Valve feedback control with two opening degree sensors

Abstract: In a throttle control system having two throttle opening sensors (4A and 4B), when one opening degree sensor being used in a PID feedback control becomes abnormal, the use of sensor output for throttle feedback control is switched from the abnormal one to normal one. Which of the throttle opening degree sensors (4A and 4B) has become abnormal is determined by monitoring the difference between the output values of the throttle opening degree sensors (4A and 4B) and the intensity of the electric current flowing to a DC motor (12) which drives a throttle valve (3). Further, when the abnormality in the another sensor (4B) being newly used is determined, the feedback control is continued based on the estimation of the throttle opening degree calculated by the output of the sensor (4B) before the malfunction thereof.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention: The present invention relates to a valve feedback control, such as throttle control for internal combustion engines for controlling opening degrees of a throttle valve by driving an electric motor according to a pedalled amount of an accelerator pedal. 2. Description of Related Art: As a prior art relating to a throttle control apparatus for internal combustion engines, Japanese Patent Publication laid-open No. 3-281969 is known. According to this art, the apparatus has a double sensor system having two throttle degree-detecting sensors provided side by side. Output values of both sensors are always compared with each other. If the difference between the output values thereof is more than a predetermined value (in consideration of tolerance), it is determined that the sensor and/or the sensors are abnormal and the output power of the internal combustion engine is restricted. In the above-described art, which of the two throttle opening degree sensors is abnormal is not determined. Thus, a control of limiting the output power of the internal combustion engine is executed although one of the throttle opening degree sensors is normal. Thus, the prior art has a disadvantage that the performance of the system deteriorates outstandingly once one of the sensors becomes abnormal. Document US-A-5170769 discloses a throttle control system according to the preamble of claim 1 (or 5). SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problem and it has a primary object to provide a valve feedback control, such as a throttle control for internal combustion engines having two sensors, for detecting the opening degree of a throttle valve, provided side by side. It also has a secondary object to provide a throttle control in which, when one of the two sensors has become abnormal, the other sensor is used to continue the control of the opening degree of the throttle valve. According to the present invention, it is determined that one of the two valve opening degree sensors is abnormal, when the difference between the outputs thereof is greater than the predetermined value. Upon this determination, which of the two opening degree sensors is abnormal is determined, based on the intensity of electric current flowing to an electric motor. Therefore, the normal opening degree sensor can be determined. Preferably, the feedback control is applied to engine throttle valve control. Preferably, determination of the sensor abnormality is made when the intensity of the electric current for driving the motor is greater than a predetermined value. That is, the intensity of the electric current for driving the motor does not become more than the predetermined value when the throttle opening degree sensor is normal. Therefore, whether the throttle opening degree sensor is abnormal or not can be detected by monitoring the intensity of the electric current for driving the motor. Preferably, when it is determined that the throttle opening degree sensor being currently used in the throttle control is abnormal, the sensor to be used for the control is switched from the abnormal throttle opening degree sensor to the normal sensor. In this manner, a normal throttle control can be continued. More preferably, when one throttle opening degree sensor is determined to be abnormal, it is further determined whether or not the other throttle opening degree sensor is also abnormal. When the other sensor is also abnormal, the opening degree of the throttle valve is controlled by using the output value of the other throttle opening degree sensor before the abnormality thereof is detected. Thus a normal throttle control may be continued by using the estimated value based on the output value of the other sensor before the abnormality thereof is detected, when the other sensor being currently used in the control has become abnormal after one throttle opening degree sensor becomes abnormal. BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings: Fig. 1 is a schematic view showing the entire construction of a throttle control apparatus for internal combustion engines according to an embodiment of the present invention; Fig. 2 is another schematic view showing the construction of main parts of the throttle control apparatus according to the embodiment of the present invention; Fig. 3 is a block diagram showing the flow of signals in the throttle control apparatus according to the embodiment of the present invention; Fig. 4 is a time chart showing a behavior of a throttle valve when one of two throttle opening degree sensors of the throttle control apparatus according to the embodiment of the present invention has become abnormal; Fig. 5 is a flowchart showing a processing procedure to be executed by an ECU which is used in the throttle control apparatus according to the embodiment of the present invention, when one of the two throttle opening degree sensors has become abnormal; Fig. 6 is a graph showing a relationship between the opening degree of the throttle valve of the throttle control apparatus according to the embodiment of the present invention and the output value of the throttle opening degree sensor thereof; and Fig. 7 is a flowchart showing a processing procedure to be executed by the ECU which is used in the throttle control apparatus according to the embodiment of the present invention, when one of the two throttle opening degree sensors has become abnormal. DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENT An embodiments of the present invention will be described below in detail with reference to the accompanying drawings. In Fig. 1 showing the entire construction of a throttle control apparatus for internal combustion engines, reference numeral 1 denotes an internal combustion engine to which air is supplied through an air intake duct 2. A throttle valve 3 is rotatably installed inside the air intake duct 2. The throttle valve 3 is operatively linked with two throttle opening degree sensors 4A and 4B for detecting the opening degrees of the throttle valve 3. Reference numeral 5 denotes an accelerator pedal linked with an accelerator opening degree sensor 6 for detecting the pedalling or depressing degrees thereof. Reference numeral 10 denotes an ECU (electronic control unit) which receives a throttle opening degree-indication signal THA, a throttle opening degree-indication signal THB, and an accelerator opening degree-indication signal Ap outputted from each of the throttle opening degree sensors 4A and 4B and the accelerator opening degree sensor 6. Reference numeral 12 denotes a direct current (DC) motor serving as an actuator to which electric current is supplied from a motor driving circuit 11 provided between the ECU 10 and the DC motor 12 as shown in Fig. 2. Reference numeral 13 denotes a reduction gear train provided between the DC motor 12 and the throttle valve 3. A return spring 14 normally biases the throttle valve 3 to the completely closed side thereof. In this embodiment, it is assumed that a PID control is executed by using the throttle opening degree sensor 4A of the two throttle opening degree sensors 4A and 4B. As shown in Fig. 2, the following signals are inputted to the ECU 10 by performing analog-to-digital conversions thereof by an A/D converter 10a: the accelerator opening degree-indication signal Ap outputted from the accelerator pedal opening degree sensor 6 in correspondence to the pedalled amount of the accelerator pedal 5; and the throttle opening degree-indication signal THA and the throttle opening degree-indication signal THB outputted from each of the throttle opening degree sensors 4A and 4B in correspondence to the opening degree of the throttle valve 3. According to the levels of the signals, the ECU 10 outputs PWM signals (pulse width-modulated signals) to the motor driving circuit 11. Upon receipt of the PWM signals, electric current is applied from the motor driving circuit 11 to the DC motor 12. As a result, the DC motor 12 is driven, and the rotation thereof is transmitted to the throttle valve 3 through the reduction gear train 13 to open or close the throttle valve 3. A closing stopper 7 for regulating the completely closed position of the throttle valve 3 is provided. As shown in Fig. 3, a PID control circuit 10b of the ECU 10 receives a deviation between a throttle opening degree-command value (target opening degree) 0- cmd calculated based on the accelerator opening degree-indication signal Ap outputted from the accelerator opening degree sensor 6 in correspondence to the opening degree of the accelerator pedal 5 and an output value (actual or feedback value) 0- th calculated based on the throttle opening degree-indication signal THA outputted from the throttle opening degree sensor 4A in correspondence to the opening degree of the throttle valve 3. Then, in the PID control circuit 10b, a compensation is performed by means of predetermined control gains Kp, Ti, and Td of respective Proportional, Integral, and Derivative terms. Thereafter, the DC motor 12 to be controlled is driven by the PWM-controlled electric current through the motor driving circuit 11 so as to zero the calculated deviation. Description is made with reference to Fig. 4 on the behavior of the sensor system when the throttle opening degree sensor 4A has become abnormal in the feedback control of the opening degree of the throttle valve 3 to be executed by the double sensor system having the throttle opening degree sensors 4A and 4B provided side by side. As shown in Fig. 4, when the throttle opening degree sensor 4A being used normally in executing the feedback control by means of the PID control becomes abnormal and consequently, when the output value (feedback value) THA of the throttle opening degree sensor 4A has deviated (for example, in throttle valve-closed side) from the throttle opening degree-command value (target opening degree of throttle valve) cmd, the DC motor 12 is rotated to the throttle valve-opening side to eliminate the deviation ( cmd - THA). At this time, the duty ratio (hereinafter referred to as merely "Duty") of the PWM signal outputted from the ECU 10 in correspondence to an intensity of the electric current for driving the DC motor 12 is normally 0% - 10%. Even though the DC motor 12 is rotated continuously, the output value of the throttle opening degree sensor 4A does not attain the throttle opening degree-command value because the throttle opening degree sensor 4A is abnormal. Even though larger electric current is applied thereto, the output of the sensor 4A will not follow because of its abnormality. As a result, the current will reach the maximum intensity ("Duty" = 100%) to rotate the DC motor 12 to the throttle valve-opening side. The output value of the throttle opening degree sensor 4A will not reach the throttle opening degree-command value and thus this state continues permanently. On the contrary, even when the throttle opening degree sensor 4B which is not used in the feedback control becomes abnormal, there occurs merely a difference between the output values of the throttle opening degree sensors 4A and 4B and thus the feedback control can be continued without problems. That is, which of the throttle opening degree sensors 4A and 4B has become abnormal can be determined by monitoring the absolute value of the difference between the output values of the throttle opening degree sensors 4A and 4B and the "Duty". Accordingly, it is possible to continue the feedback control by using the normal throttle opening degree sensor. Description is made on a processing procedure to be executed by the ECU 10 of the throttle control apparatus for internal combustion engines according to the embodiment of the present invention, with reference to a flowchart shown in Fig. 5. Initially, at step S101, it is determined whether a time period T1 (for example, 4ms; The shorter the time period T1 is, the better.) has elapsed in relation to a previous execution time at which a determination was made. If the determination condition at step S101 is not satisfied, the execution of this routine terminates. If the determination condition at step S101 is satisfied, the program goes to step S102 at which a value 0- A (same as 0- th of Fig. 3) is determined by performing an analog-to-digital conversion of the throttle opening degree-indication signal THA outputted from the throttle opening degree sensor 4A. Then, the program goes to step S103 at which a value 0- B is determined by performing an analog-to-digital conversion of the throttle opening degree-indication signal THB outputted from the throttle opening degree sensor 4B. Then, the program goes to step S104 at which it is determined whether the absolute value of the difference between the value 0- A obtained at step S102 and the value 0- B obtained at step S103 is greater than an abnormality determination constant α (for example, 10°). If the determination condition at step S104 is not satisfied, the program goes to step S105 at which an abnormality detection counter CA for detecting the abnormality of the throttle opening degree sensor 4A and an abnormality detection counter CB for detecting the abnormality of the throttle opening degree sensor 4B are cleared. Then, the execution of this routine terminates. If the determination condition at step S104 is satisfied, it is determined that the throttle opening degree sensor 4A or the throttle opening degree sensor 4B is abnormal. Then, the program goes to step S106 at which it is determined whether the "Duty" is greater than 90%. If the determination condition at step S106 is satisfied, it is determined that the throttle opening degree sensor 4A is abnormal because of use of the output of the sensor 4A. Then, the program goes to step S107 at which the count-up of the abnormality detection counter CA is executed, whereas the abnormality detection counter CB is cleared. Then, the program goes to step S108 at which it is determined whether a time period counted up by the abnormality detection counter CA is more than a predetermined time period, 200ms in this embodiment. The predetermined time period (200ms) is determined by a mechanical or electrical time constant of the system. If the determination condition at step S108 is not satisfied, the execution of this routine terminates. If the determination condition at step S108 is satisfied, i.e., if the time period counted up by the abnormality detection counter CA is more than 200ms, it is determined that the throttle opening degree sensor 4A is abnormal. Then, the program goes to step S109 at which a warning that the throttle opening degree sensor 4A is abnormal is issued. Then, the program goes to step S110 at which the throttle opening degree sensor 4A being used in the feedback control of the opening degree of the throttle valve 3 is switched to the throttle opening degree sensor 4B to continue the feedback control. Then, the execution of this routine terminates. If the determination condition at step S106 is not satisfied, it is determined that the throttle opening degree sensor 4B is abnormal. Then, the program goes to step S111 at which the abnormality detection counter CA is cleared, whereas the count-up of the abnormality detection counter CB is executed. Then, the program goes to step S112 at which it is determined whether a time period counted up by the abnormality detection counter CB is more than 200ms. If the determination condition at step S112 is not satisfied, the execution of this routine terminates. If the determination condition at step S112 is satisfied, i.e., if the time period counted up by the abnormality detection counter CB is more than 200ms, it is determined that the throttle opening degree sensor 4B is abnormal. Then, the program goes to step S113 at which a warning that the throttle opening degree sensor 4B is abnormal is issued. Then, the execution of this routine terminates. At this time, the feedback control of the opening degree of the throttle valve 3 is continued by means of the throttle opening degree sensor 4A which is normal. As described above, if one of the throttle opening degree sensors 4A and 4B, of the double sensor system, arranged side by side becomes abnormal, the abnormal throttle opening degree sensor is detected, and the normal throttle opening degree sensor is used to continue the feedback control of the opening degree of the throttle valve 3. Description will be made below with reference to Fig. 6 on the feedback control of the opening degree of the throttle valve to be executed by the sensor system by using one normal throttle opening degree sensor (single sensor system) after the other throttle opening degree sensor becomes abnormal in the feedback control of the opening degree of the throttle valve to be executed by the double sensor system having the throttle opening degree sensors 4A and 4B arranged side by side. As described previously, in the PID control, the to-be-controlled DC motor 12 is supplied with the electric current corresponding to the degree of the deviation between the throttle opening degree-command value (target opening degree of throttle valve) and the output value (feedback value) of the throttle opening degree sensor so as to reduce the deviation to zero. It is conceivable to use the output value (value at previous execution time) at a previous execution time to control the opening degree of the throttle valve 3 by always monitoring whether the variation in the output value of the throttle opening degree sensor is greater than a determination reference value so as to determine whether or not the throttle opening degree sensor is abnormal. However, if the execution of the PID control is continued by using the output value of the throttle opening degree sensor at the previous execution time, the deviation does not become small although the DC motor 12 is in operation. When the rotation speed of the DC motor 12 becomes so high that a phenomenon of an overshoot or a hunting occurs may occur in the throttle valve 3 immediately after the output value of the throttle opening degree sensor reaches a failure region. As a result, the output value of the throttle opening degree sensor changes rapidly. In consideration of the above problem, when the output value of the throttle opening degree sensor has reached the failure region, the opening degree of the throttle valve 3 is controlled not by using the output value thereof detected at the previous execution time but by using an estimated value of the output value thereof based on the variation in the output value thereof detected immediately prior to the time at which the output value thereof has reached the failure region. By executing such a control, the output value (feedback value) of the throttle opening degree sensor gradually approaches the throttle opening degree-command value (target opening degree of throttle valve) and the deviation gradually approaches zero. Consequently, the motor power becomes gradually smaller, which prevents the occurrence of the overshoot or the hunting in the throttle valve 3 after the output value of the throttle opening degree sensor reaches the failure region. Fig. 6 is a graph showing the relationship between the opening degree of the throttle valve and the output value of the throttle opening degree sensor. An equation (1) expressed below is established, supposing that an output value of the throttle opening degree sensor at a time tn is Vsn; a variation in the output value of the throttle opening degree sensor at the time tn is ωn (negative value in Fig. 6); and an estimated value of the output value of the throttle opening degree sensor at a time tn+1 is Vsn+1'. (Equation 1) Vsn + ωn = Vsn+1' When the following inequality equation (2) is satisfied as a result of a comparison between an actual output value Vsn+1 of the throttle opening degree sensor at the time tn+1 and the estimated value of the output value thereof at the time tn+1 is Vsn+1', the throttle opening degree sensor is determined as being normal. In this case, the output value Vsn+1 of the throttle opening degree sensor is used as it is in the PID control. A term β in the equation (2) which is an abnormality-determination constant for determining whether or not the throttle opening degree sensor is abnormal is determined by a mechanical time constant of the system. (Equation 2) Vsn+1' - β < Vsn+1 < Vsn+1' + β If the equation (2) is not satisfied, it is determined that the throttle opening degree sensor is abnormal. Then, a driver is warned that the throttle opening degree sensor is abnormal, and the PID control is executed by using the estimated value Vsn+1' of the output value of the throttle opening degree sensor instead of the output value thereof. In this manner, the PID control can be executed by preventing the occurrence of the overshoot or the hunting in the throttle valve 3, even though the throttle opening degree sensor becomes abnormal due to an abnormal opening degree of the throttle valve 3. With reference to a flowchart shown in Fig. 7, description is made on a processing procedure to be executed by the ECU 10 of the throttle control apparatus of the internal combustion engine according to the embodiment of the present invention, by using only one of the throttle opening degree sensors. In this embodiment, it it assumed that the throttle opening degree sensor 4A becomes abnormal and is then switched to the throttle opening degree sensor 4B. Initially, at step S201, it is determined whether a time period T1 (for example, 4ms; The shorter the time period T1 is, the better) has elapsed in relation to a previous execution time at which a determination was made. If the determination condition at step S201 is not satisfied, the execution of this routine terminates. If the determination condition at step S201 is satisfied, the program goes to step S202 at which a value Vsn (same as th of Fig. 3) is determined by performing an analog-to-digital conversion of the throttle opening degree-indication signal THA outputted from the throttle opening degree sensor 4B. Then, the program goes to step S203 at which it is determined whether the absolute value of the difference between an estimated value Vsn' of an output value of the throttle opening degree sensor 4B determined at a previous execution time and the output value thereof determined at step S202 is greater than the abnormality-determination constant β. If the determination condition at step S203 is satisfied, it is determined that the throttle opening degree sensor 4B is abnormal. Then, the program goes to step S204 at which the estimated value Vsn' of the output value of the throttle opening degree sensor 4B is substituted into the output value Vsn thereof at a current execution time. Then, the program goes to step S205. If the determination condition at step S203 is not satisfied, the program skips step S204. At step S205, an output value Vsn-1 of the throttle opening degree sensor 4B at the previous execution time is subtracted from the output value Vsn thereof at the current execution time to determine a variation ωn of the output value thereof at the current execution time. Then, the program goes to step S206 at which the output value Vsn of the throttle opening degree sensor 4B at the current execution time is stored as Vsn-1. Then, the program goes to step 207 at which the variation ωn of the output value of the throttle opening degree sensor 4B at the current execution time determined at step S205 is added to the output value Vsn thereof at the current execution time to determine the estimated value Vsn' of the output value thereof at a next execution time. Then, the execution of this routine terminates. The above-described processing allows the output value of the throttle opening degree sensor 4B in the failure region to be equal to that in the normal region and hence, the PID control to be normally executed, thus preventing the occurrence of the overshoot or the hunting in the throttle valve 3 immediately after the output value of the throttle opening degree sensor 4B reaches the failure region. The present invention having been described should not be limited to the throttle control in the presently preferred exemplary embodiment but may be applied to or modified in other ways without departing from the scope and spirit of the following claims. In a throttle control system having two throttle opening sensors (4A and 4B), when one opening degree sensor being used in a PID feedback control becomes abnormal, the use of sensor output for throttle feedback control is switched from the abnormal one to normal one. Which of the throttle opening degree sensors (4A and 4B) has become abnormal is determined by monitoring the difference between the output values of the throttle opening degree sensors (4A and 4B) and the intensity of the electric current flowing to a DC motor (12) which drives a throttle valve (3). Further, when the abnormality in the another sensor (4B) being newly used is determined, the feedback control is continued based on the estimation of the throttle opening degree calculated by the output of the sensor (4B) before the malfunction thereof.

Claims: A throttle control apparatus for internal combustion engines (1) for controlling opening degrees of a throttle valve (3) through a direct current motor (12) in accordance with a pedalled amount of an accelerator pedal (5) , the apparatus comprising: two throttle open degree sensors (4A, 4B) operatively coupled with said throttle valve to detect opening degrees of said throttle valve; abnormality determination means (10, S104) for determining that one of said two throttle open degree sensors is abnormal; and abnormal sensor determination means (10, S106-S109, S111-S113) for determining which one of said two throttle open degree sensors is abnormal, when one has been determined to be abnormal, characterized in that said abnormality determination means (10, S104) is arranged to determine that one of said two throttle open degree sensors is abnormal, when a difference between outputs of said two throttle open degree sensors is greater than a predetermined value; and said abnormal sensor determination means (10, S106-S109, S111-S113) is arranged to use an intensity of an electric driving current of said direct current motor (12) , generated in response to the sensor currently being used, to determine which one of said two throttle open degree sensors is abnormal. An apparatus according to claim 1, characterized in that sensor-switching means (10, S110) are provided for switching the use of the output of the throttle open degree sensor being currently used to the output of the other one of said two throttle open degree sensors (4A, 4B) , when said abnormal sensor determination means (10, S106-S109, S111-S113) has determined that the throttle open degree sensor being currently used in the control is abnormal. An apparatus according to claim 1 or 2, characterized in that said abnormal sensor determining means (10, S106-S109, S111-S113) is arranged to determine that the throttle open degree sensor being currently used in the control is abnormal, when the intensity of the electric driving current of said direct current motor (12) is greater than a predetermined intensity. An apparatus according to any one of the preceding claims, characterized by second abnormal sensor determination means (10, S203) for determining whether another one of said two throttle open degree sensors (4A, 4B) is abnormal, when said abnormal sensor determining means (10, S106-S109, S111-S113) has determined that one of said two throttle open degree sensors (4A, 4B) is abnormal; and abnormal time control means (10, S205-S207) for controlling the opening degrees of said throttle valve (3) by using a value based on an output value of the another throttle open degree sensor before the abnormality thereof is detected, when said second abnormal sensor determination means (10, S203) has determined that the another throttle open degree sensor is abnormal. A control method for controlling opening degrees of a valve (3) through an electric motor (12) by the use of two valve open degree sensors (4A, 4B) operatively coupled with said valve to detect opening degrees of the valve, the method comprising the steps of: determining (S104) that one of said two open degree sensors is abnormal; and determining (S106-S109, S111-S113) which one of said two open degree sensors (4A, 4B) is abnormal, when one has been determined to be abnormal, characterized in that said abnormality determining step is performed when a difference between outputs of said two open degree sensors (4A, 4B) is greater than a predetermined value; and said abnormal sensor determining step is performed by using an intensity of an electric driving current of said electric motor (12) , generated in response to the sensor currently being used to control it. A method according to claim 5, characterized by the step of switching (S110) the use of the output of the open degree sensor being currently used to the output of the other one of said two open degree sensors (4A, 4B) , when it is determined that the open degree sensor being currently used in the control is abnormal. A method according to claim 5 or 6, characterized by the steps of detecting (S106) said electric driving current flowing to said electric motor (12) . A method according to any one of claims 5 to 7, characterized in that said abnormal sensor determining step (S106-S109, S111-S113) determines that the open degree sensor being currently used in the control is abnormal, when the intensity of the electric driving current of said electric motor (12) is greater than a predetermined intensity. A method according to any one of claims 5 to 8, characterized by the steps of determining (S203) whether the other one of said two open degree sensors (4A, 4B) is abnormal, when the first abnormal sensor determining step (S106-S109, S111-S113) has determined that one of said two open degree sensors (4a, 4B) is abnormal; and controlling (S205-S207) the opening degrees of said valve (3) by using a value based on an output value of the other open degree sensor before the abnormality thereof is detected, when the second abnormal sensor determining step (S203) has determined that the another open degree sensor is abnormal. A method according to any one of claims 5 to 9, characterized in that said valve is a throttle valve (3) of an internal combustion engine (1) .

Inventors: KAMIO SHIGERU, MIYANO HIDEMASA, NAKAYA YOSHIMASA, SHIRAI KAZUNARI, KAMIO, SHIGERU, MIYANO, HIDEMASA, NAKAYA, YOSHIMASA, SHIRAI, KAZUNARI, Kamio, Shigeru, c/o Nippondenso Co., Ltd., Miyano, Hidemasa, c/o Nippondenso Co., Ltd., Nakaya, Yoshimasa, c/o Nippondenso Co., Ltd., Shirai, Kazunari, c/o Nippondenso Co., Ltd.
Applicants: DENSO CORP, DENSO CORPORATION
Application year: 1996
Main classification: F02D11
IPC codes: F02D11, F02B77, F02D45, F02D41