Automatic calibration system and method for a dual fuel internal combustion engine

• US 9,945,308 B2
• Filed: 09/13/2016
• Issued: 04/17/2018
• Est. Priority Date: 09/13/2016
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Gough, Michael D., Atterberry, Nathan, Howard, Jeff, Bell, Brian, Xu, Hua
• Primary Examiner(s): Tran, Long T
• Application Number:
  US15/263,945
• Publication Number:
  US 20180073452A1
• Time in Patent Office: 581 Days
• CPC Class Codes: F02B 3/12 Methods of operating
• CPC Class Codes: F02B 37/00 Engines characterised by provision of pumps driven at least for part of the time by exhaust
• CPC Class Codes: F02B 43/00 Engines characterised by operating on gaseous fuels; Plants including such engines engines characterised by the gas-air charge being ignited by compression ignition of an additional fuel F02B7/06; engines convertible from gas to other fuel consumption F02B69/04
• CPC Class Codes: F02B 43/12 Methods of operating
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02D 19/0647 the gaseous fuel being liquefied petroleum gas [LPG], liquefied natural gas [LNG], compressed natural gas [CNG] or dimethyl ether [DME]
• CPC Class Codes: F02D 2041/389 for injecting directly into the cylinder
• CPC Class Codes: F02D 2200/04 Engine intake system parameters
• CPC Class Codes: F02D 2200/0602 Fuel pressure
• CPC Class Codes: F02D 35/023 by determining the cylinder pressure
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/0025 Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures
• CPC Class Codes: F02D 41/0027 the fuel being gaseous non-electrical control F02D19/02
• CPC Class Codes: F02D 41/1446 the characteristics being exhaust temperatures
• CPC Class Codes: F02D 41/401 Controlling injection timing F02D41/402 takes precedence
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A system and method for automatically calibrating an engine operating with a first fuel and a second fuel includes comparing each of a plurality of engine operating parameters with a corresponding limit, determining whether any of the plurality of engine operating parameters has exceeded its corresponding limit and, while none of the plurality of engine operating parameters has exceeded its corresponding limit, automatically and incrementally advance start of injection timing.

Claims

1. A method for operating an engine, comprising:

providing a first fuel into an engine cylinder;

injecting a second fuel into the engine cylinder at a start of injection (SOI) timing;

providing an engine parameter to a controller;

providing a cylinder parameter to the controller;

monitoring the engine parameter and the cylinder parameter with the controller;

comparing the engine parameter and the cylinder parameter in the controller with corresponding limits to determine a global error that is related to the engine parameter and a local error that is related to the cylinder; and

while each of the global error and the local error indicate that the engine parameter and the cylinder parameter are below the corresponding limits, automatically advancing the SOI timing with the controller for all engine cylinders,

when the local error indicates that the cylinder parameter is above the corresponding limit, automatically retarding the SOI timing for a particular cylinder with the controller.

2. The method of claim 1, wherein the first fuel is a gaseous fuel and the second fuel is diesel fuel, and wherein the method further comprises injecting the diesel fuel directly into an engine cylinder using a diesel fuel injector.

3. The method of claim 1, wherein the engine parameter is provided from a sensor disposed to measure the engine parameter and provide a signal indicative of the engine parameter to the controller.

4. The method of claim 3, wherein the engine parameter is at least one of a turbocharger speed and an exhaust temperature.

5. The method of claim 4, further comprising:

monitoring a second engine parameter with the controller;

comparing the second engine parameter in the controller with a second limit to determine a second error;

while the error indicates that the engine parameter is below the corresponding limit, and the second error indicates that the second engine parameter is below the second limit, automatically advancing the SOI timing with the controller, and

when one of the error and the second error indicates that the engine parameter is above the corresponding limit or the second parameter is above the second limit, automatically retarding the SOI timing with the controller.

6. The method of claim 1, further comprising calculating an adjustment value in the controller based on the error.

7. The method of claim 6, further comprising adding the adjustment value to a base timing value to calculate a final timing command in the controller, the final timing command determining the SOI timing for the second fuel.

8. The method of claim 1, wherein and wherein the cylinder parameter is at least one of a cylinder pressure and a detonation value.

9. The method of claim 1, wherein the engine parameter is a fuel valve position for a fuel valve controlling a flow of the first fuel to the engine, and wherein the method further comprises:

determining a second limit for a second engine parameter based on then-present engine operating conditions;

comparing the second limit with the second engine parameter to determine a second error; and

setting a limit for the amount of second fuel that can be provided to the engine based on the error and the second error.

10. An engine having an engine cylinder for burning a mixture of a first fuel and a second fuel, comprising:

a first fuel system configured for providing the first fuel into the engine cylinder;

a fuel injector configured for injecting the second fuel into the engine cylinder at a start of injection (SOI) timing;

a first sensor operating to monitor a global engine parameter and to provide a first signal indicative of the global engine parameter;

a second sensor operating to monitor a cylinder-specific parameter of the engine cylinder and provide second signal indicative of a cylinder-specific engine parameter;

a controller disposed to receive the first signal and the second signal and operating to monitoring the global engine parameter and the cylinder-specific engine parameter;

wherein the controller is configured to;

compare the global engine parameter with a corresponding limit to determine a global error;

compare the cylinder-specific parameter with a corresponding limit to determine a local error; and

while the global error indicates that the engine parameter and the local error indicates that the cylinder-specific parameter are below their corresponding limits, automatically advance the SOI timing with the controller for all engine cylinders, and

while the local error indicates that the cylinder-specific parameter is above the corresponding limit, automatically retard the SOI timing for the particular engine cylinder with the controller.

11. The engine of claim 10, wherein the first fuel is a gaseous fuel and the second fuel is diesel fuel, and wherein the fuel injector is configured to inject the diesel fuel directly into the engine cylinder.

12. The engine of claim 10, wherein the global engine parameter is at least one of a turbocharger speed and an exhaust temperature, and wherein the cylinder-specific parameter is at least one of a peak cylinder pressure and a detonation value.

13. The engine of claim 12, wherein the engine includes a plurality of engine cylinder, wherein the controller is further configured to determine a plurality of local errors, each of the plurality of local errors corresponding to one of the plurality of engine cylinders, and wherein when one of the plurality of local errors exceeds its corresponding limit, the controller operates to automatically retard the SOI for the corresponding engine cylinder independently from the remaining engine cylinders in the plurality of engine cylinders.

14. The engine of claim 10, wherein the controller is further configured to calculate an adjustment value for the SOI timing based on the global error or the local error.

15. The engine of claim 14, wherein the controller is further configured to add the adjustment value to a base timing value to calculate a final timing command, the final timing command determining the SOI timing for the second fuel.

16. The engine of claim 10, wherein the engine parameter is a fuel valve position for a fuel valve controlling a flow of the first fuel to the engine, and wherein the controller is further configured to:

determine a second limit for a second engine parameter based on then-present engine operating conditions;

compare the second limit with the second engine parameter to determine a second error; and

set a limit for the amount of second fuel that can be provided to the engine based on the error and the second error.

17. The engine of claim 10, further comprising a gaseous fuel injector associated with the engine cylinder and disposed to inject the first fuel directly into the first cylinder.

18. A method for automatically calibrating an engine operating with a first fuel and a second fuel, the method comprising:

comparing each of a plurality of global and local engine operating parameters with corresponding limits;

determining whether any of the plurality of global and local engine operating parameters has exceeded its corresponding limit;

while none of the plurality of global and local engine operating parameters has exceeded its corresponding limit, automatically and incrementally advance start of injection (SOI) timing for all engine cylinders; and

in the event at least one of the local engine operating parameters exceeds its corresponding limit, retarding the start of injection timing for one of the engine cylinders at which the local engine operating parameter corresponds.

19. The method of claim 18, wherein the plurality of engine operating parameters includes a peak cylinder pressure, a detonation value, a turbocharger speed and an exhaust temperature.

20. The method of claim 19, wherein the plurality of engine parameters includes global engine parameters, which global engine parameters are affected by operation of a plurality of engine cylinders, and local engine parameters, which local engine parameters are affected by operation of a particular engine cylinder from the plurality of engine cylinders, and wherein the method further includes adjusting SOI for all of the plurality of engine cylinders based on the global engine parameters and adjusting SOI for particular engine cylinders independently from the remaining engine cylinders in the plurality of engine cylinders based on local engine parameters.