Method and system for catalyst temperature control

• US 9,556,771 B2
• Filed: 01/16/2013
• Issued: 01/31/2017
• Est. Priority Date: 01/16/2013
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Ulrey, Joseph Norman, Ruona, William Charles, Leone, Thomas G., Surnilla, Gopichandra
• Primary Examiner(s): Trieu, Thai Ba
• Assistant Examiner(s): Thiede, Paul
• Application Number:
  US13/743,247
• Publication Number:
  US 20140196454A1
• Time in Patent Office: 1,476 Days
• Field of Search: 606/052, 123/568.21
• US Class Current: 1/1
• CPC Class Codes: F01N 3/10 by thermal or catalytic conversion of noxious components of exhaust by using other chemical processes, chemical aspects of catalytic conversion, e.g. using specified catalysts, B01D53/34
• CPC Class Codes: F01N 3/2006 Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F02D 2250/41 Control to generate negative pressure in the intake manifold, e.g. for fuel vapor purging or brake booster
• CPC Class Codes: F02D 37/02 one of the functions being ignition
• CPC Class Codes: F02D 41/0055 Special engine operating conditions, e.g. for regeneration of exhaust gas treatment apparatus
• CPC Class Codes: F02D 41/0255 to accelerate the warming-up of the exhaust gas treating apparatus at engine start
• CPC Class Codes: F02D 9/04 concerning exhaust conduits throttle valves, or arrangements thereof in conduits F02D9/08
• CPC Class Codes: F02M 26/05 High pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust system upstream of the turbine and reintroduced into the intake system downstream of the compressor
• CPC Class Codes: F02M 26/06 Low pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust downstream of the turbocharger turbine and reintroduced into the intake system upstream of the compressor
• CPC Class Codes: F02M 26/07 Mixed pressure loops, i.e. wherein recirculated exhaust gas is either taken out upstream of the turbine and reintroduced upstream of the compressor, or is taken out downstream of the turbine and reintroduced downstream of the compressor
• CPC Class Codes: F02M 26/10 having means to increase the pressure difference between the exhaust and intake system, e.g. venturis, variable geometry turbines, check valves using pressure pulsations or throttles in the air intake or exhaust system
• CPC Class Codes: F02M 26/15 in relation to engine exhaust purifying apparatus
• CPC Class Codes: F02M 26/24 with two or more coolers
• CPC Class Codes: F02M 26/25 with coolers having bypasses
• CPC Class Codes: F02M 26/36 with means for adding fluids other than exhaust gas to the recirculation passage; with reformers
• CPC Class Codes: F02M 26/44 in which a main EGR passage is branched into multiple passages
• CPC Class Codes: F02M 26/47 the characteristics being temperatures, pressures or flow rates
• CPC Class Codes: F02P 5/1502 using one central computing unit
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

Methods and systems are provided for controlling and coordinating control of a post-catalyst exhaust throttle and an EGR valve to expedite catalyst heating. By closing both valves during an engine cold start, an elevated exhaust backpressure and increased heat rejection at an EGR cooler can be synergistically used to warm each of an engine and an exhaust catalyst. The valves may also be controlled to vary an amount of exhaust flowing through an exhaust venturi so as to meet engine vacuum needs while providing a desired amount of engine EGR.

Claims

1. A method for expediting activation of an exhaust catalyst coupled to an engine, comprising:

during a cold-start of the engine,

closing an exhaust throttle, disposed downstream of the exhaust catalyst, and an EGR valve while diverting at least a portion of throttled exhaust gas through an EGR cooler and then through a bypass passage joined to an EGR passage at a junction,

wherein the EGR cooler is coupled to an exhaust passage upstream of the throttle,

wherein the EGR valve is coupled to the EGR passage downstream of the junction, and

wherein the EGR cooler is in thermal communication with a coolant system, the coolant system in thermal communication with the engine.

2. The method of claim 1, wherein the closing and diverting is performed for a duration until a temperature of the exhaust catalyst is above a threshold temperature, and wherein the exhaust gas diverted through the bypass passage is not recirculated to an engine intake.

3. The method of claim 2, further comprising, while the temperature of the exhaust catalyst is below the threshold temperature, intermittently opening the exhaust throttle in response to an exhaust back-pressure estimated upstream of the throttle and downstream of the catalyst being higher than a threshold pressure.

4. The method of claim 3, wherein diverting the portion of the throttled exhaust gas through the EGR cooler includes diverting the portion of the throttled exhaust gas through the EGR cooler located inside the EGR passage while maintaining the EGR valve in the EGR passage at a more closed position, the EGR passage fluidly coupling an engine exhaust from upstream of the exhaust throttle and downstream of the exhaust catalyst to an engine intake, upstream of an intake compressor.

5. The method of claim 4, wherein the EGR passage is a low pressure EGR passage.

6. The method of claim 4, wherein the bypass passage is coupled to the EGR passage downstream of an outlet of the EGR cooler and upstream of the EGR valve, and the bypass passage is coupled to the engine exhaust downstream of the exhaust throttle.

7. The method of claim 6, wherein the bypass passage includes an ejector and wherein routing the portion of throttled exhaust gas via the bypass passage includes flowing the portion of throttled exhaust gas through the ejector, the method further comprising drawing vacuum at the ejector.

8. The method of claim 2, further comprising, while the temperature of the exhaust catalyst is below the threshold temperature and while the exhaust throttle is closed, retarding spark ignition timing, an amount of spark retard adjusted based on the temperature of the exhaust catalyst.

9. The method of claim 8, further comprising, after the temperature of the exhaust catalyst is above the threshold temperature, maintaining the exhaust throttle closed while advancing spark ignition timing.

10. The method of claim 9, further comprising, after the temperature of the exhaust catalyst is above the threshold temperature, adjusting the exhaust throttle based on an EGR cooler outlet temperature.

11. The method of claim 10, wherein the adjusting includes, as the outlet temperature of the EGR cooler increases, shifting the exhaust throttle from a more closed position to a more open position.

12. A method for an engine, comprising:

during a cold-start of the engine,

restarting the engine with each of a post-catalyst exhaust throttle and an EGR valve closed;

with the EGR valve and exhaust throttle closed, diverting at least a portion of throttled exhaust gas around the exhaust throttle via an EGR cooler and an ejector, where the diverted portion of throttled exhaust gas is not recirculated to an engine intake; and

maintaining each of the throttle and the EGR valve closed until an EGR cooler outlet temperature is above a threshold,

wherein the EGR cooler is in thermal communication with a coolant system, the coolant system in thermal communication with the engine.

13. The method of claim 12, further comprising, while diverting a portion of throttled exhaust gas via the ejector, drawing vacuum at a neck of the ejector, and providing the drawn vacuum to one or more vacuum consumers.

14. The method of claim 12, further comprising opening the EGR valve after the EGR cooler outlet temperature is above the threshold, wherein each of the EGR valve and the EGR cooler are positioned in a low pressure EGR passage, the EGR passage fluidly coupling an engine exhaust, from upstream of the exhaust throttle and downstream of a catalyst to the engine intake, upstream of an intake compressor while the EGR valve is open, wherein the ejector is joined to the EGR passage downstream of the EGR cooler at a junction, and wherein the EGR valve is located in the EGR passage downstream of the junction.

15. The method of claim 12, further comprising, as the EGR cooler outlet temperature increases above the threshold, moving the exhaust throttle to a more open position.

16. The method of claim 15, wherein during the restarting, while the EGR cooler outlet temperature is below the threshold and while the exhaust throttle is closed, retarding spark ignition timing from maximum brake torque (MBT), and as the EGR cooler outlet temperature increases toward the threshold, advancing spark ignition timing towards MBT.

17. The method of 12, further comprising, while the EGR cooler outlet temperature is below the threshold, opening the exhaust throttle for a predetermined duration in response to an exhaust back-pressure upstream of the throttle being above a threshold pressure.

18. An engine system, comprising:

an engine including an intake and an exhaust;

a turbocharger including an intake compressor and an exhaust turbine;

an exhaust catalyst;

a post-catalyst exhaust throttle;

an EGR system including an EGR passage, an EGR cooler and an EGR valve, the EGR system fluidly coupling the engine exhaust downstream of the catalyst and upstream of the throttle, to the engine intake, upstream of the compressor;

a branch passage including an ejector fluidly coupling an outlet of the EGR cooler to the engine exhaust, downstream of the throttle, where the EGR valve is located in the EGR passage downstream of a location where the branch passage couples to the EGR passage; and

a controller including a non-transitory computer-readable medium with instructions for;

operating the system in a first mode with each of the throttle and the EGR valve closed and while flowing exhaust gas from the catalyst, through the EGR cooler and then through the ejector, where the exhaust gas is not recirculated to the engine intake;

operating the system in a second mode with each of the throttle and the EGR valve open and while flowing exhaust gas from the catalyst, through the EGR cooler and then through the ejector; and

during both the first mode and the second mode, drawing vacuum with a neck of the ejector disposed in the branch passage.

19. The system of claim 18, wherein the controller operates the system in the first mode during conditions when the exhaust catalyst is below a threshold temperature, and wherein the controller operates the system in the second mode during conditions when the exhaust catalyst is above the threshold temperature and an engine vacuum requirement is higher than a threshold.

20. The system of claim 18, wherein while operating in the first mode, an ignition spark timing is retarded by a first amount and while operating in the second mode, an ignition spark timing is retarded by a second amount, the first amount larger than the second amount.