System and method for controlling ammonia levels in a selective catalytic reduction catalyst using a nitrogen oxide sensor

A system according to the principles of the present disclosure includes an air/fuel ratio determination module and an emission level determination module. The air/fuel ratio determination module determines an air/fuel ratio based on input from an air/fuel ratio sensor positioned downstream from a three-way catalyst that is positioned upstream from a selective catalytic reduction (SCR) catalyst. The emission level determination module selects one of a predetermined value and an input based on the air/fuel ratio. The input is received from a nitrogen oxide sensor positioned downstream from the three-way catalyst. The emission level determination module determines an ammonia level based on the one of the predetermined value and the input received from the nitrogen oxide sensor.

FIELD

The present disclosure relates to systems and methods for controlling ammonia levels in a selective catalytic reduction catalyst using a nitrogen oxide sensor.

BACKGROUND

Three-way and selective catalytic reduction (SCR) catalysts reduce emissions in exhaust from an engine. When the air/fuel ratio of the engine is rich or stoichiometric, the three-way catalyst reduces hydrocarbon, carbon monoxide, and nitrogen oxide and produces ammonia, and the SCR catalyst stores the ammonia. When the air/fuel ratio is lean, the three-way catalyst reduces hydrocarbon and carbon monoxide, and the ammonia stored in the SCR catalyst is used to reduce nitrogen oxide. Thus, the amount of ammonia stored in the SCR catalyst decreases when the air/fuel ratio is lean.

Typically, the air/fuel ratio is adjusted to lean to improve fuel economy. Passive SCR systems may switch the air/fuel ratio from lean to rich to increase ammonia storage levels in the SCR catalyst. Active SCR systems inject a dosing agent, such as urea, into exhaust to increase ammonia storage levels in the SCR catalyst. The dosing agent breaks down to form ammonia that is stored in the SCR catalyst.

SUMMARY

A system according to the principles of the present disclosure includes an air/fuel ratio determination module and an emission level determination module. The air/fuel ratio determination module determines an air/fuel ratio based on input from an air/fuel ratio sensor positioned downstream from a three-way catalyst that is positioned upstream from a selective catalytic reduction (SCR) catalyst. The emission level determination module selects one of a predetermined value and an input based on the air/fuel ratio. The input is received from a nitrogen oxide sensor positioned downstream from the three-way catalyst. The emission level determination module determines an ammonia level based on the one of the predetermined value and the input received from the nitrogen oxide sensor.

DETAILED DESCRIPTION

The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, and/or objects. The term shared, as used above, means that some or all code from multiple modules may be executed using a single (shared) processor. In addition, some or all code from multiple modules may be stored by a single (shared) memory. The term group, as used above, means that some or all code from a single module may be executed using a group of processors or a group of execution engines. For example, multiple cores and/or multiple threads of a processor may be considered to be execution engines. In various implementations, execution engines may be grouped across a processor, across multiple processors, and across processors in multiple locations, such as multiple servers in a parallel processing arrangement. In addition, some or all code from a single module may be stored using a group of memories.

Engine control systems may estimate an ammonia storage level in a selective catalytic reduction (SCR) catalyst positioned downstream from a three-way catalyst and adjust the air/fuel ratio of an engine based on the ammonia storage level. The ammonia storage level may be estimated based on exhaust flow and ammonia levels in exhaust. The ammonia levels may be estimated based on exhaust temperature and hydrocarbon levels, hydrogen levels, nitrogen oxide levels, and carbon monoxide levels in exhaust entering and/or exiting the three-way catalyst.

Estimating the ammonia levels in this manner requires calibration effort to correlate the ammonia levels and the factors used to estimate the ammonia levels for a specific vehicle application. In addition, estimating the ammonia levels in this manner requires computation power in an engine control unit (ECU) that controls the engine. Calibration effort and additional ECU computation power may increase vehicle costs. The ammonia levels may be measured using an ammonia sensor positioned in the exhaust stream. However, the ammonia sensor may also increase vehicle costs.

Three-way catalysts reduce nitrogen oxide and produce ammonia when the air/fuel ratio is rich. Thus, nitrogen oxide levels in exhaust exiting the three-way catalyst may be near zero when the air/fuel ratio is rich and ammonia levels in exhaust exiting the three-way catalyst may be near zero when the air/fuel ratio is lean. A nitrogen oxide sensor may be used to detect both the nitrogen oxide levels and the ammonia levels.

A system and method according to the present disclosure determines the ammonia level in exhaust from an engine based on input received from an air/fuel ratio sensor and a nitrogen oxide sensor positioned downstream from a three-way catalyst. When the air/fuel ratio sensor indicates that an air/fuel ratio of the engine is stoichiometric or rich, the ammonia level is determined based on the input received from the nitrogen oxide sensor. When the air/fuel ratio sensor indicates that an air/fuel ratio of the engine is lean, the ammonia level is determined to be a predetermined value (e.g., zero).

A system and method according to the present disclosure may estimate an ammonia storage level in an SCR catalyst positioned downstream from the three-way catalyst based on the ammonia level, one or more exhaust temperatures, and an exhaust flow rate. The nitrogen oxide sensor may be positioned at an outlet of the three-way catalyst. The exhaust temperatures may be measured at an inlet and an outlet of the SCR catalyst. The air/fuel ratio of the engine may be switched between rich and lean based on the estimated ammonia storage level.

A system and method according to the present disclosure may determine the ammonia storage level in the SCR catalyst using nitrogen oxide sensors positioned at the inlet of the SCR catalyst and midway between the inlet and the outlet of the SCR catalyst. The air/fuel ratio may be switched to rich or stoichiometric when the ratio of the midpoint ammonia level to the inlet ammonia level is less than a first value. The air/fuel ratio may be switched to lean when a ratio of the midpoint ammonia level to the inlet ammonia level is greater than or equal to a second value. The first and second values may be equal or different, and may be predetermined to maintain the ammonia storage level within a desired range between saturated and depleted.

Determining ammonia levels in exhaust using an air/fuel ratio sensor and a nitrogen oxide sensor positioned downstream from the three-way catalyst requires less calibration effort and less computation power compared to other methods. Determining the ammonia level in this manner also enables detection of high levels of ammonia (e.g., 2,000 ppm). In addition, nitrogen oxides sensors are often used for other diagnostic and control systems, and therefore may not increase vehicle costs. Determining ammonia levels using sensors position at the inlet and the midpoint of the SCR catalyst enables controlling the ammonia storage level without determining the ammonia storage level, requiring even less calibration effort and computation power.

Referring now toFIG. 1, a functional block diagram of an exemplary engine system100is presented. The engine system100includes an engine102that combusts an air/fuel mixture to produce drive torque for a vehicle based on driver input from a driver input module104. Air is drawn into the engine102through an intake system106. For example only, the intake system106may include an intake manifold108and a throttle valve110. For example only, the throttle valve110may include a butterfly valve having a rotatable blade. An engine control module (ECM)112controls a throttle actuator module116, which regulates opening of the throttle valve110to control the amount of air drawn into the intake manifold108.

Air from the intake manifold108is drawn into cylinders of the engine102. While the engine102may include multiple cylinders, for illustration purposes a single representative cylinder114is shown. For example only, the engine102may include 2, 3, 4, 5, 6, 8, 10, and/or 12 cylinders. The ECM112may deactivate some of the cylinders, which may improve fuel economy under certain engine operating conditions.

The engine102may operate using a four-stroke cycle. The four strokes, described below, are named the intake stroke, the compression stroke, the combustion stroke, and the exhaust stroke. During each revolution of a crankshaft (not shown), two of the four strokes occur within the cylinder114. Therefore, two crankshaft revolutions are necessary for the cylinder114to experience all four of the strokes.

During the intake stroke, air from the intake manifold108is drawn into the cylinder114through an intake valve117. The ECM112controls a fuel actuator module118, which regulates fuel injection to achieve a desired air/fuel ratio. Fuel may be injected into the intake manifold108at a central location or at multiple locations, such as near the intake valve117of each of the cylinders. In various implementations (not shown), fuel may be injected directly into the cylinders or into mixing chambers associated with the cylinders. The fuel actuator module118may halt injection of fuel to cylinders that are deactivated.

The injected fuel mixes with air and creates an air/fuel mixture in the cylinder114. During the compression stroke, a piston (not shown) within the cylinder114compresses the air/fuel mixture. The engine102may be a compression-ignition engine, in which case compression in the cylinder114ignites the air/fuel mixture. Alternatively, the engine102may be a spark-ignition engine, in which case a spark actuator module120energizes a spark plug122in the cylinder114based on a signal from the ECM112, which ignites the air/fuel mixture. The timing of the spark may be specified relative to the time when the piston is at its topmost position, referred to as top dead center (TDC).

The spark actuator module120may be controlled by a timing signal specifying how far before or after TDC to generate the spark. Because piston position is directly related to crankshaft rotation, operation of the spark actuator module120may be synchronized with crankshaft angle. In various implementations, the spark actuator module120may halt provision of spark to deactivated cylinders.

Generating the spark may be referred to as a firing event. The spark actuator module120may have the ability to vary the timing of the spark for each firing event. The spark actuator module120may even be capable of varying the spark timing for a next firing event when the spark timing signal is changed between a last firing event and the next firing event.

During the combustion stroke, the combustion of the air/fuel mixture drives the piston down, thereby driving the crankshaft. The combustion stroke may be defined as the time between the piston reaching TDC and the time at which the piston returns to bottom dead center (BDC).

During the exhaust stroke, the piston begins moving up from BDC and expels the byproducts of combustion through an exhaust valve124. The byproducts of combustion are exhausted from the vehicle via an exhaust system126.

The engine system100may include a boost device that provides pressurized air to the intake manifold108. For example,FIG. 1shows a turbocharger including a hot turbine128-1that is powered by hot exhaust gases flowing through the exhaust system126. The turbocharger also includes a cold air compressor128-2, driven by the turbine128-1, which compresses air leading into the throttle valve110. In various implementations, a supercharger (not shown), driven by the crankshaft, may compress air from the throttle valve110and deliver the compressed air to the intake manifold108.

A wastegate130may allow exhaust to bypass the turbine128-1, thereby reducing the boost (the amount of intake air compression) of the turbocharger. The ECM112may control the turbocharger via a boost actuator module132. The boost actuator module132may modulate the boost of the turbocharger by controlling the position of the wastegate130. In various implementations, multiple turbochargers may be controlled by the boost actuator module132. The turbocharger may have variable geometry, which may be controlled by the boost actuator module132.

An intercooler (not shown) may dissipate some of the heat contained in the compressed air charge, which is generated as the air is compressed. The compressed air charge may also have absorbed heat from components of the exhaust system126. Although shown separated for purposes of illustration, the turbine128-1and the compressor128-2may be attached to each other, placing intake air in close proximity to hot exhaust.

The engine system100may include an exhaust gas recirculation (EGR) valve134, which selectively redirects exhaust gas back to the intake manifold108. The EGR valve134may be located upstream of the turbocharger's turbine128-1. The EGR valve134may be controlled by an EGR actuator module136.

The exhaust system126includes a three-way catalyst (TWC)138and a selective catalytic reduction (SCR) catalyst140. When the air/fuel ratio of the engine102is rich or stoichiometric, the TWC138reduces hydrocarbon, carbon monoxide, and nitrogen oxide and produces ammonia, and the SCR catalyst140stores the ammonia. When the air/fuel ratio is lean, the TWC138reduces hydrocarbon and carbon monoxide and the ammonia stored in the SCR catalyst140is used to reduce nitrogen oxide.

The position of the crankshaft may be measured using a crankshaft position (CPS) sensor142. The ECM112may determine the speed of the crankshaft (i.e., the engine speed) based on the crankshaft position. The temperature of the engine coolant may be measured using an engine coolant temperature (ECT) sensor144. The ECT sensor144may be located within the engine102or at other locations where the coolant is circulated, such as a radiator (not shown).

The pressure within the intake manifold108may be measured using a manifold absolute pressure (MAP) sensor146. In various implementations, engine vacuum, which is the difference between ambient air pressure and the pressure within the intake manifold108, may be measured. The mass flow rate of air flowing into the intake manifold108may be measured using a mass air flow (MAF) sensor148. In various implementations, the MAF sensor148may be located in a housing that also includes the throttle valve110. The throttle actuator module116may monitor the position of the throttle valve110using one or more throttle position sensors (TPS)150. The ambient temperature of air being drawn into the engine102may be measured using an intake air temperature (IAT) sensor151.

Levels of nitrogen oxide and ammonia in exhaust may be measured using nitrogen oxide (NOx) sensors152,154,156. The NOx sensor152is positioned downstream from the TWC138, such as at an outlet of the TWC138. The NOx sensor154may be positioned at an inlet of the SCR catalyst140and the NOx sensor156may be positioned midway between the inlet and an outlet of the SCR catalyst140. Alternatively, the NOx sensor154may be positioned at a midpoint of the SCR catalyst140and/or the NOx sensor156may be positioned at another location downstream from the inlet of the SCR catalyst140, such as at the outlet of the SCR catalyst140.

An air/fuel ratio of exhaust from the engine102may be measured using an air/fuel ratio (AFR) sensor158. The AFR sensor158is positioned downstream from the TWC138, such as at an outlet of the TWC138. Although referred to as an air/fuel ratio sensor, the AFR sensor158may be an oxygen sensor or a lambda sensor. Temperatures of exhaust may be measured using temperature sensors160,162. The temperature sensors160,162may be positioned at the inlet and the outlet of the SCR catalyst140, respectively, as shown.

The ECM112may use signals from the sensors to make control decisions for the engine system100and to identify a malfunction in the engine system100. The ECM112may activate a malfunction indicator light (MIL)164when the ECM112identifies a malfunction in the engine system100. When activated, the MIL164notifies a driver of a malfunction in the engine system100. Although the MIL164is referred to as a light, the MIL164may use indicating mediums other than light, including sound and vibration.

The ECM112determines the air/fuel ratio of exhaust exiting the TWC138based on input received from the AFR sensor158. When the air/fuel ratio is lean, the ECM112determines that ammonia levels in exhaust exiting the TWC138are equal to a predetermined value (e.g., approximately zero). When the air/fuel ratio is rich or stoichiometric, the ECM112determines ammonia levels in exhaust exiting the TWC138based on input received from one or more of the NOx sensors152,154,156.

Referring toFIG. 2, the ECM112includes an air/fuel ratio (AFR) determination module202and an ammonia level determination module204. The AFR determination module202determines an air/fuel ratio based on input received from the AFR sensor158. The AFR determination module202outputs the air/fuel ratio.

The emission level determination module204determines one or more emission levels based on the air/fuel ratio and input received from one or more of the NOx sensors152,154,156. The emission levels include one or more nitrogen oxide levels and one or more ammonia levels. When the air/fuel ratio is lean, the emission level determination module204determines the nitrogen oxide levels using the NOx sensors152,154,156and determines that the ammonia levels are equal to a predetermined value (e.g., approximately zero). When the air/fuel ratio is rich or stoichiometric, the emission level determination module204determines that the nitrogen oxide levels are equal to a predetermined value (e.g., approximately zero) and determines the ammonia levels using the NOx sensors152,154,156.

The nitrogen oxide levels may include a TWC outlet NOx level, an SCR inlet NOx level, and a SCR midpoint NOx level determined based on input from the NOx sensors152,154,156, respectively. The ammonia levels may include a TWC outlet NH3 level, an SCR inlet NH3 level, and a SCR midpoint NH3 level determined based on input from the NOx sensors152,154,156, respectively. The ammonia level determination module204outputs the nitrogen oxide levels and the ammonia levels.

A storage level estimation module206estimates an ammonia storage level in the SCR catalyst140based on one or more of the nitrogen oxide levels, one or more of the ammonia levels, one or more exhaust temperatures, and/or an exhaust flow rate. The storage level estimation module206may determine SCR inlet and outlet temperatures based on input received from the temperature sensors160,162, respectively. The storage level estimation module206may determine the exhaust flow rate based on input received from the MAF sensor148. The storage level estimation module206may estimate the ammonia storage level based on the TWC outlet NOx and NH3 levels, the SCR inlet and outlet temperatures, and the exhaust flow rate.

The storage level estimation module206may determine NOx and NH3 flow rates based on the TWC outlet NOx and NH3 levels, respectively, and the exhaust flow rate. The storage level estimation module206may estimate an ammonia storage efficiency of the SCR catalyst140based on the SCR inlet and outlet temperatures. The storage level estimation module206may estimate a decrease in the ammonia storage level during a lean period based on a product of the NOx flow rate and the lean period. The storage level estimation module206may estimate an increase in the ammonia storage level during a rich period based on a product of the NH3 flow rate, the ammonia storage efficiency, and the rich period. The storage level estimation module206outputs the estimated ammonia storage level.

A storage level determination module208determines the ammonia storage level based the SCR inlet and midpoint NOx levels, the SCR inlet and midpoint NH3 levels, and the exhaust flow rate. The exhaust flow rate may be received from the storage level estimation module206. The storage level determination module208may determine inlet and midpoint NOx flow rates based on the SCR inlet and midpoint NOx levels, respectively, and the exhaust flow rate. The storage level determination module208may determine inlet and midpoint NH3 flow rates based on the SCR inlet and midpoint NH3 levels, respectively, and the exhaust flow rate.

The storage level determination module208may determine a decrease in the ammonia storage level during a lean period based on a product of the lean period and a difference between the inlet and midpoint NOx flow rates. The storage level determination module208may determine an increase in the ammonia storage level during a rich period based on a product of the rich period and a difference between the inlet and midpoint NH3 flow rates. The storage level determination module208outputs the determined ammonia storage level.

An air/fuel ratio (AFR) control module210controls the air/fuel ratio of the engine102based on the ammonia levels, the estimated ammonia storage level, and/or the determined ammonia storage level. The AFR control module210may adjust the air/fuel ratio to rich or stoichiometric when the ratio of the SCR midpoint NH3 level to the SCR inlet NH3 level is less than a first value. The AFR control module210may adjust the air/fuel ratio to lean when a ratio of the SCR midpoint NH3 level to the SCR inlet NH3 level is greater than or equal to a second value. The first and second values may be equal or different, and may be predetermined to maintain the ammonia storage level within a desired range between saturated and depleted.

The AFR control module210may adjust the air/fuel ratio to rich or stoichiometric when the estimated or determined ammonia storage level is less than a first level. The AFR control module210may adjust the air/fuel ratio to lean when the estimated or determined ammonia storage level is greater than or equal to a second level. The first and second levels may be equal or different, and may be predetermined to maintain the ammonia storage level within a desired range between saturated and depleted.

A storage ability determination module212determines an ammonia storage ability of the SCR catalyst140based on the ammonia storage efficiency of the SCR catalyst140. The ammonia storage ability of the SCR catalyst140may be affected by factors such as contamination, temperature, and thermal degradation. Thus, a change in the ammonia storage efficiency may not indicate a permanent change in the ammonia storage ability if, for example, the change is due to a change in temperature. The storage ability determination module212may receive the inlet and midpoint NH3 levels from the storage level estimation module206and determine the ammonia storage efficiency based on a ratio of the midpoint NH3 level to the inlet NH3 level.

The storage ability determination module212may determine the ammonia storage ability based on the ammonia storage efficiency and a predetermined relationship between ammonia storage efficiency and temperature. The storage ability determination module212may determine the ammonia storage ability based on a present storage efficiency at a first temperature and a previous storage efficiency at the first temperature. The storage ability determination module212may receive the estimated ammonia storage efficiency from the storage level estimation module206. The storage ability determination module212may determine the ammonia storage ability based on the determined and estimated ammonia storage efficiencies.

The storage ability determination module212may activate the MIL164when the ammonia storage ability decreases, for example, due to factors other than temperature. The storage ability determination module212may activate the MIL164when the determined ammonia storage efficiency is less than the estimated ammonia storage efficiency.

Referring now toFIG. 3, a method for controlling ammonia levels in a SCR catalyst using a NOx sensor begins at302. At304, the method determines an air/fuel ratio of exhaust from an engine. The method may determine the air/fuel ratio based on an AFR sensor positioned downstream from a TWC.

At306, the method determines whether the air/fuel ratio is lean. If306is true, the method continues at308. If306is false, the method continues at310. At308, the method determines that ammonia levels in exhaust from the engine are equal to a predetermined value (e.g., approximately zero). At312, the method determines one or more nitrogen oxide levels based on input received from one or more NOx sensors positioned downstream from the TWC.

At310, the method determines one or more ammonia levels based on input received from the NOx sensors. At314, the method determines that the nitrogen oxide levels are equal to a predetermined value (e.g., approximately zero). The NOx sensors may be positioned at an outlet of the TWC, at an inlet of the SCR catalyst, and at a midpoint of the SCR catalyst between the inlet of the SCR catalyst and an outlet of the SCR catalyst.

At316, the method estimates an ammonia storage level in the SCR catalyst. The method may estimate the ammonia storage level based on decreases in the ammonia storage level when the air/fuel ratio is lean and increases in the ammonia storage level when the air/fuel ratio is rich or stoichiometric. The decreases may be estimated based on a TWC outlet NOx level and an exhaust flow rate. The increases may be estimated based on a TWC outlet NH3 level, an exhaust temperature, and the exhaust flow rate.

At318, the method determines the ammonia storage level. The method may determine the ammonia storage level based on decreases in the ammonia storage level when the air/fuel ratio is lean and increases in the ammonia storage level when the air/fuel ratio is rich or stoichiometric. The decreases may be determined based on an exhaust flow rate and a difference between a SCR inlet NOx level and a SCR midpoint NOx level. The increases may be determined based on the exhaust flow rate and a difference between a SCR inlet NH3 level and a SCR midpoint NH3 level.

At320, the method determines whether the air/fuel ratio is lean. If320is true, the method continues at322. If320is false, the method continues at324. At322, the method determines whether the ammonia storage level is less than a first level. Alternatively, the method may determine whether a ratio of the SCR midpoint NH3 level to the SCR inlet NH3 level is less than a first value. If322is true, the method continues at326. If322is false, the method continues at328. At326, the method adjusts the air/fuel ratio to rich or stoichiometric.

At324, the method determines whether the ammonia storage level is greater than or equal to a second level. Alternatively, the method may determine whether the ratio of the SCR midpoint NH3 level to the SCR inlet NH3 level is greater than or equal to a second value. If324is true, the method continues at330. If324is false, the method continues at328. At330, the method switches the air/fuel ratio to lean.

The first and second levels may be equal or different and the first and second values may be equal or different. The first and second levels and the first and second values may be predetermined to maintain the ammonia storage level within a desired range between saturated and depleted.

At328, the method estimates an ammonia storage efficiency of the SCR catalyst. The method may estimate the ammonia storage efficiency based on the exhaust temperature. The exhaust temperature may include a SCR inlet temperature and a SCR outlet temperature.

At332, the method determines the ammonia storage efficiency. The method may determine the ammonia storage efficiency based on a difference between a SCR inlet NH3 flow rate and a SCR midpoint NH3 flow rate. The SCR inlet NH3 flow rate and the SCR midpoint NH3 flow rate may be determined based on the SCR inlet NH3 level and the SCR midpoint NH3 level, respectively, and the exhaust flow rate.

At334, the method determines whether the determined ammonia storage efficiency is less than the estimated ammonia storage efficiency. The method may determine whether a difference between the determined ammonia storage efficiency and the estimated ammonia storage efficiency is greater than a predetermined value. If334is true, the method continues at336. If334is false, the method continues at304.

At336, the method activates a malfunction indicator light. The method may activate the malfunction indicator light to notify a driver of a decrease in an ammonia storage ability of the SCR catalyst. The ammonia storage ability of the SCR catalyst may be decreased due to contamination and/or thermal degradation.