Induction diagnostics for skip fire engines

• US 9,891,137 B2
• Filed: 07/03/2017
• Issued: 02/13/2018
• Est. Priority Date: 10/23/2014
• Status: Active Grant

• Current Assignee: Tula Technology, Incorporated (BorgWarner Incorporated)
• Original Assignee: Tula Technology, Incorporated (BorgWarner Incorporated)
• Inventors: Chen, Shikui Kevin, Kotwicki, Allan J., Van Ess, Joel D., Bailey, Robert S., Pirjaberi, Mohammad R.
• Primary Examiner(s): GRAY, FRANCIS C
• Application Number:
  US15/641,097
• Publication Number:
  US 20170299466A1
• Time in Patent Office: 225 Days
• CPC Class Codes: F02D 2200/101 Engine speed
• CPC Class Codes: F02D 41/0087 Selective cylinder activation, i.e. partial cylinder operation deceleration cut-off F02D41/123
• CPC Class Codes: F02D 41/221 relating to the failure of actuators or electrically driven elements
• CPC Class Codes: F02M 35/1038 for temperature or pressure
• CPC Class Codes: G01M 15/05 by combined monitoring of two or more different engine parameters
• CPC Class Codes: G01M 15/09 by monitoring pressure in fluid ducts, e.g. in lubrication or cooling parts

Abstract

A variety of methods and arrangements for detecting failure of the commanded air induction in an internal combustion engine are described. In some embodiments, the intake manifold pressure is monitored. An air induction event generates a fluctuation in the intake manifold pressure, which is recorded. The signal is processed through a diagnostic filter to help determine whether the actual induction matched the commanded induction. In other embodiments, measured crankshaft acceleration is compared with estimated crankshaft acceleration. If the two quantities differ by a threshold amount an induction fault is detected. The two detection methods may also be combined. The describe approaches are particularly well suited for use in engines operating in a skip fire mode with cylinder deactivation and/or a dynamic firing level modulation mode.

Claims

1. A method of detecting an induction fault of a cylinder in an internal combustion engine having a crankshaft, the method comprising:

measuring the angular acceleration of the crankshaft to generate a crankshaft acceleration signal;

comparing the crankshaft angular acceleration signal with a reference angular acceleration wherein the reference is based at least in part on a commanded skip/fire decision; and

generating a fault signal when an induction fault is detected, wherein the induction fault detection is based at least in part on a determination that the crankshaft angular acceleration signal has deviated from the reference angular acceleration by at least a prescribed threshold.

2. A method as recited in claim 1 wherein the reference acceleration is further based at least in part on a valve lift schedule.

3. A method as recited in claim 1 wherein the reference acceleration is further based at least in part on the intake manifold pressure or mass air charge per cylinder.

4. An engine control unit arranged to control the operation of an engine, the engine control unit including an induction fault detection unit, the induction fault detection unit comprising:

a crankshaft angular acceleration comparator that compares a measured crankshaft angular acceleration with an expected crankshaft angular acceleration, wherein the expected crankshaft angular acceleration is based at least in part on a commanded skip/fire decision; and

wherein the induction fault detection unit is configured to generate a fault signal when an induction fault is detected, wherein the induction fault detection is based at least in part on a determination that the measured crankshaft angular acceleration has deviated from the expected angular acceleration by more than a prescribed amount.

5. An engine control unit as recited in claim 4 wherein the expected acceleration is further based at least in part on a valve lift schedule.

6. An engine control unit as recited in claim 4 wherein the expected acceleration is further based at least in part on the intake manifold pressure or mass air charge per cylinder.

7. An engine control unit as recited in claim 4 configured to direct operation of the engine in a skip fire mode, the engine control unit further comprising a firing timing determining unit arranged to determine the timing of working chamber firings when the engine, is operated in the skip fire operating mode, wherein the induction fault detection unit is configured to detect induction faults while the internal combustion engine is operated in the skip fire operating mode.

8. An engine control unit as recited in claim 4 configured to direct operation of the engine in a dynamic firing level modulation mode, the engine control unit further comprising a firing timing determining unit arranged to determine the magnitude of working chamber firings when the engine, is operated in the dynamic firing level modulation mode, wherein the induction fault detection unit is configured to detect induction faults while the internal combustion engine is operated in the dynamic firing level modulation mode.

9. An engine control unit as recited in claim 4 wherein the induction fault detection unit is configured to generate the fault signal during the same engine cycle in which a fault occurs.

10. An engine control unit as recited in claim 4 wherein the induction fault detected by the induction fault detection unit is selected from the group consisting of:

a valve activation failure indicative of the failure of an intake valve to open when the valve is expected to open;

a valve deactivation failure indicative of the failure of the intake valve to remain closed when the valve is intended to be kept closed;

a valve lift too low failure indicative of the intake valve lift being lower than intended; and

a valve lift too high threshold indicative of the intake valve lift being higher than intended.

11. An engine control unit as recited in claim 4 wherein the engine control unit includes a processor and the functionality of the induction fault detection unit is embodied in computer code executing on the processor.

29. A method as recited in claim 4 wherein the fault signal is generated during the same engine cycle in which the fault occurs.

30. A method as recited in claim 29 further comprising operating the engine in a skip fire mode, whereby the induction fault detection occurs while the internal combustion engine is operated in the skip fire operating mode.

31. A method as recited in claim 29 further comprising operating the engine in a dynamic firing level modulation mode wherein the engine induction fault detection occurs while the internal combustion engine is operated in the dynamic firing level modulation operating mode.

12. An engine control unit arranged to control the operation of an engine, the engine control unit including an induction fault detection unit, the induction fault detection unit comprising:

a manifold pressure comparator that compares a measured intake manifold pressure with an expected intake manifold pressure;

a crankshaft angular acceleration comparator that compares a measured crankshaft angular acceleration with an expected crankshaft angular acceleration; and

wherein the induction fault detection unit is configured to generate a fault signal when an induction fault is detected, wherein the induction fault detection is based at least in part on a determination that both (i) the measured intake manifold pressure has deviated from the expected intake manifold pressure by more than a first prescribed threshold, and (ii) the measured crankshaft angular acceleration has deviated from the expected crankshaft angular acceleration by more than a second prescribed threshold.

13. An engine control unit as recited in claim 12 further comprising a filter arranged to filter a signal indicative of the intake manifold pressure to reduce low frequency signal components of the intake manifold pressure signal, wherein the filtered intake manifold pressure signal is used by the manifold pressure comparator in the comparison of the measured intake manifold pressure with the expected intake manifold pressure.

14. An engine control unit as recited in claim 13 wherein the filter includes a complementary filter.

15. An engine control unit as recited in claim 13 wherein the filter includes cascaded first and second first order low pass filters that filter the intake manifold pressure signal and a subtractor arranged to subtract the output of low pass filters from the intake manifold pressure signal to produce the filtered intake manifold pressure signal.

16. An engine control unit as recited in claim 13 wherein the filter further comprises an adder arranged to sum an output of the complementary filter with a delayed output of the complementary filter to obtain the filtered intake manifold pressure signal.

17. An engine control unit as recited in claim 13 wherein the filtered intake manifold pressure signal has a zero centered output.

18. An engine control unit as recited in claim 12 wherein the expected acceleration is further based at least in part on a valve lift schedule.

19. An engine control unit as recited in claim 12 wherein the expected acceleration is further based at least in part on the intake manifold pressure or mass air charge per cylinder.

20. An engine control unit as recited in claim 12 configured to direct operation of the engine in a skip fire mode, the engine control unit further comprising a firing timing determining unit arranged to determine the timing of working chamber firings when the engine, is operated in the skip fire operating mode, wherein the induction fault detection unit is configured to detect induction faults while the internal combustion engine is operated in the skip fire operating mode.

21. An engine control unit as recited in claim 12 configured to direct operation of the engine in a dynamic firing level modulation mode, the engine control unit further comprising a firing timing determining unit arranged to determine the magnitude of working chamber firings when the engine, is operated in the dynamic firing level modulation mode, wherein the induction fault detection unit is configured to detect induction faults while the internal combustion engine is operated in the dynamic firing level modulation mode.

22. An engine control unit as recited in claim 12 wherein the induction fault detection unit is configured to generate the fault signal during the same engine cycle in which a fault occurs.

23. An engine control unit as recited in claim 12 wherein the induction fault detected by the induction fault detection unit is selected from the group consisting of:

a valve activation failure indicative of the failure of an intake valve to open when the valve is expected to open;

a valve deactivation failure indicative of the failure of the intake valve to remain closed when the valve is intended to be kept closed;

a valve lift too low failure indicative of the intake valve lift being lower than intended; and

a valve lift too high threshold indicative of the intake valve lift being higher than intended.

24. An engine control unit as recited in claim 12 wherein the engine control unit includes a processor and the functionality of the induction fault detection unit is embodied in computer code executing on the processor.

25. A method of detecting an induction fault of a cylinder in an internal combustion engine having an intake manifold and crankshaft, the method comprising:

measuring the intake manifold pressure;

comparing the measured intake manifold pressure with an expected intake manifold pressure;

measuring the crankshaft angular acceleration;

comparing the measured crankshaft angular acceleration with an expected crankshaft angular acceleration;

generating a fault signal when an induction fault is detected, wherein the induction fault detection is based at least in part on a determination that both (i) the measured intake manifold pressure has deviated from the expected intake manifold pressure by more than a first prescribed threshold, and (ii) the measured crankshaft angular acceleration has deviated from the expected crankshaft angular acceleration by more than a second prescribed threshold.

26. A method of detecting an induction fault as recited in claim 25 further comprising filtering a signal indicative of the intake manifold pressure to reduce low frequency signal components of the intake manifold pressure signal and using the filtered intake manifold pressure signal in the comparison of the measured intake manifold pressure with the expected intake manifold pressure.

27. A method as recited in claim 25 wherein the induction fault is selected from the group consisting of:

a valve activation failure indicative of the failure of an intake valve to open when the valve is expected to open;

a valve deactivation failure indicative of the failure of the intake valve to remain closed when the valve is intended to be kept closed;

a valve lift too low failure indicative of the intake valve lift being lower than intended; and

a valve lift too high threshold indicative of the intake valve lift being higher than intended.

28. A method as recited in claim 25 wherein a complementary filter is used to filter the intake manifold signal.

32. A method as recited in claim 28 further comprising summing an output of the complementary filter with a delayed output of the complementary filter to obtain an output signal that helps identify induction faults.