Abstract:
The present invention provides a method and system for purging a vapor canister in a Hybrid Electric Vehicle during vehicle idle conditions. The present invention first determines whether purging is necessary by measuring fuel tank pressure and the time since the last purge. If either of these elements exceeds a calibratable threshold, the controller determines that the engine needs to be on and that purging must occur. An electronic throttle controller can also be used to command the throttle plate to low positions to increase intake manifold vacuum while purging. This allows for very rapid ingestion of the fuel vapor without risk of engine stalls, if used in an HEV where the engine speed is controlled by an electric motor. Upon completion of the purging process, the engine is shut “off” and the vehicle is returned to its normal idle conditions.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present invention relates to a Hybrid Electric Vehicle (“HEV”) where a vehicle system controller or engine controller determines if a canister collecting fuel vapor needs to be purged during vehicle idle. 
     2. Discussion of the Prior Art 
     The need to reduce fossil fuel consumption and pollutants of automobiles and other vehicles powered by Internal Combustion Engines (“ICEs”) is well known. Vehicles powered by electric motors have attempted to address these needs. However, electric vehicles have limited range and limited power coupled with the substantial time needed to recharge their batteries. An alternative solution is to combine both an ICE and electric traction motor into one vehicle. Such vehicles are typically called Hybrid Electric Vehicles (“HEVs”). See generally, U.S. Pat. No. 5,343,970 (Severinsky). 
     The HEV has been described in a variety of configurations. Many HEV patents disclose systems where an operator is required to select between electric and internal combustion operation. In others, the electric motor drives one set of wheels and the ICE drives a different set. 
     Other configurations have developed. A Series Hybrid Electric Vehicle (“SHEV”) is a vehicle with an engine (most typically an ICE) which powers a generator. The generator, in turn, provides electricity for a battery and motor coupled to the drive wheels of the vehicle. There is no mechanical connection between the engine and the drive wheels. A Parallel Hybrid Electrical Vehicle (“PHEV”) is a vehicle with an engine (most typically an ICE), battery, and electric motor combined to provide torque to power the wheels of the vehicle. 
     A Parallel/Series Hybrid Electric Vehicle (“PSHEV”) has characteristics of both a PHEV and a SHEV. The PSHEV is also known as a torque (or power) splitting powertrain configuration. Here, the torque output of the engine is given in part to the drive wheels and in part to an electrical generator. The electric generator powers a battery and motor that also provide torque output. In this configuration, torque output can come from either source or both simultaneously. In this configuration the vehicle braking system can even deliver torque to drive the generator to produce charge to the battery. 
     The desirability of combining an ICE with an electric motor is clear. The combination provides the opportunity to reduce the ICE&#39;s fuel consumption and pollutants with no appreciable loss of performance or range of the vehicle. Nevertheless, there remains substantial room for development of ways to optimize these HEV&#39;s operational parameters. 
     One such area of improvement is the HEV&#39;s tailpipe and evaporative emission control systems. Tailpipe emissions require very tight control of the Air to Fuel ratio (A/F). Controlling the A/F ratio requires an oxygen sensor to measure the amount of oxygen leaving the engine after combustion. A controller then monitors the oxygen levels and controls the amount of fuel provided by the injectors in an attempt to create an optimal A/F ratio, thereby reducing unwanted emissions. 
     Controlling the A/F ratio becomes more complex when fuel vapor is considered. Fuel vapor is generated in the fuel system (tank and lines) because of the heat of the fuel when the engine is running at its stabilized operating temperature. If not managed properly, the vapor can build, causing the fuel vapor pressure to increase to the point where the vapor can leak out of the fuel system into the atmosphere as unwanted evaporative emissions. Thus, a charcoal canister is typically installed between the fuel tank and the engine to collect the fuel vapor. Over time, the canister becomes full and must be emptied or purged. In order to purge, a vapor management valve (VMV) is opened in a controlled manner by a VMV controller, thereby allowing the fuel vapor into the intake manifold, as long as there is sufficient vacuum present inside the manifold. During the purging process, the A/F controller maintains the optimum A/F ratio (and thus compensates for the additional fuel vapor entering the cylinders) by adjusting the fuel amount delivered by the injectors. Then, the VMV controller determines when the canister is empty and closes the VMV. Specifically, the VMV controller determines the canister&#39;s condition by estimating how much fuel vapor is being drawn into the intake manifold and cylinders. The amount that the A/F controller must correct the fuel delivery through the fuel injectors when the purging process is occurring reflects how much fuel vapor is coming from the vapor canister and causing the A/F disturbance. 
     Although it is desirable to purge the canister as quickly as possible, the rate of purging must be controlled. If the purge valve opens too quickly, especially if the intake manifold is in a high vacuum condition, the A/F controller may not be able to compensate fast enough for the incoming fuel vapor. This, in turn, can cause the A/F ratio to become too lean and causes poor engine combustion. In a conventional vehicle, if the A/F is too lean, the engine could stall. Thus, in conventional vehicles (and perhaps some HEV configurations), even though the vapor canister can be purged faster if the VMV is opened quickly and if higher vacuum conditions are present in the intake manifold, the risk exists that the engine may stall. 
     HEVs present additional purge problems. First, the engine is not always running, particularly during idle conditions (when the vehicle is not in motion). The canister can still store vapor, but it is not possible to purge the canister if the engine is not running. 
     Second, some HEVs run the engine at near wide-open throttle conditions (when the engine is running) because it is more fuel-efficient. However, little or no vacuum is available to draw the vapor into the intake manifold when the VMV is opened. This, in turn, makes it very difficult to purge the vapor canister. 
     Finally, most engine control systems implement an adaptive fuel strategy that “learns” or “adapts” the long term fuel shifts in the fuel delivery system caused by variation in fuel system components (injectors and mass air flow sensor). A typical engine control system does not allow the purging process to occur while the adaptive fuel shifts are learned because the purging process introduces A/F ratio shifts that should not be attributed to the fuel delivery system but rather to purge vapor. Thus, for the reduced amount of time that the engine is running during an HEV drive cycle, the adaptive fuel and purge strategies are competing for time to accomplish their objective. 
     The aforementioned issues make it difficult to purge the vapor canister often enough during a given HEV drive cycle. This increases the risk that fuel vapors will be released into the environment, which is not consistent with current emission goals and standards. Therefore, it is desirable to develop a method of purging the canister of an HEV to minimize the release of fuel vapor to the environment. 
     SUMMARY OF THE INVENTION 
     The present invention provides a method and system for purging a vapor canister in an HEV. Even though this invention is for an HEV, it uses a conventional-type purge control strategy that runs normally when the engine is “on” and conventional purging conditions are met (such as the adaptive fuel strategy is not running). This strategy includes the vehicle idle modes encountered in an HEV drive cycle where the engine is required to be “on” for reasons other than purging the vapor canister. The reasons include but are not limited to battery charging and running the air conditioner if mechanically driven by the engine front end accessory drive belt, etc. 
     When the engine is running, it is not always at an optimal point for purging (low vacuum or adaptive fuel strategy is running). Further, since most vehicle idle modes have the engine “off”, the vapor canister status and purge must be monitored at appropriate times to insure efficiency and emissions goals are met. The best opportunity for doing this is when the vehicle is at idle. 
     The present invention forces the engine to remain (or turn) on at vehicle idle conditions to purge the vapor canister if required by certain canister conditions. These canister conditions can include, but are not limited to, fuel tank pressure and the time lapse since the last purge cycle exceeding a calibratable threshold. Once it is determined that purging is required, the engine is turned on (if not already on) and is commanded to operate at lower throttle positions so that more vacuum is available in the intake manifold to draw in the fuel vapor. This part of the invention can only be accomplished if an electronic throttle controller is used with the engine. 
     In some HEV configurations where the engine speed is controlled by an electric motor (such as a PSHEV or “powersplit”), these very high intake manifold vacuum conditions can be forced via throttle control without risking an engine stall. If the A/F ratio were too lean because the A/F controller cannot accommodate the incoming fuel vapor, the engine would not stall because of poor combustion. The electric motor controls the engine speed. The controller then maintains the engine running in this high vacuum state until the vapor canister is empty so that the purging process can be stopped and the engine turned “off” again during vehicle idle conditions. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates the configuration of a basic powersplit Hybrid Electrical Vehicle. 
     FIG. 2 illustrates the general layout of a fuel system and an exhaust system. 
     FIG. 3 is a flow chart illustrating the HEV purging process. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention relates to Electric Vehicles and, more particularly, Hybrid Electric Vehicles (HEVs). FIG. 1 demonstrates just one possible configuration, specifically a Parallel/Series Hybrid Electric Vehicle (powersplit) configuration. 
     In a basic powersplit HEV, a Planetary Gear Set  20  mechanically couples a Carrier Gear  22  to an Engine  24  via a One Way Clutch  26 . The Planetary Gear Set  20  also mechanically couples a Sun Gear  28  to a Generator Motor  30  and a Ring (output) Gear  32 . The Generator Motor  30  also mechanically links to a Generator Brake  34  and is electrically linked to a Battery  36 . A Traction Motor  38  is mechanically coupled to the Ring Gear  32  of the Planetary Gear Set  20  via a Second Gear Set  40  and is electrically linked to the Battery  36 . The Ring Gear  32  of the Planetary Gear Set  20  and the Traction Motor  38  are mechanically coupled to Drive Wheels  42  via an Output Shaft  44 . 
     The Planetary Gear Set  20 , splits the Engine  24  output energy into a series path from the Engine  24  to the Generator Motor  30  and a parallel path from the Engine  24  to the Drive Wheels  42 . Engine  24  speed can be controlled by varying the split to the series path while maintaining the mechanical connection through the parallel path. The Traction Motor  38  augments the Engine  24  power to the Drive Wheels  42  on the parallel path through the Second Gear Set  40 . The Traction Motor  38  also provides the opportunity to use energy directly from the series path, essentially running off power created by the Generator Motor  30 . This reduces losses associated with converting energy into and out of chemical energy in the Battery  36  and allowing all Engine  24  energy, minus conversion losses, to reach the Drive Wheels  42 . 
     A Vehicle System Controller (VSC)  46  controls many components in this HEV configuration by connecting to each component&#39;s controller. The Engine Control Unit (ECU)  48  connects to the Engine  24  via a hardwire interface. The ECU  48  and VSC  46  can be based in the same unit, but are actually separate controllers. The HEV purge control, which is the subject of this invention, can be handled in either the VSC  46  or ECU  48 . The VSC  46  communicates with the ECU  48 , as well as a Battery Control Unit (BCU)  50  and a Transaxle Management Unit (TMU)  52  through a communication network, such as a Controller Area Network (CAN)  54 . The BCU  50  connects to the Battery  36  via a hardwire interface. The TMU  52  controls the Generator Motor  30  and Traction Motor  38  via a hardwire interface. 
     FIG. 2 illustrates the general layout of a typical fuel system, exhaust system, for the Engine  24 . A Fuel Tank  70  supplies the fuel to Fuel Injectors  92  via a Conventional Fuel Pump  74 . A conventional Vacuum Relief Valve  72  is provided on the Fuel Tank  70  cap for equalizing pressure applied to the Fuel Tank  70 . The Fuel Tank  70  further includes a Fuel Tank Pressure Transducer  78  that senses fuel tank vapor pressure and sends the signal to the ECU  48 . 
     A fuel Vapor Canister  80  is provided for trapping, storing, and subsequently releasing fuel vapor dispelled from the Fuel Tank  70  for combustion into the Engine  24 . An Electric Vapor Management Valve (“EVMV”)  84 , when closed, prevents fuel vapor from escaping into the Engine  24  and diverts it to the Vapor Canister  80 . When opened, the EVMV  84  allows fuel vapor to flow into the Intake Manifold  86  of Engine  24 . The Vapor Canister  80  is connected to the atmosphere through a Canister Vent Valve  104 . A Filter  106  may be provided between the Canister Vent Valve  104  and the atmosphere for filtering the air pulled into the vapor Canister  80 . The Canister Vent Valve  104  is a normally open solenoid valve controlled by the ECU  48 . 
     After combustion, exhaust enters an Exhaust Manifold  90  where an Oxygen Sensor  100  measures the oxygen level in the exhaust to determine the A/F ratio. The exhaust then proceeds to a Catalytic Converter  102  and finally to the atmosphere. 
     In an HEV, the purging process can only be invoked when the Engine  24  is running. However, when the Engine  24  is running, the conditions may not allow purging. The HEV Engine  24  typically runs at or near wide-open throttle to maximize fuel efficiency. This is not suitable for purging. In addition, an adaptive fuel routine typically needs to compete with the purging routine for Engine  24  running time to accomplish its tasks. 
     During the modes when the HEV Engine  24  is not running (the Engine  24  is frequently shut down for fuel efficiency purposes), the purging process also can not be undertaken even though fuel vapor can still collect in the Vapor Canister  80 . Therefore, it is necessary to determine when the Engine  24  should be forced “on” when it would otherwise normally be “off” (particularly at vehicle idle conditions) so that the purging process can be executed. 
     The present invention provides a method for purging the Vapor Canister  80  of an HEV, in particular by commanding the Engine  24  to come (or stay) “on” during vehicle idle conditions so that the purging process can be executed, and by controlling the Engine  24  throttle plate (not shown) while purging to provide a high Intake Manifold  86  vacuum, thereby drawing the fuel vapor in very rapidly. 
     To determine whether this HEV purge routine at idle is necessary, the controller (either VSC  46  or ECU  48 ) runs through a strategy that is illustrated in FIG.  3 . (It should be noted this invention is a component part to the patent application for Engine Idle Arbitration, Invention Disclosure #200-0318. 
     At Step  200  the vehicle being “keyed on” to start a given HEV drive cycle. At this step, the controller initializes two parameters used in the HEV purge routine. The first is PURGE — 1  1 ST_PASS, which is initialized to 0, and is used to force the Engine  24  “on” at the first vehicle idle condition encountered and is used to make sure the Vapor Canister  80  has a chance to be cleaned for the given drive cycle, even if the cycle is short in duration. The second parameter is LAST_PRG_TMR, which is initialized to 0, and is then allowed to begin counting. This is used to indicate how long it has been since the purging process was last completed. 
     The strategy proceeds next to Step  202  where the controller (either VSC  46  or EMU  48 ) determines if vehicle idle conditions are met. These conditions can include, but are not limited to, determinations of whether the accelerator position (PEDAL_POSITION) is less than a calibratable threshold and if the vehicle speed (VEHICLE_SPEED) is less than a calibratable threshold. If these conditions are not met, the vehicle will remain in its current driving mode, regardless of whether the Engine  24  is currently “on” or “off”. If the idle conditions are satisfied, then the logic proceeds to Step  206  and begins an HEV purge routine  206 . The first step in the HEV purge routine  206  is to proceed to Step  208 , which checks to see if PURGE — 1  1 ST_PASS=0. If PURGE — 1  1 ST_PASS=0, the purging process is attempted at least once for the given drive cycle. If yes, the routine proceeds directly to Step  214  where the Engine  24  is started via the command ENGINE—MODE=1 and then to Step  216  where the conventional purge strategy is invoked via the command PURGE_ENABLE=1. The conventional purge strategy works by opening the EVMV  84  between the Vapor Canister  80  and the Intake Manifold  86 , thereby allowing fuel vapor to enter the Engine  24  to be combusted. 
     If PURGE — 1ST_PASS=1, then the strategy proceeds to Step  210  where a check is made to see if TANK_PRESSURE exceeds a calibratable threshold. If yes, the logic goes to Step  214  to start the Engine  24  and Step  216  to enable the conventional purge strategy, as described previously. 
     If TANK_PRESSURE does not exceed the calibratable threshold, the logic moves to Step  212  where LAST_PRG_TMR is compared to a calibratable threshold. If LAST_PRG_TMR exceeds the threshold, then the strategy proceeds directly to Step  214  to start the Engine  24  and Step  216  to enable the conventional purge strategy, as described previously. 
     If LAST_PRG_TMR does not exceed the calibratable threshold, then the strategy jumps directly to a last step, Step  226 , where the HEV purge routine ends and the Engine  24  is allowed to shut off for the given vehicle idle condition (via ENGINE_MODE=0). 
     Once the Engine  24  has started at Step  214  and the conventional purge strategy has invoked at Step  216 , the logic proceeds to Step  218  where the Engine  24  throttle plate is commanded to a calibratable position intended to produce high vacuum conditions in the Intake Manifold  86 . Higher vacuum allows for faster purging because the fuel vapors will enter the manifold quickly. 
     Once the purging process has started from Steps  216  and  218 , the logic determines at Step  220  the condition of the Vapor Canister  80 . The condition is determined by using conventional methods, such as using feedback from the oxygen sensor, to determine how far the A/F controller has shifted due to the introduction of the Fuel Tank  70  vapors into the Intake Manifold  86 . This can then be used to infer the weight or mass of fuel vapor remaining in the Vapor Canister  80 . When this determination is accomplished, Step  222  determines whether the Vapor Canister  80  is sufficiently empty of fuel vapors. If yes, the logic proceeds to Step  226  where the HEV purge routine ends and the Engine  24  is allowed to shut off for the given vehicle idle condition (via ENGINE_MODE=0). If the Vapor Canister  80  is not considered to be empty, then the strategy continues the purging process (Step  224 ) and repeats the Vapor Canister  80  empty check at Steps  220  and  222  until the Vapor Canister  80  is clean. 
     At Step  226 , where the HEV purge routine ends and the Engine  24  is allowed to shut off for the given vehicle idle condition (via ENGINE_MODE=0), the LAST_PRG_TMR is reset to 0 and then incremented once again until the next purging sequence occurs.