System for managing catalytic converter temperature

• US 9,726,094 B2
• Filed: 11/19/2014
• Issued: 08/08/2017
• Est. Priority Date: 11/21/2013
• Status: Active Grant

• Current Assignee: Tula Technology, Incorporated
• Original Assignee: Tula Technology, Incorporated
• Inventors: Subramanian, Ram, Younkins, Matthew A., Breton, Leo
• Primary Examiner(s): Vo, Hieu T
• Assistant Examiner(s): Castro, Arnold
• Application Number:
  US14/548,138
• Publication Number:
  US 20150136082A1
• Time in Patent Office: 993 Days
• CPC Class Codes: F02D 2041/0265 to decrease temperature of the exhaust gas treating apparatus
• CPC Class Codes: F02D 2200/0802 Temperature of the exhaust gas treatment apparatus
• CPC Class Codes: F02D 2200/0804 Estimation of the temperature of the exhaust gas treatment apparatus
• CPC Class Codes: F02D 41/0087 Selective cylinder activation, i.e. partial cylinder operation deceleration cut-off F02D41/123
• CPC Class Codes: F02D 41/025 by changing the composition of the exhaust gas, e.g. for exothermic reaction on exhaust gas treating 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 41/06 for engine starting or warming up F02D41/0255 takes precedence
• CPC Class Codes: F02D 41/1446 the characteristics being exhaust temperatures
• CPC Class Codes: F02D 41/1454 the characteristics being an oxygen content or concentration or the air-fuel ratio
• CPC Class Codes: F02D 41/263 the program execution being modifiable by physical parameters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Various methods and arrangements for controlling catalytic converter temperature are described. In one aspect, an engine controller includes a catalytic monitor and a firing timing determination unit. The catalytic monitor obtains data relating to a temperature of a catalytic converter. Based at least partly on this data, the firing timing determination unit generates a firing sequence for operating the engine in a skip fire manner. Another aspect of the invention relates to an engine exhaust system that can help expedite the heating of a catalytic converter.

Claims

1. An engine controller for operating an internal combustion engine in a skip fire manner, the engine controller including a plurality of working chambers, the engine controller comprising:

a catalytic monitor arranged to obtain data relating to a temperature of a catalytic converter wherein the catalytic converter temperature data is obtained from one selected from the group consisting of a catalytic converter temperature model and a sensed catalytic converter temperature; and

a firing timing determination unit that is arranged to determine a firing sequence for operating the working chambers of the engine in a skip fire manner wherein the firing sequence is generated at least in part based on the catalytic converter temperature data; and

wherein the firing timing determination unit is arranged to perform firings only in a first subset of the working chambers and not in a second subset of the working chambers during an engine startup period.

2. An engine controller as recited in claim 1 wherein the catalytic converter temperature model is based on one or more selected from the group consisting of oxygen sensor data, exhaust gas temperature, ambient temperature, ambient humidity, barometric pressure and engine coolant temperature.

3. An engine controller as recited in claim 1 wherein the engine controller is arranged to generate the firing sequence during an engine startup period that takes place immediately after the engine is activated from a cold start.

4. An engine controller as recited in claim 1 wherein the firing sequence is determined on a firing opportunity by firing opportunity basis.

5. An engine controller as recited in claim 1 wherein the operation of the engine in a skip fire manner involves firing at least one selected working cycle of at least one selected working chamber and skipping at least one selected working cycle of at least one selected working chamber wherein individual working chambers are sometimes skipped and sometimes fired.

10. An engine controller as recited in claim 1 wherein the firing timing determination unit uses a sigma delta converter to determine the firing sequence.

11. An engine controller as recited in claim 1 further comprising a firing fraction calculator that is arranged to determine a firing fraction that delivers a desired torque wherein:

the firing sequence is based at least partly on the firing fraction; and

the firing fraction is determined based at least partly on one selected from the group consisting of oxygen sensor data, exhaust gas temperature, catalytic converter temperature, ambient temperature, barometric pressure and engine coolant temperature.

6. An engine controller for operating an internal combustion engine in a skip fire manner, the engine controller including a plurality of working chambers, the engine controller comprising:

a catalytic monitor arranged to obtain data relating to a temperature of a catalytic converter wherein the catalytic converter temperature data is obtained from one selected from the group consisting of a catalytic converter temperature model and a sensed catalytic converter temperature; and

a firing timing determination unit that is arranged to determine a firing sequence for operating the working chambers of the engine in a skip fire manner wherein the firing sequence is generated at least in part based on the catalytic converter temperature data, wherein,

the operation of the engine in a skip fire manner involves firing at least one selected working cycle and skipping at least one selected working cycle;

the skipping of at least one selected working cycle involves delivering air to at least one selected working chamber, thereby passing oxygen to the catalytic converter; and

unburnt hydrocarbon is delivered to the catalytic converter such that unburnt hydrocarbon reaches the catalytic converter and exothermically reacts with the oxygen from the skipped working chambers, thereby heating the catalytic converter.

7. An engine controller as recited in claim 6 wherein heating of the catalytic converter during an engine startup period is performed using exhaust gases, the excess fuel and the air generated through the skip fire operation of the working chambers and does not require an additional pump for delivering air to the catalytic converter.

8. An engine controller as recited in claim 7 wherein the firing timing determination unit is arranged to perform firings only in a first subset of the working chambers and not in a second subset of the working chambers during the engine startup period.

9. An engine controller for operating an internal combustion engine in a skip fire manner, the engine controller including a plurality of working chambers, the engine controller comprising:

a catalytic monitor arranged to obtain data relating to a temperature of a catalytic converter wherein the catalytic converter temperature data is obtained from one selected from the group consisting of a catalytic converter temperature model and a sensed catalytic converter temperature; and

a firing timing determination unit that is arranged to determine a firing sequence for operating the working chambers of the engine in a skip fire manner wherein the firing sequence is generated at least in part based on the catalytic converter temperature data; and

wherein the engine controller is arranged to determine whether a temperature of the catalytic converter is above a predetermined threshold; and

wherein if it is determined that the temperature of the catalytic converter is above the predetermined threshold, the engine controller is arranged to pass additional air using skipped working chambers to the catalytic converter, thereby helping to cool the catalytic converter until a desired temperature level is reached.

12. A method for controlling a temperature of a catalytic converter using skip fire engine control, the method comprising:

obtaining data relating to a temperature of a catalytic converter wherein the catalytic converter temperature data is obtained from one selected from the group consisting of a catalytic converter temperature model and a sensed catalytic converter temperature; and

determining a firing sequence for operating the working chambers of the engine in a skip fire manner wherein the firing sequence is generated at least in part based on the catalytic converter temperature data;

during at least one skipped working cycle in the firing sequence, delivering air to and pumping air through at least one selected working chamber, thereby passing oxygen to the catalytic converter; and

causing unburnt hydrocarbon to be delivered to the catalytic converter such that the unburnt hydrocarbon exothermically reacts with the oxygen passed through the at least one selected working chamber during the at least one skipped working cycle, thereby heating the catalytic converter.

13. A method as recited in claim 12 wherein the catalytic converter temperature model is based on one or more selected from the group consisting of oxygen sensor data, exhaust gas temperature, ambient temperature, barometric pressure and engine coolant temperature.

14. A method as recited in claim 12 wherein the engine controller is arranged to generate the firing sequence during an engine startup period that takes place immediately after the engine is activated from a cold start.

15. A method as recited in claim 12 wherein the firing sequence is determined on a firing opportunity by firing opportunity basis.

16. An engine exhaust system for an internal combustion engine having a plurality of working chambers, the plurality of working chambers including a first subset of working chambers and a second subset of working chambers, the first and second subsets of working chambers being mutually exclusive, the engine exhaust system comprising:

an upstream catalytic converter that is coupled with and is arranged to receive exhaust gases from only the first subset of working chambers of the engine; and

a downstream catalytic converter that is coupled to the upstream catalytic converter and is arranged to receive gases from the upstream catalytic converter wherein the downstream catalytic converter is connected with the second set of working chambers such that exhaust gases from the second set of working chambers do not pass through any catalytic converter before being received at the downstream catalytic converter; and

a tailpipe that is coupled with the downstream catalytic converter.

17. An engine exhaust system as recited in claim 16 further comprising:

a Y pipe that is connected with the tailpipe, the Y pipe and tailpipe arranged such that gases passing from the Y pipe to the tailpipe pass through the downstream catalytic converter; and

a piping system that separately connects the first and second subsets of working chambers with the Y pipe such that exhaust gases from the first subset of working chambers pass through the upstream catalytic converter before reaching the Y pipe and exhaust gases from the second subset of working chambers do not pass through any catalytic converter before reaching the Y pipe.

18. An engine exhaust system as recited in claim 16, further comprising an engine controller that is arranged to operate the working chambers in a skip fire manner such that firings take place in the first subset of working chambers and not in the second subset of working chambers during a startup period of the engine.

19. An engine exhaust system for an internal combustion engine having a plurality of working chambers, the plurality of working chambers including a first subset of working chambers and a second subset of working chambers, the engine exhaust system comprising:

an upstream catalytic converter that is coupled with and is arranged to receive exhaust gases from the first subset of working chambers of the engine;

a downstream catalytic converter that is coupled to the upstream catalytic converter and is arranged to receive gases from the upstream catalytic converter wherein the downstream catalytic converter is connected with the second set of working chambers such that exhaust gases from the second set of working chambers do not pass through any catalytic converter before being received at the downstream catalytic converter;

a tailpipe that is coupled with the downstream catalytic converter; and

an engine controller that is arranged to operate the working chambers in a skip fire manner such that firings take place in the first subset of working chambers and not in the second subset of working chambers during a startup period of the engine, and wherein the engine controller is further arranged to fire at least one selected working cycle of at least one selected working chamber and to skip at least one selected working cycle of at least one selected working chamber wherein a rich air fuel mixture is delivered to the fired working chambers and additional air is allowed to pass through the skipped working chambers such that the excess fuel and additional air exothermically react in the catalytic converter to generate heat in the catalytic converter.

20. An engine exhaust system for an internal combustion engine having a plurality of working chambers, the plurality of working chambers including a first subset of working chambers and a second subset of working chambers, the engine exhaust system comprising:

an upstream catalytic converter that is coupled with and is arranged to receive exhaust gases from the first subset of working chambers of the engine; and

a downstream catalytic converter that is coupled to the upstream catalytic converter and is arranged to receive gases from the upstream catalytic converter wherein the downstream catalytic converter is connected with the second set of working chambers such that exhaust gases from the second set of working chambers do not pass through any catalytic converter before being received at the downstream catalytic converter; and

a tailpipe that is coupled with the downstream catalytic converter; and

an engine controller that is arranged to operate the working chambers in a variable displacement mode such that the first subset of working chambers are fired and the second subset of working chambers are deactivated during an engine startup period.