:

wherein retarding the region of the surge line includes adjusting the region of the surge line to right of the surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow; and

wherein the second selected amount of retard is based on a surge intensity.

7. The method of claim 6, further comprising retarding the region of the surge line in response to a number of surge events greater than a threshold number of surge events;

and wherein each of the number of the surge events occurs at a region on the compressor map corresponding to the region on the surge line.

8. The method of claim 7, further comprising retarding the region of the surge line in response to the region on the compressor map located to the right of the surge line on the compressor map.

9. The method of claim 1, further comprising:

globally advancing the entire surge line in response to detecting a number of tip-outs greater than a threshold number and not detecting the surge event during each of the number of tip-outs, each tip-out greater than a threshold amount;

wherein globally advancing the entire surge line includes adjusting all regions of the surge line to left of the surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow.

10. The method of claim 1, further comprising, globally retarding the entire surge line in response to detecting a number of surge events greater than a threshold number;

wherein globally retarding the entire surge line includes adjusting the entire surge line to the right of the surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow.

11. A method for operating a turbocharged engine including a compressor, comprising:

in response to a request to learn a compressor surge line,

during a first condition,

determining an advancing gain; and

adjusting the surge line by locally advancing at least a first region on a surge line of a compressor map based on the advancing gain, the compressor map stored in a memory of an engine controller; and

during a second condition,

determining a retarding gain; and

adjusting the surge line by locally retarding at least a second region on the surge line based on the retarding gain;

wherein locally advancing the first region includes adjusting the first region to left of the surge line on the compressor map as a function of compressor pressure ratio and compressor flow; and

wherein locally retarding the second region includes adjusting the second region to the right of the surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow.

12. The method of claim 11,

wherein the first condition includes a tip-out amount greater than a threshold amount and the compressor not surging during the tip-out, the tip-out based on a change in pedal position indicated from a pedal position sensor;

and

wherein the tip-out occurs at a tip-out compressor operating point on the compressor map, the tip-out compressor operating point located to a left side of the surge line on the compressor map, and wherein the tip-out compressor operating point on the map is located closer to the first region including a first point and a second point on the surge line than remaining points on the surge line.

13. The method of claim 11,

wherein the second condition includes detecting a compressor surge event based on a frequency of a signal from a throttle inlet pressure sensor located downstream of an outlet of the compressor;

and

wherein the compressor surge event occurs at a compressor operating point on the compressor map, the compressor operating point located to a right side of the surge line on the compressor map, and

wherein the compressor operating point on the map is located closer to the second region including a third point and a fourth point on the surge line than remaining points on the surge line.

14. The method of claim 13, further comprising:

during the first condition, globally advancing the entire surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow in response to a number of tip-outs greater than a first threshold number, the entire surge line including all regions of the surge line; and

during the second condition, globally retarding the entire surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow in response to a number of surge events greater than a second threshold number, the surge events based on the frequency of the signal from the throttle inlet pressure sensor; and

wherein at the number of the tip-outs, a tip-out amount is greater than a threshold amount, the signal from the throttle inlet pressure sensor indicates that the compressor is not surging, and the number of the tip-outs occurs in a region located to the left of the surge line on the compressor map.

15. The method of claim 11, wherein the retarding gain is greater than the advancing gain.

16. The method of claim 11,

wherein the advancing gain is based on an amount of tip-out based on a change in pedal position indicated by a pedal position sensor, and the retarding gain is based on a surge intensity based on a signal from a throttle inlet pressure sensor;

and

wherein the first region is separate from the second region.

17. The method of claim 16, further comprising not retarding the advanced first region until all regions on the surge line are adjusted;

and further comprising not advancing the retarded second region until all the regions on the surge line are adjusted.

18. A turbocharger system of an internal combustion engine, comprising:

a compressor;

a throttle inlet pressure sensor located downstream of an outlet of the compressor and upstream of an intake throttle; and

a controller with computer readable instructions stored in non-transitory memory, and further including a compressor map stored in the memory for;

in response to a request to learn a compressor surge line adaptation,

detecting a compressor surge event based on an amplitude of the pressure sensor greater than a threshold amplitude and the amplitude within a threshold frequency range of the pressure sensor;

determining a number of compressor surge events in a first compressor map region including a surge operating point on the compressor map at which the surge event is detected; and

in response to the number of the surge events in the first map region greater than a threshold number, retarding a first surge line region located on a surge line of the compressor map, the first surge line region corresponding to the surge operating point;

wherein, retarding the first surge line region includes adjusting the first surge line region to the right of the surge line on the compressor map as a function of compressor pressure ratio and compressor flow.

19. The system of claim 18,

wherein the controller includes further instructions for,

in response to the request to learn the surge line adaptation, detecting an absence of the compressor surge event during a tip-out greater than a threshold;

determining a number of tip-out events in a second compressor map region including a tip-out operating point on the compressor map at which the tip-out is detected; and

in response to the number of tip-out events in the second compressor map region greater than a threshold number of tip-outs, advancing a second surge line region located on the surge line, the second surge line region corresponding to the tip-out operating point; and

wherein advancing the second surge line region includes adjusting the second surge line region to the left of the surge line on the compressor map as a function of the compressor pressure ratio and the compressor flow.

20. The system of claim 19,

wherein the controller includes further instructions for, linking the first surge line region and the second surge line region via linear interpolation to obtain a final surge line;

and

wherein the first surge line region is adjacent to the second surge line region.