Method and system for particulate filter leakage detection

• US 9,645,068 B2
• Filed: 02/11/2016
• Issued: 05/09/2017
• Est. Priority Date: 10/13/2015
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Zhang, Xiaogang
• Primary Examiner(s): SHANSKE, JASON D
• Application Number:
  US15/041,462
• Publication Number:
  US 20170102311A1
• Time in Patent Office: 453 Days
• Field of Search: 60277
• CPC Class Codes: F01N 11/002 the diagnostic devices measuring or estimating temperature or pressure in, or downstream of the exhaust apparatus
• CPC Class Codes: F01N 2470/30 Tubes with restrictions, i.e. venturi or the like, e.g. for sucking air or measuring mass flow
• CPC Class Codes: F01N 2550/04 Filtering activity of particulate filters
• CPC Class Codes: F01N 2560/08 the means being a pressure sensor
• CPC Class Codes: F01N 2900/0408 using a feed-back loop
• CPC Class Codes: F01N 3/005 for draining or otherwise eliminating condensates or moisture accumulating in the apparatus F01N3/02 takes precedence
• CPC Class Codes: F01N 3/021 by means of filters
• CPC Class Codes: F01N 3/023 using means for regenerating the filters, e.g. by burning trapped particles by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/0275 using electric discharge means
• CPC Class Codes: G01M 15/106 using pressure sensors
• CPC Class Codes: G01N 15/0656 using electric, e.g. electrostatic methods or magnetic methods by investigating individual particles G01N15/1031, G01N15/12
• CPC Class Codes: G01N 2015/0046 in gas, e.g. smoke
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

Methods and systems are provided for determining degradation of a particulate filter in an exhaust conduit. In one example, a method may include diverting exhaust gas to a secondary soot sensor assembly comprising a second filter downstream of a first filter, and determining degradation based on time intervals between subsequent filter regenerations of the second filter in the secondary soot sensor assembly.

Claims

1. A method, comprising:

flowing exhaust from downstream of a first filter towards each of a first pressure sensor coupled at a first location in an exhaust pipe and a second pressure sensor coupled at a second location in a passage external to the exhaust pipe, the passage including a second filter coupled to an electric circuit; and

indicating degradation of the first filter based on an interval between successive regenerations of the second filter.

2. The method of claim 1, further comprising, measuring a first pressure at the first location by the first pressure sensor coupled to the exhaust pipe, and measuring a second pressure at the second location by the second pressure sensor coupled downstream of the second filter in the passage external to the exhaust pipe.

3. The method of claim 2, further comprising, regenerating the second filter responsive to a pressure difference between the second pressure and the first pressure being lower than a lower threshold.

4. The method of claim 3, further comprising, regenerating the second filter by closing a switch of the electric circuit and flowing electricity through the second filter until the pressure difference between the second pressure and the first pressure is higher than an upper threshold.

5. The method of claim 1, further comprising, in response to the indication, limiting an engine speed or load.

6. The method of claim 1, wherein the indicating includes indicating degradation responsive to the interval between successive regenerations of the second filter being lower than a threshold duration.

7. The method of claim 6, wherein the interval is measured from initiation of a first regeneration event of the second filter to initiation of a second, immediately subsequent regeneration event of the second filter.

8. The method of claim 1, wherein the first filter is a diesel or gasoline particulate matter filter having a first, higher soot capacity, and wherein the second filter is a metal filter having a second, lower soot capacity, and wherein the indicating includes indicating the first filter is leaking by setting a diagnostic code.

9. The method of claim 1, wherein the second filter is coupled upstream of the second pressure sensor, and wherein flowing exhaust towards the second pressure sensor includes:

flowing exhaust from the exhaust pipe into an inlet pipe, from the inlet pipe into the passage, the inlet pipe converging with the passage at a location external to the exhaust pipe, and from the passage into the exhaust pipe via an outlet pipe, the passage converging into the outlet pipe at a location downstream of the second pressure sensor and external to the exhaust pipe.

10. The method of claim 1, wherein a direction of flowing exhaust through the inlet pipe and the outlet pipe is perpendicular to a direction of exhaust flow through each of the exhaust pipe and the passage.

11. An engine exhaust system, comprising:

an exhaust pipe including a first particulate filter;

a soot detection system including an inlet pipe and an outlet pipe coupled to the exhaust pipe, downstream of the first particulate filter, the inlet pipe merging into a passage external to the exhaust pipe, the outlet pipe merging out of the passage external to the exhaust pipe;

a second particulate filter coupled to the passage between the inlet pipe and the outlet pipe, the second particulate filter coupled to a source of electricity via a switch;

a first pressure sensor at a first location in the exhaust pipe;

a second pressure sensor at a second location in the passage external to the exhaust pipe; and

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

flowing a first portion of exhaust gas from downstream of the first filter towards the first pressure sensor;

flowing a remaining portion of exhaust gas towards the second pressure sensor;

regenerating the second filter based on output from first and the second pressure sensors; and

adjusting engine operation based on a time elapsed between successive regenerations of the second filter.

12. The system of claim 11, wherein the inlet pipe comprises a plurality of perforations on a side of the inlet pipe within the exhaust pipe and proximate to the first filter, a diameter of the perforations sized to enable conglomerated particulates to impinge on a side of the inlet pipe within the exhaust pipe and distal to the first filter, the conglomerated particulates released from the inlet pipe into the exhaust pipe via a perforation on a bottom of the inlet pipe.

13. The system of claim 11, wherein the first location is downstream of the first filter in the exhaust pipe and the second location is downstream of the second filter in the passage external to the exhaust pipe.

14. The system of claim 11, wherein regenerating the second filter based on the pressure difference between the first location and the second location includes initiating regeneration of the second filter when the pressure difference is lower than a lower threshold, and terminating regeneration of the second filter when the pressure difference is higher than a upper threshold.

15. The system of claim 14, wherein adjusting engine operation based on a time elapsed between successive regenerations of the second filter includes regenerating the first filter when the time elapsed is higher than a threshold interval by retarding spark timing or enriching the exhaust gas, and indicating degradation of the first filter when the time elapsed is lower than the threshold interval.

16. The system of claim 15, further comprising ceasing regeneration of the first filter responsive to the indication of degradation.

17. A method, comprising:

flowing exhaust gas from downstream of a particulate filter positioned in an engine exhaust conduit upstream of a first pressure sensor and a metal filter positioned upstream of a second pressure sensor in an exhaust bypass, the exhaust bypass external to the exhaust conduit, and

adjusting engine operation based on degradation of the particulate filter, the degradation determined based on a time interval between a first regeneration and a second regeneration of the metal filter, the first regeneration and the second regeneration each performed based on a pressure difference between a pressure measured by the second pressure sensor and a pressure measured by the first pressure sensor.

18. The method of claim 17, wherein the adjusting includes:

in response to the time interval being greater than a threshold time interval, regenerating the particulate filter in the engine exhaust conduit when particulate filter regeneration conditions are met via one or more of a retarding spark and decreasing an air/fuel ratio; and

in response to the time interval being less than the threshold time interval, indicating to an operator degradation of the particulate filter and adjusting an engine actuator to reduce engine torque output,

wherein the threshold time interval is based on a time elapsed between completion of a regeneration event immediately preceding the first regeneration and completion of the first regeneration, and wherein the time interval between the first regeneration and the second regeneration of the metal filter includes a time elapsed between completion of the first regeneration and completion of the second regeneration.

19. The method of claim 17, wherein performing each of the first regeneration and the second regeneration based on the pressure difference includes regenerating the second filter when the pressure difference between the second location and the first location is lower than a lower threshold, and maintaining the regenerating until the pressure difference is higher than an upper threshold.