Method to diagnose SCR catalyst

• US 9,638,122 B2
• Filed: 12/20/2013
• Issued: 05/02/2017
• Est. Priority Date: 12/20/2013
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Smith, Jason Ronald, Bogema, John Paul, Lyon, Peter Mitchell, Mangion, John Anthony, Murphy, Kevin R., Luke, Darrin Blaine
• Primary Examiner(s): Bradley, Audrey K
• Assistant Examiner(s): AYALA DELGADO, ANTHONY
• Application Number:
  US14/136,894
• Publication Number:
  US 20150176512A1
• Time in Patent Office: 1,229 Days
• Field of Search: 60277, 60286, 60299, 60295, 60272
• CPC Class Codes: F01N 11/00 Monitoring or diagnostic devices for exhaust-gas treatment apparatus , e.g. for catalytic activity safety, indicating or supervising devices for internal combustion engines F02B77/08; testing of machines G01M13/00
• CPC Class Codes: F01N 2550/02 Catalytic activity of catalytic converters
• CPC Class Codes: F01N 2900/1602 Temperature of exhaust gas apparatus
• CPC Class Codes: F01N 2900/1621 Catalyst conversion efficiency
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: F02D 41/0235 in relation with the state of the exhaust gas treating apparatus control of exhaust gas treating apparatus per se F01N
• CPC Class Codes: F02D 41/1461 of the exhaust gases emitted by the engine
• CPC Class Codes: F02D 41/1463 of the exhaust gases downstream of exhaust gas treatment apparatus
• CPC Class Codes: F02D 41/401 Controlling injection timing F02D41/402 takes precedence
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

Methods and systems are described for an engine with a SCR system including NOx sensors upstream and downstream of catalyst. One method includes monitoring SCR performance via calculating SCR conversion efficiency at different catalyst temperatures. Further, feedgas NOx levels are artificially increased when SCR device temperature is above a threshold to obtain more reliable readings from NOx sensors.

Claims

1. A method for an engine including a SCR catalyst, the method comprising:

for a vehicle in motion;

in response to SCR temperature below a first threshold;

monitoring SCR conversion efficiency in a first mode based on NOx-in and NOx-out concentrations, but without adjusting engine operation to artificially increase feedgas NOx;

in response to SCR temperature above the first threshold, artificially increasing feedgas NOx by adjusting an EGR valve to reduce EGR flow, and monitoring SCR conversion efficiency in a second mode based on NOx-in and NOx-out concentrations; and

indicating SCR degradation based on the monitored conversion efficiency from each of the first and second modes.

2. The method of claim 1, wherein NOx sensors are positioned immediately upstream and downstream of the SCR catalyst.

3. The method of claim 1, wherein when SCR temperature is above the first threshold, feedgas NOx levels are increased by advancing fuel injection timing, the artificial NOx increase being smaller when feedgas NOx is greater than a threshold, and being larger when feedgas NOx is smaller than the threshold.

4. The method of claim 1, wherein SCR degradation is indicated based on the monitored conversion efficiency with and without the artificial NOx increase.

5. The method of claim 1, wherein during the vehicle motion and the SCR conversion efficiency monitoring, the engine is operated, and maintained operating, to provide all drive power to the vehicle to maintain vehicle motion.

6. The method of claim 1, wherein the SCR catalyst is operating under steady warmed up conditions.

7. The method of claim 1, wherein feedgas NOx levels are artificially increased only when SCR catalyst conversion efficiency is above a minimum threshold.

8. The method of claim 1, wherein feedgas NOx levels are artificially increased only when a level of NOx in feedgas is below a threshold.

9. A method for monitoring performance of a SCR catalyst in an engine with NOx sensors, the method comprising:

operating the engine in a first mode when SCR temperature is below a first threshold and monitoring SCR conversion efficiency;

operating the engine in a second mode when SCR temperature is above the first threshold and feedgas NOx concentration is above a threshold, by artificially increasing feedgas NOx by a first amount and monitoring SCR conversion efficiency;

operating the engine in the second mode when SCR temperature is above the first threshold and feedgas NOx concentration is below the threshold, by increasing feedgas NOx by a second amount, the second amount greater than the first amount, and monitoring SCR conversion efficiency; and

indicating SCR degradation based on cumulative monitored efficiency of the two modes.

10. The method of claim 9, further comprising monitoring SCR performance when a vehicle is in motion and the engine is maintained operating to provide drive power to the vehicle.

11. The method of claim 10, wherein during the second mode of engine operation, feedgas NOx levels are increased when SCR conversion efficiency is above a minimum threshold and when feedgas NOx levels are lower than a NOx threshold.

12. The method of claim 9, wherein feedgas NOx levels are artificially increased by reducing EGR flow or advancing fuel injection timing.

13. A system for an engine in a vehicle comprising:

a SCR catalyst;

one or more NOx sensors; and

a controller with computer readable instructions stored in non-transitory memory for;

when the vehicle is travelling;

during a first condition, when SCR catalyst temperature is below a first threshold,

evaluating SCR conversion efficiency in a first mode based on NOx-in and NOx-out concentrations; and

during a second condition, when SCR catalyst temperature is above the first threshold,

artificially raising feedgas NOx levels, the artificial NOx increase being smaller when feedgas NOx concentration is greater than a threshold, and being larger when feedgas NOx concentration is smaller than the threshold; and

monitoring SCR conversion efficiency in a second mode based on NOx-in and NOx-out concentrations.

14. The system of claim 13, further comprising an indication of SCR degradation based on monitored conversion efficiency during both conditions.

15. The system of claim 13, wherein during SCR conversion efficiency monitoring, the engine is operated, and maintained operating, to provide all drive power to the vehicle to maintain vehicle motion.

16. The system of claim 13, wherein during the second condition, feedgas NOx is increased temporarily by reducing EGR.

17. The system of claim 13, wherein during the second condition, feedgas NOx is increased temporarily by advancing fuel injection timing.

18. The system of claim 13, wherein feedgas NOx is increased only when NOx levels in exhaust gases entering the SCR catalyst reduce below a minimum threshold.

19. The system of claim 13, wherein NOx levels in exhaust gases are increased only when the SCR conversion efficiency is above a minimum threshold.

20. The system of claim 13, further comprising instructions for, during a third condition, when SCR catalyst temperature is higher than a first threshold and feedgas NOx levels are higher than a minimum threshold:

increasing feedgas NOx to a smaller degree;

monitoring SCR conversion efficiency; and

indicating SCR degradation based on measurements performed in all three conditions.