Fault detecting apparatus designed to detect different types of faults of gas sensor

• US 20040221641A1
• Filed: 05/10/2004
• Published: 11/11/2004
• Est. Priority Date: 05/09/2003
• Status: Active Grant

• Current Assignee: DENSO Corporation, Nippon Soken, Inc.
• Original Assignee: DENSO CORPORATION AND NIPPON SOKEN, INC.
• Inventors: Tomura, Takanao, Moritsugu, Michiyasu, Mizutani, Keigo, Makino, Daisuke, Kurokawa, Eiichi
• Granted Patent: US 7,073,320 B2
• Time in Patent Office: Days
• US Class Current: 73/23.31
• CPC Class Codes: G01N 27/4175 Calibrating or checking the analyser
• CPC Class Codes: G01N 33/007 Arrangements to check the analyser calibrating G01N33/0006

Abstract

A fault detecting apparatus for a gas concentration sensor is provided. The apparatus includes a storage device and a fault detecting circuit. The storage device stores therein fault detectable conditions in which preselected different types of faults of the gas concentration sensor are allowed to be detected, respectively. The fault detecting circuit works to detect a selected one of the faults stored in said storage device. When one of the fault detectable conditions is encountered during operation of the gas concentration sensor, the fault detecting circuit initiates detection of a corresponding one of the faults based on an output of the gas concentration sensor, thereby enabling the fault detecting circuit to identify the type of one of the faults to be detected correctly.

Claims

1. A fault detecting apparatus for a gas concentration sensor which has a sensor element including a solid electrolyte body, a plurality of electrodes affixed to the solid electrolyte body, and a gas chamber to which a gas to be measured is introduced and at least one of the electrode is exposed and works to produce an electrical signal between two of the electrodes as a function of an amount of oxygen ions traveling through the solid electrolyte body, comprising:

a storage device which stores therein fault detectable conditions in which preselected different types of faults of the gas concentration sensor are allowed to be detected, respectively; and

a fault detecting circuit working to detect a selected one of the faults stored in said storage device, when one of the fault detectable conditions is encountered during operation of the gas concentration sensor, said fault detecting circuit initiating detection of a corresponding one of the faults based on an output of the gas concentration sensor.

2. A fault detecting apparatus as set forth in claim 1, wherein when one of the fault detectable conditions in which a concentration of oxygen in the gas is known is encountered, said fault detecting circuit initiates detection of a corresponding one of the faults of the gas concentration sensor.

3. A fault detecting apparatus as set forth in claim 2, wherein when one of the fault detectable conditions in which a concentration of oxygen in the gas has increased is encountered, said fault detecting circuit monitor a resulting output of the gas concentration sensor, when the resulting output shows a value smaller than that corresponding to an increase in the concentration of oxygen, said fault detecting circuit determining that one of the faults in introducing the gas into the gas chamber has occurred.

4. A fault detecting apparatus as set forth in claim 3, wherein when the output of the gas concentration sensor is smaller than a threshold used to determine the fault in introducing the gas into the gas chamber, said fault detecting circuit determines as one of the faults that a wire leading to one of the electrodes of the sensor element has been broken.

5. A fault detecting apparatus as set forth in claim 2, wherein when one of the fault detectable conditions in which a concentration of oxygen in the gas has a given higher value is encountered, and a resulting output of the gas concentration sensor is greater than a preselected normal range, said fault detecting circuit determines as one of the faults that a cark is formed in a partition wall defining the gas chamber.

6. A fault detecting apparatus as set forth in claim 2, wherein the gas introduced into the gas chamber is an exhaust gas of an internal combustion engine, and wherein when one of the fault detectable conditions in which the engine is undergoing a fuel cut is encountered, said fault detecting circuit initiates the detection of the corresponding one of the faults of the gas concentration sensor.

7. A fault detecting apparatus as set forth in claim 1, wherein the gas concentration sensor also includes a reference oxygen gas chamber facing the gas chamber across the solid electrolyte body, and wherein when one of the fault detectable conditions in which a concentration of oxygen in the gas changes to a given lower value is encountered, and a resulting value of the output of the gas concentration sensor is different from one corresponding to the given lower value, said fault detecting circuit determines as one of the faults that a crack is formed in a partition wall defining the reference oxygen gas chamber.

8. A fault detecting apparatus as set forth in claim 7, wherein the gas introduced into the gas chamber is an exhaust gas of an internal combustion engine, and wherein when one of the fault detectable conditions in which a rich air-fuel ratio corresponding exhaust gas is introduced into the gas chamber is encountered, said fault detecting circuit initiates detection of said fault.

9. A fault detecting apparatus as set forth in claim 1, wherein when one of the fault detectable conditions in which a time when it is unnecessary to measure a concentration of the gas is reached is encountered, said fault detecting circuit increases and decreases a voltage applied across the two of the electrodes of the sensor element to determine a resistance value of the sensor element, when the resistance value is greater than a given value, said fault detecting circuit determining as one of the faults that a failure has occurred in activating the sensor element.

10. A fault detecting apparatus as set forth in claim 1, wherein when one of the fault detectable conditions in which the output of the gas concentration sensor increases up to near a limit of a current capacity of a driver circuit used to actuate the sensor element during operation of the gas concentration sensor is encountered, said fault detecting circuit determines as one of the faults that an electrical short has occurred between the electrodes of the sensor element.

11. A fault detecting apparatus for a gas concentration sensor which has a sensor element including a first chamber into which a gas to be measured is introduced, a second chamber leading to the first chamber, a first cell which works to pump oxygen into and out of the first chamber selectively to keep a concentration of oxygen at a given level within the first chamber and produces an electrical signal as a function of the concentration of oxygen, and a second cell which works to produce an electrical signal as a function of a concentration of a specified component of the gas flowing from the first chamber into the second chamber, comprising:

a storage device which stores therein fault detectable conditions in which preselected different types of faults of the gas concentration sensor are allowed to be detected, respectively; and

a fault detecting circuit working to detect a selected one of the faults stored in said storage device, when one of the fault detectable conditions is encountered during operation of the gas concentration sensor, said fault detecting circuit initiating detection of a corresponding one of the faults based on outputs of the first and second cells.

12. A fault detecting apparatus as set forth in claim 11, wherein when one of the fault detectable conditions in which the concentration of oxygen in the gas is known is encountered, said fault detecting circuit initiates detection of a corresponding one of the faults of the gas concentration sensor using the output of the first cell.

13. A fault detecting apparatus as set forth in claim 12, wherein when one of the fault detectable conditions in which the concentration of oxygen in the gas has increased is encountered, said fault detecting circuit monitors a resulting output of the first cell, when the resulting output shows a value smaller than that corresponding to an increase in the concentration of oxygen, said fault detecting circuit determining that one of the faults in introducing the gas into the first chamber has occurred.

14. A fault detecting apparatus as set forth in claim 13, wherein when the output of the first cell is smaller than a threshold used to determine the fault in introducing the gas into the first chamber, said fault detecting circuit determines as one of the faults that a wire leading to an electrode of the first cell has been broken.

15. A fault detecting apparatus as set forth in claim 12, wherein when one of the fault detectable conditions in which the concentration of oxygen in the gas has a given higher value is encountered, and a resulting output of the first cell is greater than a preselected normal range, said fault detecting circuit determines as one of the faults that a crack is formed in a partition wall defining the first chamber.

16. A fault detecting apparatus as set forth in claim 12, wherein the gas introduced into the gas chamber is an exhaust gas of an internal combustion engine, and wherein when one of the fault detectable conditions in which the engine is undergoing a fuel cut is encountered, said fault detecting circuit initiates the detection of the corresponding one of the faults of the gas concentration sensor.

17. A fault detecting apparatus as set forth in claim 11, wherein the sensor element also includes a reference oxygen gas chamber facing the first chamber across the first cell, and wherein when one of the fault detectable conditions in which the concentration of oxygen in the gas changes to a given lower value is encountered, and a resulting value of the output of the first cell is different from one corresponding to the given lower value, said fault detecting circuit determines as one of the faults that a crack is formed in a partition wall defining the reference oxygen gas chamber.

18. A fault detecting apparatus as set forth in claim 17, wherein the gas introduced into the first chamber is an exhaust gas of an internal combustion engine, and wherein when the one of the fault detectable conditions in which a rich air-fuel ratio corresponding exhaust gas is introduced into the gas chamber is encountered, said fault detecting circuit initiates detection of said fault.

19. A fault detecting apparatus as set forth in claim 11, wherein when one of the fault detectable conditions in which a time when it is unnecessary to measure the concentration of the specified component of the gas is reached is encountered, said fault detecting circuit increases and decreases a voltage applied across electrodes of one of the first and second cells to determine a resistance value of the one of the first and second cells, when the resistance value is greater than a given value, said fault detecting circuit determining as one of the faults that a failure has occurred in activating the one of the first and second cells.

20. A fault detecting apparatus as set forth in claim 11, wherein when one of the fault detectable conditions in which the concentration of oxygen in the first chamber is kept by the first cell at the given level is encountered, and when the output of the second cell is greater than a given normal range, said fault detecting circuit determines as one of the faults that a crack is formed in a partition wall defining the second chamber.

21. A fault detecting apparatus as set forth in claim 11, wherein when one of the fault detectable conditions in which the output of one of the first and second cells increases up to near a limit of a current capacity of a driver circuit used to actuate the one of the first and second cells during operation of the gas concentration sensor is encountered, said fault detecting circuit determines as one of the faults that an electrical short has occurred between electrodes of the one of the first and second cells.

22. A fault detecting apparatus as set forth in claim 11, wherein when one of the fault detectable conditions in which a voltage to be applied to the first cell is decreased below that used to measure the concentration of the specified gas component is encountered, and when a resulting value of the output of the second cell is smaller than a given value, said fault detecting circuit determines as one of the faults that a wire leading to an electrode of the second cell is broken.

23. A fault detecting apparatus as set forth in claim 11, wherein when one of the fault detectable conditions in which a time when it is unnecessary to measure the concentration of the specified component of the gas is reached is encountered, said fault detecting circuit shifts a voltage applied to the first cell to a lower level to find a voltage level applied to the first cell at which a value of the output of the second cell changes suddenly in relation to a change in the voltage applied to the first cell, when the found voltage level is greater than a given normal level, said fault detecting circuit determining as one of the faults that a failure has occurred in activating the first cell.

24. A fault detecting apparatus as set forth in claim 11, wherein the sensor element also includes a third cell which produces an output as a function of a concentration of oxygen within the second chamber, and the gas concentration sensor is designed to control a voltage applied to the first cell, and wherein when a selected one of the fault detectable conditions is encountered during operation of the gas concentration sensor, said fault detecting circuit initiates the detection of a corresponding one of the faults based on the output of the third cell.

25. A fault detecting apparatus as set forth in claim 24, wherein when one of the fault detectable conditions in which a time when it is unnecessary to measure the concentration of the specified component of the gas is reached is encountered, said fault detecting circuit increases and decreases a voltage applied to the third cell to find a resistance value of the third cell, when the resistance value is greater than a given value, said fault detecting circuit determining as one of the faults that a failure has occurred in activating the third cell.

26. A fault detecting apparatus as set forth in claim 24, wherein when one of the fault detectable conditions in which the concentration of oxygen in the first chamber is kept by the first cell at the given level is encountered, and when the output of the third cell is greater than a given normal range, said fault detecting circuit determines as one of the faults that a crack is formed in a partition wall defining the second chamber.

27. A fault detecting apparatus as set forth in claim 24, wherein when one of the fault detectable conditions in which the output of the third cell increases up to near a limit of a current capacity of a driver circuit used to actuate the third cell during operation of the gas concentration sensor is encountered, said fault detecting circuit determines as one of the faults that an electrical short has occurred between electrodes of the third cell.

28. A fault detecting apparatus as set forth in claim 24, wherein when one of the fault detectable conditions in which a voltage to be applied to the first cell is decreased below that used to measure the concentration of the specified gas component is encountered, and when a resulting value of the output of the third cell is smaller than a given value, said fault detecting circuit determines as one of the faults that a wire leading to an electrode of the third cell is broken.

29. A fault detecting apparatus as set forth in claim 24, wherein when one of the fault detectable conditions in which a time when it is unnecessary to measure the concentration of the specified component of the gas is reached is encountered, said fault detecting circuit shifts a voltage applied to the first cell to a lower level to find a voltage level applied to the first cell at which a value of the output of the third cell changes suddenly in relation to a change in the voltage applied to the first cell, when the found voltage level is greater than a given normal level, said fault detecting circuit determining as one of the faults that a failure has occurred in activating the third cell.