Oxygen sensing method and system

A method of controlling an engine to help achieve a target air:fuel ratio based on data from an oxygen sensor, and related systems. At least one engine operating parameter and a sensed oxygen level are determined at two or more points in one of a rich and lean region based on data from the oxygen sensor. This information is used to help control engine operation in the other of the rich and lean regions without using directly sensed oxygen level data from that region. Thus, a control paradigm is developed in a first operating region based on oxygen level data from the oxygen sensor, and then used for control in a different second operating region without direct sensed oxygen level data in that second operating region. In some embodiments, the control paradigm may be adaptive based on changing conditions.

BACKGROUND

This application is directed to oxygen sensors, methods of using oxygen sensors, and related systems for use with internal combustion engines.

As known by those of skill in the art, the air:fuel ratio in internal combustion engines is typically represented by lambda (λ), with λ defined as is the actual air:fuel ratio divided by the air:fuel ratio at the exact stoichiometric mixture. Thus, in mathematical terms λ=air:fuelactual/air:fuelstoichiometric. Values less than 1.0 are fuel-rich (rich), values greater than 1.0 are fuel-lean (lean). For many internal combustion engines, maximum power is achieved around λ=0.86, and maximum fuel economy is achieved around λ=1.45-1.55. As can be appreciated, engine management systems typically focus heavily on controlling λ. As such, most large internal combustion engines have oxygen sensors to sense exhaust gas oxygen levels, with the data from the oxygen sensor used by the engine management systems for various engine management functions. For smaller internal combustion engines, such as those used in motorcycles, all-terrain vehicles, recreational marine applications, and unmanned air vehicles, the size constraints of the engines presents difficulties in identifying suitable oxygen sensors.

Fortunately, small resistive-based oxygen sensors are known, see, for example, U.S. Patent Application Publication 2011/0186446. Such oxygen sensors find a particular application in engine management control for small internal combustion engines. In addition, such sensors are useful for individual cylinder control in multi-cylinder engines and hybrid engines for automotive and off-road applications.

The 2011/0186446 oxygen sensor may be considered as a switching oxygen sensor with some unique properties. Such sensors have a drastic change (orders of magnitude) in the resistance of the sensor element when transitioning across the stoichiometric boundary in air:fuel ratio of Lambda (λ)=1.00. For example, for the n-type semiconductor version of the 2011/0186446 sensor, above this crossover point (in the lean region with λ>1.00), the sensor's resistance is very high and not significantly responsive to changes in the oxygen content in the gasses to which it is exposed; however, below this crossover point (in the rich region with λ<1.00) the resistance is significantly lower and has a positive relationship with oxygen content. Conversely, for the p-type semiconductor version of the 2011/0186446 sensor, the resistance is very high in the rich region, but is lower and has a positive relationship with oxygen content in the lean region. Because the sensor has a measurable relationship over part of the overall lambda range, the different versions of the 2011/0186446 sensor may be thought of as a “semi-wideband oxygen sensor.”

While the 2011/0186446 sensor is useful for many situations, such as those described in the 2011/0186446 publication, there remains a need for alternative oxygen sensor arrangements, and for alternative methods of oxygen sensing and controlling engines based on the sensed oxygen level(s), and related systems.

SUMMARY

In general, the present invention is directed to a method of controlling an engine to achieve a target air:fuel ratio based on data from an oxygen sensor, and related systems.

In one or more embodiments, at least one engine operating parameter (e.g., fuel metering rate) and a sensed oxygen level are determined at two or more points in one of a rich and lean region based on data from the oxygen sensor. This information is used to help control engine operation in the other of the rich and lean regions without using oxygen level data from that region. Thus, a control paradigm is developed in a first operating region based on oxygen level data from the oxygen sensor, and then used for control in the opposing second operating region without direct sensed oxygen level data in that second operating region. In some embodiments, the control may be adaptive based on changing conditions.

In an illustrative embodiment, a method of controlling an internal combustion engine is provided. The engine is capable of operating both in a rich mode where an air:fuel ratio supplied to a combustion chamber of the engine is below stoichiometric, and in a lean mode where the air:fuel ratio supplied to the combustion chamber is above stoichiometric. The method includes both a) determining both a first parameter value of a first engine parameter and a first sensed value of an oxygen sensor disposed in an exhaust plenum of the internal combustion engine while the engine is operating at a first air:fuel ratio point in the rich mode; and b) thereafter, determining both a second parameter value of the first engine parameter and a second sensed value of the oxygen sensor while the engine is operating at a second air:fuel ratio point in the rich mode, the second point being different from the first point. The method includes thereafter, switching the operation of the engine to the lean mode and controlling operation of the engine in the lean mode based on the first sensed value, the second sensed value, the first parameter value, and the second parameter value. The controlling the operation of the engine in the lean mode may comprise estimating a target parameter value of the first engine parameter to achieve a target air:fuel ratio based on the first sensed value, the second sensed value, the first parameter value, and the second parameter value; and controlling the engine so that the first engine parameter assumes the target parameter value. The method may further include, for greater accuracy, prior to switching operation of the engine to the lean mode, determining both a third parameter value of the first engine parameter and a third sensed value of the oxygen sensor while the engine is operating at a third air:fuel point in the rich mode, the third point being different from both the first and second points. Thus, the controlling operation of the engine in the lean mode may comprise controlling operation of the engine in the lean mode further based on the third parameter value and the third sensed value.

In some embodiments, determining the first sensed value comprises sensing both a resistance and a temperature associated with the oxygen sensor while the engine is operating at the first air:fuel ratio point. In some embodiments, determining the second sensed value comprises sensing both a resistance and a temperature associated with the oxygen sensor while the engine is operating at the second air:fuel ratio point. In some embodiments, the first parameter value is an element of a first set of parameter values corresponding to a plurality of engine parameters; the second parameter value is an element of a second set of parameter values corresponding to the plurality of engine parameters; the target parameter value is an element of a target set of parameter values corresponding to the plurality of engine parameters, and the controlling operation of the engine in the lean mode comprises controlling operation of the engine in the lean mode so that the plurality of engine parameter values assume their corresponding values in the target set of parameter values.

In some embodiments, the controlling may be adaptive (e.g., dynamic). Thus the method may include in response to sensing at least one of a change in ambient environmental conditions and a change in engine operating conditions and a change in engine load, thereafter returning the engine to the rich mode. These embodiments may continue with, while operating the engine in the rich mode: a) determining both a fifth parameter value of the first engine parameter and a fifth sensed value of the oxygen sensor while the engine is operating at a fifth air:fuel ratio point in the rich mode; and b) determining both a sixth parameter value of the first engine parameter and a sixth sensed value of the oxygen sensor while the engine is operating at a sixth air:fuel ratio point in the rich mode, the sixth point being different from the fifth point. These embodiments may continue with thereafter, returning the engine to the lean mode, and controlling operation of the engine while returned to the lean mode based on the fifth sensed value, the sixth sensed value, the fifth parameter value, and the sixth parameter value.

In one or more embodiments, an engine control system for an internal combustion engine is provided. The engine is capable of operating both in a rich mode where an air:fuel ratio supplied to a combustion chamber of the engine is below stoichiometric, and in a lean mode where the air:fuel ratio supplied to the combustion chamber is above stoichiometric. The engine control system comprises a first oxygen sensor disposed in an exhaust plenum of the engine; a second engine parameter sensor configured to sense an engine parameter; a controller comprising one or more processing circuits. The controller is operative to control operations of the engine and configured to: determine both a first parameter value of a first engine parameter and a first sensed value of the oxygen sensor while the engine is operating at a first air:fuel ratio point in the rich mode; thereafter, determine both a second parameter value of the first engine parameter and a second sensed value of the oxygen sensor while the engine is operating at a second air:fuel ratio point in the rich mode, the second point being different from the first point; thereafter, cause the engine switch to operating in the lean mode and control operation of the engine in the lean mode based on the first sensed value, the second sensed value, the first parameter value, and the second parameter value. The engine control system may operate, in various embodiments, according to the various methods described above.

In one or more embodiments, the method is like that described above, but with the lean and rich regions swapped. Thus, the method may include both a) determining both a first parameter value of a first engine parameter and a first sensed value of an oxygen sensor disposed in an exhaust plenum of the internal combustion engine while the engine is operating at a first air:fuel ratio point in the lean mode; and b) thereafter, determining both a second parameter value of the first engine parameter and a second sensed value of the oxygen sensor while the engine is operating at a second air:fuel ratio point in the lean mode, the second point being different from the first point. The method includes thereafter, switching the operation of the engine to the rich mode and controlling operation of the engine in the rich mode based on the first sensed value, the second sensed value, the first parameter value, and the second parameter value. The controlling the operation of the engine in the rich mode may comprise estimating a target parameter value of the first engine parameter to achieve a target air:fuel ratio based on the first sensed value, the second sensed value, the first parameter value, and the second parameter value; and controlling the engine so that the first engine parameter assumes the target parameter value. The method may further include, for greater accuracy, prior to switching operation of the engine to the rich mode, determining both a third parameter value of the first engine parameter and a third sensed value of the oxygen sensor while the engine is operating at a third air:fuel point in the lean mode, the third point being different from both the first and second points. Thus, the controlling operation of the engine in the rich mode may comprise controlling operation of the engine in the rich mode further based on the third parameter value and the third sensed value.

In some embodiments, determining the first sensed value comprises sensing both a resistance and a temperature associated with the oxygen sensor while the engine is operating at the first air:fuel ratio point. In some embodiments, determining the second sensed value comprises sensing both a resistance and a temperature associated with the oxygen sensor while the engine is operating at the second air:fuel ratio point. In some embodiments, the first parameter value is an element of a first set of parameter values corresponding to a plurality of engine parameters; the second parameter value is an element of a second set of parameter values corresponding to the plurality of engine parameters; the target parameter value is an element of a target set of parameter values corresponding to the plurality of engine parameters, and the controlling operation of the engine in the rich mode comprises controlling operation of the engine in the rich mode so that the plurality of engine parameter values assume their corresponding values in the target set of parameter values.

In some embodiments, the controlling may be adaptive (e.g., dynamic). Thus the method may include in response to sensing at least one of a change in ambient environmental conditions and a change in engine operating conditions and a change in engine load, thereafter returning the engine to the lean mode. These embodiments may continue with, while operating the engine in the lean mode: a) determining both a fifth parameter value of the first engine parameter and a fifth sensed value of the oxygen sensor while the engine is operating at a fifth air:fuel ratio point in the lean mode; and b) determining both a sixth parameter value of the first engine parameter and a sixth sensed value of the oxygen sensor while the engine is operating at a sixth air:fuel ratio point in the lean mode, the sixth point being different from the fifth point. These embodiments may continue with thereafter, returning the engine to the rich mode, and controlling operation of the engine while returned to the rich mode based on the fifth sensed value, the sixth sensed value, the fifth parameter value, and the sixth parameter value.

In one or more embodiments, another engine control system for an internal combustion engine is provided. The engine is capable of operating both in a lean mode where an air:fuel ratio supplied to a combustion chamber of the engine is below stoichiometric, and in a rich mode where the air:fuel ratio supplied to the combustion chamber is above stoichiometric. The engine control system comprises a first oxygen sensor disposed in an exhaust plenum of the engine; a second engine parameter sensor configured to sense an engine parameter; a controller comprising one or more processing circuits. The controller is operative to control operations of the engine and configured to: determine both a first parameter value of a first engine parameter and a first sensed value of the oxygen sensor while the engine is operating at a first air:fuel ratio point in the lean mode; thereafter, determine both a second parameter value of the first engine parameter and a second sensed value of the oxygen sensor while the engine is operating at a second air:fuel ratio point in the lean mode, the second point being different from the first point; thereafter, cause the engine switch to operating in the rich mode and control operation of the engine in the rich mode based on the first sensed value, the second sensed value, the first parameter value, and the second parameter value. The engine control system may operate, in various embodiments, according to the various methods described above.

The various aspects discussed above may be used alone or in any combination. The various apparatus disclosed herein may operate according to any combination of various method disclosed herein, and vice versa. Further, the present invention is not limited to the above features and advantages. Indeed, those skilled in the art will recognize additional features and advantages upon reading the following detailed description, and upon viewing the accompanying drawings.

DETAILED DESCRIPTION

In one or more embodiments, the present application is directed to a method of controlling an engine to achieve a target air:fuel ratio based on data from an oxygen sensor, and related systems. At least one engine operating parameter and a sensed oxygen level are determined at two or more points in one of a rich and lean region based on data from the oxygen sensor. This information is used to help control engine operation in the other of the rich and lean regions without using oxygen level data from that region. Thus, a control paradigm is developed in a first operating region based on oxygen level data from the oxygen sensor, and then used for control in the opposing second operating region without direct sensed oxygen level data in that second operating region. In some embodiments, the control may be adaptive based on changing conditions.

For simplicity, the discussion below may generally be in the context of an oxygen sensor for a small displacement gasoline powered internal combustion engine, but it should be understood that the oxygen sensor(s) disclosed herein may be used in other internal combustion engine applications, such a hydrogen powered engines, other hydrocarbon powered engines, diesel engines, Homogeneous Charge Compression Ignition (HCCI) engines, and Reactivity Controlled Compression Ignition (RCCI) engines.

FIG. 1shows a schematic of an internal combustion engine10, which may be of any type (e.g., piston, rotary, nutating disk, etc.). The engine10includes at least one combustion chamber12with associated piston, valves, etc. (note shown), an intake manifold18, an exhaust manifold19, and an engine management system40. The intake manifold18supplies air to the combustion chamber12. An mass airflow sensor22advantageously with associated temperature sensor is disposed in the intake18manifold so that the incoming air conditions may be monitored and/or controlled. A controllable fuel metering system such as a throttle body and fuel injector16supplies fuel to the combustion chamber under control of the engine management system40. For spark ignition engines, a spark ignition device14, e.g., spark plug, operates under the control of the engine management system40to ignite the air and fuel mixture in the combustion chamber12at the desired time in the cycle for proper combustion. An oxygen sensor30is disposed in the exhaust plenum19to sense the amount of oxygen in the exhaust gases, so that the proper air:fuel ratio may be properly metered and maintained. The engine management system40includes one or more processing circuits42(collectively “controller”) that control the fuel supply, ignition timing, and other engine parameters based on the input from the various sensors and the programming of the processing circuits42. Other than the particulars of the oxygen sensor30and the operation of the processing circuit(s)42described in greater detail below, the configuration and operations of the engine10are well known to those of skill in the art, and are not discussed further herein in the interests of clarity.

As can be appreciated, the engine10is able to operate in a rich mode or region R where λ<1.00, in a lean mode or region L where λ<1.00, and at a stoichiometric point S where λ=1.00. Referring toFIG. 2, the engine10is able to operate at multiple air:fuel ratio points in the rich region R, such as at points X, Y, and Z. The points X, Y, and Z, may, for example, correspond to λ values of 0.85, 0.90, 0.95, respectively. Likewise, the engine10is able to operate at a stoichiometric air:fuel point S, and at multiple air:fuel ratio points in the lean region L, such as J, K, and N. The points J, K, and N may, for example correspond to λ values of 1.05, 1.10, and 1.20 respectively. The engine management system40uses the oxygen sensor30, as described below, to help control the engine10so that the engine10operates at the desired air:fuel ratio.

The oxygen sensor30is advantageously a resistive-based oxygen sensor, such as those described in U.S. Patent Application Publication No. 2011/0186446, or similar. The '6446 publication discloses, in one or more embodiments, an oxygen sensor that includes an n-type or p-type semiconductor that connects two intermeshing comb type electrodes for functioning as an oxygen sensing portion32and a resistance-based heater portion34. The comb electrodes include a plurality of comb fingers having lengths and spacing. The length and spacing of the comb fingers, and the particular materials, including the semiconducting and catalytic materials, may be adjusted as desired for the particular operating conditions for the sensor30. For purposes of the initial discussion below, the sensor30will be initially assumed to have an n-type semiconductor such that the resistance is significantly lower and has a positive relationship with oxygen content in the rich region R, while the resistance is relatively high and uncorrelated to the oxygen content in the lean region L.

Referring toFIG. 3, the oxygen sensor30is connected to the controller42so that the sensed oxygen level data from the sensor is supplied to the controller42. In one or more illustrative embodiments, changes in the resistance of the sensor30are converted into a voltage signal, such as by being routed through a resistance network36, so that the controller42receives different voltage inputs for different sensed oxygen levels. The resistive network36may be as shown inFIG. 3, although such is not required in all embodiments. The resistor network ofFIG. 3includes a shunt resistor RHS, resistors R1and R2, a twelve volt voltage source VSA, a five volt voltage source VS2, a power line LP, a ground line G, an oxygen sense line LS, and a reference line LG. The heater portion34is disposed between LPand G, and is supplied with power from twelve volt power source VS1, via shunt resistor RHS. A voltage drop VHSis measured across shunt resistor RHS. A voltage drop VR2is measured across resistor R2, between line LSand line LG. The controller42advantageously receives LS, LG, and VHSused to calculate the relevant values as discussed further below. Note further that voltage drop VHSmay be sensed via two leads, one on each side of shunt resistor RHS, with each lead feeding a line to controller42; this arrangement is shown in simplified fashion inFIG. 3for clarity. Note that the resistance network36may be integrated into an oxygen sensor assembly, integrated into the controller42, be a separate component or components between the oxygen sensor30and the controller42, or dispersed in any suitable manner.

The resistance RSof the oxygen sensing portion32may be determined by any suitable way. For example, the current ISthrough the oxygen sensing portion32may be calculated as the voltage drop VR2across resistor R2. Further, the overall resistance RSCalong the five volt circuit through resistor R1, oxygen sensing portion32, and resistor R2may be calculated as RSC=voltage of the circuit divided by current of the circuit, or 5 (volts) divided by IS. Then, the resistance RSof the oxygen sensing portion32may be calculated as RS=RSC−R1−R2. Thus, the resistance RSof the oxygen sensing portion32may be determined based on knowledge of the voltage of voltage source VS2, the resistance of resistors R1and R2, the voltage drop VR2across resistor R2(voltage difference between line LSand LG). In alternate embodiments, resistor R1may be omitted from the circuit, or additional resistors may be added. If resistor R1is omitted, then the resistance RSof the oxygen sensing portion32may be calculated as RS=RSC−R2; or, if additional resistors are added, the calculation of RSadvantageously takes their presence into account. The oxygen level in the exhaust gases may then be determined based on the resistance of the oxygen sensing portion32.

The controller42receives the inputs from the oxygen sensor30and other sensors, and controls the operation of the ignition timing and related engine functions. Relevant to the present discussion, the controller42causes the engine10to operate at two or more air:fuel points in the rich region R, and takes oxygen level readings (via the oxygen sensor30) and one or more engine parameter readings at each point. Examples of suitable engine parameters include air intake mass, air intake temperature, fuel metering rate, ignition timing, engine speed (rpm), engine load, and the like. The controller42then causes the engine10to switch to be operating in the lean region L, and controls the engine10in the lean region based on the reference relationship between the air:fuel ratio and the engine parameter established in the rich region R. Thus, while the particular n-type oxygen sensing portion32of the oxygen sensor30is not able to accurately measure the oxygen content while the engine10is in the lean region L, due to the response of the n-type semiconductor, the engine10may still be controlled to achieve a desired air:fuel ratio in the lean region L, without using oxygen level readings from the oxygen sensor30in the lean region L.

An exemplary process is shown inFIG. 4. The process begins with the engine10operating the rich region R, at a first air:fuel ratio point X (step210). The oxygen level in the exhaust gas is sensed by the oxygen sensor30, so that the controller42is able to determine a first sensed value A1 of the oxygen sensor30. The engine parameter B is also sensed, via suitable sensor(s), so that the controller42is able to determine a first value B1 of the engine parameter. The controller42then causes the engine10to operate at another air:fuel point Y in the rich region R (step220), different from the first point X. A corresponding sensed oxygen value A2 and engine parameter value B2 are then determined for the engine10when operating at air:fuel point Y. Based on this data, the controller42is able to determine a reference relationship between the sensed oxygen values A and the engine parameter B, for the engine10operating in the rich region R.

The controller42then causes the engine10to switch operation mode, so that the engine10operates in the lean region L (step240). Due to the n-type semiconductor of the oxygen sensing circuit32of oxygen sensor30, there is not a reliable relationship between the resistance of the oxygen sensing circuit32and the oxygen level when the engine10is operating in the lean region L. However, achieving a desired or target oxygen level, and hence target air:fuel ratio, in the lean region L is useful for the controller42. As such, the controller42controls the engine10based on the information gathered while the engine10is operating in the rich region R. More particularly, the controller42controls the engine in the lean region L based on A1, A2, B1, and B2 (step250). This controlling may be achieved by determining a target air:fuel ratio TAF, and then determining a target engine parameter value BT by extrapolating the reference relationship between the oxygen level A and the engine parameter B from the rich region R into the lean region L. Thus, the controller42may determine a target engine parameter value BT that is estimated to result in the target air:fuel ratio TAF, based on A1, A2, B1, and B2 (step252). Because the engine parameter is able to be monitored in the lean region L, the controller42is able to control the engine so as to achieve the target engine parameter value BT (the current engine parameter value assumes value BT)(step254), which should result in the target air:fuel ratio TAF being achieved. For example, the controller42may control the operation of the engine10by causing the fuel supply rate to be increased or decreased.

Note that in the discussion above, two reference air:fuel ratio points in the rich region R were used to establish the reference relationship between A and B. However, the process may advantageously include using three or more reference air:fuel ratio points in the rich region R, in order to better define the relationship. For example, the controller42, prior to switching the engine10operation over to the lean region L (step240), may cause the engine10to operate at a third air:fuel ratio point Z in the rich region R (step230). A corresponding sensed oxygen value A3 and engine parameter value B3 are then determined for the engine10when operating at air:fuel point Z. Then, the controller42may control the engine (step250) in the lean region L based on A1, A2, A3, B1, B2, and B3 (step250). Thus, the controller42may determine the target engine parameter value BT based on the target air:fuel ratio TAF and based on A1, A2, A3, B1, B2, and B3 (step252). The engine10may then be controlled so that the target engine parameter value BT is achieved (step254). Of course, more than three reference points may alternatively be used using a similar approach.

Similarly, the discussion above has been in the context of one engine parameter B used as the basis for controlling the engine10. However, instead of a single engine parameter, for example rpm, being used, a set of a plurality of engine parameters, for example rpm, fuel metering rate, exhaust gas temperature, air intake mass, air intake temperature, and the like, may be used. Thus, at point X, values for multiple engine parameters may be determined as a first set, with second, and (optionally) third sets of the same engine parameters determined for points Y, and (optionally) Z. The relevant relationship may then be between A and the set of engine parameters, and a target set of engine parameters determined based on TAF, A1, A2, and optionally A3, and the relevant sets of values (step252). The engine10is then controlled to achieve the engine parameters of the target set (step254).

The controller42uses the process outlined above to establish the relationship between the engine parameter(s) and the value of the sensed oxygen content of the exhaust gas. In some embodiments, the relationship may be established only once, and then used for all future operations. In other embodiments, the controller42advantageously adaptively determines the relationship by periodically causing the engine10to temporarily return to operate in the rich region R to collect new values for updating the relationship (operate at multiple points, etc.), and then causing the engine to return to operate in the lean region L. In some embodiments, the temporary return to operation in the rich region R to update the relationship may be a triggered response to changing conditions, with the trigger being a detected change in ambient environmental conditions (e.g., incoming air temperature or pressure), and/or a detected change in engine operating conditions (e.g., detection of some fault, detected significant change in exhaust gas temperature, etc.) and/or a detected change in engine load. The reference points used in the updating process may be the same or different, or some same and some different, than used in the original establishment of the reference relationship.

Note that the discussion above has been in terms of establishing a baseline relationship between A and B (or A and several B's) in the rich region R, and then determining a current air:fuel ratio FC when operating in the lean region L. Such an approach is appropriate for an oxygen sensor30using an n-type semiconductor. However, a similar approach may also be used with the roles of the rich and lean regions reversed when the oxygen sensor30instead uses a p-type semiconductor. Thus, as shown inFIG. 5, the baseline relationship between A and B (or A and a set of B's) may be determined based on data from operating the engine10in the lean region L, and then the engine10switched to rich region R, and the engine controlled in the rich region R based on A1, A2, B1, and B2. Thus, the controller42may cause the engine10to operate at air:fuel ratio point J in the lean region L, collect value A1 corresponding to the sensed oxygen level, and determine the corresponding value B1 of the engine parameter (step310). The controller42may then cause the engine10to operate at air:fuel ratio point K in the lean region L, collect value A2 corresponding to the sensed oxygen level, and determine the corresponding value B2 of the engine parameter (step320). The controller42may then optionally cause the engine10to operate at air:fuel ratio point N in the lean region L, collect value A3 corresponding to the sensed oxygen level, and determine the corresponding value B3 of the engine parameter (step330). The controller42may then cause the engine10to switch operation to the rich region R (step340). The controller42then controls the engine in the rich region R based on A1, A2, B1, B2 (step350). Thus, the controller42may determine a target air:fuel ratio TAF, and then determine BT by extrapolating the reference relationship between the oxygen level A and the engine parameter B from the lean region L into the rich region R (step352). So, similar to the above, the controller42may determine the target engine parameter value BT that is estimated to result in the target air:fuel ratio TAF, based on A1, A2, B1, and B2 (step352). Because the engine parameter is able to be monitored in the rich region R, the controller42is able to control the engine so as to achieve the target engine parameter value BT (the current engine parameter value assumes value BT)(step354), which should result in the target air:fuel ratio TAF being achieved. Likewise, the multiple engine parameter, updating, and other processes described above with respect to the rich/lean sequence may be similarly followed, with suitable swapping of rich and lean regions/points.

As can be appreciated, various parameters may be considered/measured when establishing the baseline relationship and when estimating the current air:fuel ratio FC. These parameters include, for example, incoming air temperature, incoming air pressure, incoming moisture content, temperature of the oxygen sensor30and the like. For example, the temperature of the oxygen sensor30may be measured by measuring a resistance associated with the heater portion34of the oxygen sensor30or by a suitable dedicated temperature sensor35(the presence of heater portion34being optional for some embodiments). For example, the current IHin the heater portion34may be calculated as the voltage drop VHSacross the shunt resistor RHS, divided by the resistance of the shunt resistor RHS, or IH=VHS/RHS. Then, the resistance RHof the heater portion34may be calculated based on the voltage drop across the heater portion34divided by the current IHthrough the heater portion34. Thus, RHmay be calculated as RH=(12−VHS/IH. Note that if RHis significantly small relative RH, then RHmay be calculated as simply RH=12/IH. Then, using RH, temperature T may be calculated using a suitable formula, for example T=(M×RH)+B, where the slope M and the constant B are dependent on the heater design. As can be appreciated, M and B can be determined in a calibration process, and the relevant values stored in memory of the engine management system40for use by the controller42. This temperature may then be used to help determine the value of the oxygen content based on the resistance of the oxygen sensing portion32of the oxygen sensor30and the temperature of the oxygen sensor30. The relevant values, whether based on temperature or not, may be stored in suitable memory (not shown) that is part of or accessible by the controller42. For example, the memory may contain a lookup table of oxygen sensing portion32resistance, heater portion34resistance, and air:fuel ratio (expressed as lambda or otherwise), or a series of such lookup tables, indexed for example based on incoming air temperature or pressure. Alternatively, the controller42may be programmed with a suitable non-lookup table temperature compensation routine for temperature adjusting the values of oxygen content based on the signal(s) from the oxygen sensing portion32and the sensed temperature of the oxygen sensor30.

The discussion above has generally been in the context of controlling an engine10having a single cylinder/combustion chamber. However, a similar approach may be used with engines having multiple cylinders, such as that shown inFIG. 6with cylinders A, B, C, and D. InFIG. 6, a single common oxygen sensor30is used for multiple cylinders. The controller42may control the engine parameters (e.g., fuel metering rate) based on readings from the oxygen sensor30, or, if the oxygen sensor30has fast enough response time, the controller42may be able to control the engine parameters on an individual cylinder basis. Another multi-cylinder arrangement is shown inFIG. 7, where each cylinder has its own dedicated oxygen sensor30. With this arrangement, the controller42may more easily control the cylinder-specific engine parameters (e.g., fuel metering rate) on an individual cylinder basis based on readings from the corresponding oxygen sensor30.

Note that when the engine is operating in the region where the oxygen sensor30is able to accurately sense the oxygen level, the controller42may control the engine10in a conventional close-loop fashion based on the oxygen level data from the oxygen sensor30.

Note that as used herein, the use of the labels “first”, “second”, “third”, and the like in relation to the various sensed values of the oxygen sensor30and the various determined values of the engine parameter(s), and sets thereof, are merely for convenience so as to differentiate between the values, and are not intended to convey a particular sequence or presence. Thus, the relevant values of the oxygen sensor30may be the first, second, and fourth values, and there may or may not be a corresponding “third” value and/or the second one may be taken before the first one. Likewise for the engine parameters and sets thereof.

Further, note that as used herein, the term “engine parameter” excludes exhaust oxygen content. As such, sensing or determining an “engine parameter” is different from sensing or determining exhaust gas oxygen content. And, as used herein, an air:fuel ratio may be expressed as an un-normalized ratio (e.g., 14.7:1 for gasoline), or as a normalized ratio (e.g., λ).

The methods and engine control systems discussed above provide the opportunity for enhanced engine control so that greater fuel economy and/or reduced emissions may be achieved.

The disclosure of all patents and patent publications mentioned above are incorporated herein by reference in their entirety.

The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the scope of the invention. The present embodiments are, therefore, to be considered as illustrative and not restrictive.