Induction diagnostics for skip fire engines

• US 9,995,652 B1
• Filed: 01/16/2018
• Issued: 06/12/2018
• 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
• Primary Examiner(s): Gray, Francis
• Application Number:
  US15/872,675
• Publication Number:
  US 20180156692A1
• Time in Patent Office: 147 Days
• CPC Class Codes: F02D 13/06 Cutting-out cylinders
• CPC Class Codes: F02D 17/02 Cutting-out cutting-out engines in multiple engine arrangements F02D25/04
• CPC Class Codes: F02D 2041/001 for engines with variable valve actuation
• CPC Class Codes: F02D 2041/1432 the system including a filter, e.g. a low pass or high pass filter
• CPC Class Codes: F02D 2200/0406 Intake manifold pressure
• CPC Class Codes: F02D 2250/14 Timing of measurement, e.g. synchronisation of measurements to the engine cycle
• CPC Class Codes: F02D 41/0002 Controlling intake air
• CPC Class Codes: F02D 41/0087 Selective cylinder activation, i.e. partial cylinder operation deceleration cut-off F02D41/123
• CPC Class Codes: F02D 41/22 Safety or indicating devices for abnormal conditions in air/fuel ratio feedback systems F02D41/1495, in electric control linkage F02D11/107, in purge control systems F02M25/0809
• CPC Class Codes: F02D 41/2422 Selective use of one or more tables
• CPC Class Codes: F02D 41/3058 the engine working with a variable number of cycles
• CPC Class Codes: F02M 35/1038 for temperature or pressure
• CPC Class Codes: F02P 5/1512 with particular means concerning an individual cylinder
• 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
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A variety of methods, diagnostic modules and other arrangements for detecting air induction faults during operation of an internal combustion engine are described. In some embodiments, the intake manifold pressure is monitored with the intake pressure being read for each induction opportunity. Induction faults may be detected based at least in part on a comparison of the manifold pressure readings for sequential induction opportunities. In some embodiments, an induction fault is identified when the difference between the manifold pressure associated with an induction opportunity and the immediately preceding induction opportunity exceeds an induction fault threshold.

Claims

1. A method of detecting an induction fault in an internal combustion engine having an intake manifold that supplies air to at least one working chamber of the internal combustion engine, and an intake manifold pressure sensor configured to sense an air pressure within the intake manifold, the method comprising:

obtaining a first pressure reading indicative of the intake manifold pressure at a time associated with a first working chamber air induction opportunity;

obtaining a second pressure reading indicative of the intake manifold pressure at a time associated with a second working chamber air induction opportunity that follows the first working chamber induction opportunity, the second air induction opportunity being the next air induction opportunity following the first air induction opportunity; and

determining whether an induction fault has occurred in association with the second air induction opportunity based at least in part on the first and second pressure readings.

2. A method as recited in claim 1 further comprising:

determining a difference between the first and second pressure readings;

comparing the difference to a threshold; and

identifying an induction fault for the second air induction opportunity when the difference is beyond the threshold.

3. A method as recited in claim 1 wherein each pressure reading is based on a plurality of pressure measurement samples.

4. A method as recited in claim 1 wherein each pressure reading is made at substantially the same phase in a working cycle associated with its associated induction opportunity.

5. A method as recited in claim 4 wherein each pressure reading is made:

during an associated intake stroke of a piston in an associated working chamber in which the associated working cycle occurs; and

within a range of 150 degrees±

30 degrees of crankshaft rotation after top dead center of the piston in the associated intake stroke.

6. A method as recited in claim 1 wherein the threshold is based at least in part on how many air induction opportunities were skipped immediately before the second air induction opportunity.

7. A method as recited in claim 1 wherein the threshold is based at least in part on an intake manifold pressure ratio, wherein the intake manifold pressure ratio is a ratio of intake manifold pressure to barometric pressure.

8. A method as recited in claim 1 wherein the threshold is based at least in part on a current operational firing fraction of the engine.

9. A method as recited in claim 1 wherein the threshold is based at least in part on a current engine speed.

10. A method as recited in claim 1 performed while the engine is operating in a multi-charge level operational mode.

11. A method as recited in claim 1 performed while the engine is operating in a skip fire operational mode.

12. An induction fault lookup table embodied in a non-transitory computer readable medium associated with an engine controller for use in identifying air induction faults, the induction fault lookup table comprising:

a multiplicity of entries that identify induction fault thresholds, and

wherein the induction fault lookup table includes at least one index selected from the group consisting of (i) a number of skipped induction opportunities that immediately preceded a current induction opportunity, (ii) an intake manifold pressure ratio, (iii) an operational firing fraction, and (iv) an engine speed.

13. An induction fault lookup table as recited in claim 12 wherein the induction fault lookup table includes at least two indices selected from the group consisting of (i) the number of skipped induction opportunities that immediately preceded a current induction opportunity, (ii) the intake manifold pressure ratio, (iii) the operational firing fraction, and (iv) the engine speed.

14. An induction fault lookup table as recited in claim 12 wherein the induction fault lookup table is a multi-dimensional lookup table having both (i) the number of skipped induction opportunities that immediately preceded a current induction opportunity, and (ii) the intake manifold pressure ratio as indices.

15. An induction fault lookup table as recited in claim 12 wherein an additional index for the lookup table is selected from the group consisting of:

a skip frequency indicative of a number of induction skips that are expected to occur in a designated period of time;

a throttle position;

intake manifold pressure;

cam phase;

boost pressure;

intake valve lift profile; and

skip/induct decision for a next firing opportunity.

16. An induction fault lookup table as recited in claim 12 composed of first and second lookup table segments, wherein:

a first index for the first lookup table segment is intake manifold pressure ratio;

a second index for the first lookup table segment is engine speed;

a first index for the second lookup table segment is firing fraction; and

a second index for the second lookup table segment is the number of skipped induction opportunities that immediately precede the current induction opportunity; and

wherein values retrieved from the first and second lookup tables segments are summed to determine to provide a composite induction fault threshold.

17. A diagnostics module configured to detect induction faults that occur during operation of an internal combustion engine that includes an intake manifold that supplies air to at least one working chamber of the internal combustion engine, and an intake manifold pressure sensor configured to sense an air pressure within the intake manifold, the diagnostic module comprising a controller configured to:

obtain a first pressure reading indicative of the intake manifold pressure at a time associated with a first working chamber induction opportunity that has the potential to draw air from the intake manifold;

obtain a second pressure reading indicative of the intake manifold pressure at a time associated with a second working chamber induction opportunity that has the potential to draw air from the intake manifold, the second working chamber induction opportunity being the next working chamber induction opportunity following the first working chamber induction opportunity; and

determine whether an induction fault has occurred in association with the second working chamber induction opportunity based at least in part on the first and second pressure readings.

18. A diagnostics module as recited in claim 17 further comprising an induction fault lookup table embodied in a computer readable medium associated with the controller for use in identifying induction faults, the induction fault lookup table comprising a multiplicity of entries that identify induction fault thresholds used in the determination of whether an induction fault has occurred, wherein different entries in the induction fault lookup table correspond to thresholds suitable for use under different operating conditions.

19. A diagnostics module as recited in claim 18 wherein the induction fault lookup table includes at least one index selected from the group consisting of (i) a number of skipped induction opportunities that immediately preceded the second working chamber induction opportunity, (ii) an intake manifold pressure ratio, or (iii) an operational firing fraction.

20. A diagnostics module as recited in claim 18 wherein the controller is further configured to:

determine a difference between the first and second pressure readings;

compare the difference to a threshold; and

identifying an induction fault for the second induction opportunity when the difference exceeds the threshold.

21. A diagnostics module as recited in claim 18 wherein the controller is further configured to make a pressure reading at substantially the same phase in each working cycle.

22. An engine controller comprising the diagnostics module as recited in claim 17 and a skip fire controller configured to direct operation of an engine in a skip fire operational mode and wherein:

the diagnostic module is configured to detect induction faults during skip fire operation of the engine.

23. An engine controller comprising the diagnostics module as recited in claim 17 and a cylinder output level modulation controller configured to direct operation of an engine in a cylinder output level modulation operational mode and wherein:

the diagnostic module is configured to detect induction faults during cylinder output level modulation operation of the engine.