System and method for mode selection in a variable displacement engine

Abstract: A system and method for selecting the operating mode of a variable displacement engine includes a controller (18) with a stored engine map, an engine speed sensor (12), and an inferred desired fractional manifold vacuum which would be required for the engine to operate on a fractional number of cylinders, given the driver's current torque requirements, a specific emissions calibration, and environmental conditions, deriving this inferred desired fractional manifold vacuum from stored information and assorted engine sensor input. The system compares its inferred desired fractional manifold vacuum and current engine speed to one or more stored maps of inferred desired fractional manifold vacuum versus engine speed in order to decide which operating mode should be selected.

Description: The present invention relates to a system for determining when to operate less than the maximum possible number of cylinders of a multi-cylinder variable displacement engine, and, more particularly, to utilising inferred desired manifold vacuum to make this determination, see e.g. GB-A-2 101 683. Automotive vehicle designers and manufacturers have realised for years that it is possible to obtain increased fuel efficiency by operating an engine on less than its full complement of cylinders during certain running conditions. Accordingly, at low speed, low load operation, it is possible to save fuel by operating, for example, an eight cylinder engine on only four or six cylinders, or a six cylinder engine on only three or four cylinders. In fact, one manufacturer offered a 4-6-8 variable displacement engine several years ago. Also, Ford Motor Company designed a six cylinder engine which was capable of operating or, three cylinders. While never released for production, Ford's engine was developed to a highly refined state. Unfortunately, both of the aforementioned engines suffered from deficiencies associated with their control strategies. Specifically, customer acceptance of the engine actually in production was unsatisfactory because the powertrain tended to "hunt" or shift frequently between the various cylinder operating modes. In other words, the engine would shift from four to eight cylinder operation frequently, producing noticeable torque excursions. This unfavourably caused the driver to perceive excessive changes in transmission gear in the nature of downshifting or upshifting. Additionally, prior art systems did not always consider whether the driver's demand for torque could be met by a fractionally operating engine before deciding to operate in fractional mode. Decisions were often based on direct measurements of real-time parameters, without considering how those parameters would be affected by fractional operation. As detailed in U.S. Patent Application No. 08/172,359 Ford initially addressed some of the aforementioned concerns by utilising inferred engine load based on accelerator control position as a decision criteria. The present invention is directed at improving this system by utilising a more precise set of engine information in deciding whether to operate an engine on less than its full complement of cylinders. According to the present invention, there is provided a system for determining a number of cylinders to operate in a variable displacement engine, the system comprising: an engine speed sensor; means for inferring a desired fractional manifold vacuum, said inferred desired fractional manifold vacuum representing an amount required to accommodate a desired torque and a specific emissions calibration for the variable displacement engine operating on a fractional number of cylinders; and a controller for determining whether the variable displacement engine should be operated on a fractional number of cylinders based on said engine speed sensor and said means for inferring desired fractional manifold vacuum, the controller further comprising storage for one or more engine speed limits, storage for one or more inferred desired fractional manifold vacuum limits, storage for a fractional operation indicator, and means for comparing both said engine speed to said engine speed limit and said inferred desired fractional manifold vacuum to said inferred desired fractional manifold vacuum limit to determine whether the variable displacement engine should be operated on a fractional number of cylinders. Further according to the present invention, there is provided a method of determining a number of cylinders to operate in a variable displacement engine, comprising the steps of: sensing a current speed of the variable displacement engine; inferring a desired fractional manifold vacuum required to accommodate a desired torque and a specific emissions calibration for the variable displacement engine operating on a fractional number of cylinders at said current engine speed; detecting whether the variable displacement engine is operating on a fractional number of cylinders; selecting limits based on a fractional operation of said variable displacement engine, said limits utilising said current engine speed and said inferred desired fractional manifold vacuum; comparing said current engine speed to said current engine speed limits and said inferred desired fractional manifold vacuum to said inferred desired fractional manifold vacuum limits; and recommending said fractional operation or a maximum operation of the variable displacement engine. A primary advantage of this invention is that it more directly addresses the driver's demand for torque and accounts for the emissions calibration and environmental conditions in deciding whether to operate in fractional mode. An additional advantage is that the invention minimises mode shifting by using an inferred parameter as a basis for deciding whether to operate in fractional mode, so that decisions to switch modes are based on a consistent method of computation. Yet another advantage is that the system can be adapted for a variety of engines by customising the stored limit criteria for the particular application. The invention will now be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a block diagram of a variable displacement engine mode selection system according to the present invention; Figure 2 illustrates an engine mode selection map for a preferred embodiment, where mode is a function of inferred desired fractional manifold vacuum, engine speed, and current engine operation; Figure 3 illustrates an engine mode selection map for an alternative embodiment showing mode as nonlinear functions of inferred desired fractional manifold vacuum, engine speed, and current engine operation; Figure 4 is a flow chart of a preferred embodiment showing a mode selection process for a variable displacement engine according to the present invention; Figure 5 illustrates an engine mode selection map for an alternative embodiment where an inferred fractional manifold vacuum limit is adjusted during the course of engine operation; and Figure 6 is a timing diagram illustrating adjustments to an inferred desired fractional manifold vacuum limit over time. Referring to Figure 1, a mode selection system for a variable displacement engine has an engine speed sensor 12 for sensing engine speed, an air charge temperature sensor 16 for measuring the temperature of the air flowing into the engine, and additional assorted engine sensors 10 for measuring other engine characteristics and inferring the angle of the accelerator pedal controlled by the driver. Sensors 10, 12, 16 provide signals to a controller 18 of the type commonly used for providing engine control. Controller 18 includes a microprocessor 20 that utilises input from various sensors such as sensors 10, 12, and 16, which may include air charge temperature, engine speed, engine coolant temperature, and other sensors known to those skilled in the art and suggested by this disclosure. In addition to sensor input, microprocessor 20 also utilises its own scored information (not shown), which may include limit values for various engine parameters or time-oriented data Controller 18 may operate spark timing/control, air/fuel ratio control, exhaust gas recirculation (EGR), intake airflow, and other engine and power transmission functions. In addition, through a plurality of engine cylinder operators 22, controller 18 has the capability of disabling selected cylinders in the engine, causing the engine to have a decreased effective displacement. An engine operating with less than its full complement of cylinders is said to be in fractional mode, as opposed to maximum mode which utilises all engine cylinders to provide maximum effective displacement. For example, with an eight-cylinder engine, controller 18 may operate the engine on three, four, five, six, seven, or eight cylinders, as the driver's demanded torque, a specific emissions calibration, and environmental conditions warrant. Those skilled in the art will appreciate in view of this disclosure that a number of different disabling devices are available for selectively rendering inoperative one or more engine cylinders. Such devices include mechanisms for preventing any of the cylinder valves in a disabled cylinder from opening, such that gas remains trapped within the cylinder. Controller 18 operates electronic throttle operator 24, which may comprise a torque motor, stepper motor, or other type of device which positions an electronic throttle 26. Electronic throttle 26 is different from a mechanical throttle, which may be employed in connection with a manually operable accelerator control. Electronic throttle operator 24 provides feedback to controller 18 regarding the position of the electronic throttle 26. As shown in the engine mode selection map of Figure 2, the present invention utilises inferred desired fractional manifold vacuum, engine speed, and the engine's current mode of operation in deciding whether to operate in fractional or maximum mode, with limit information being stored within the controller. Engine speed is shown on the horizontal axis. In a preferred embodiment, engine speed is expressed in RPM, with values increasing from left to right along the horizontal axis. For example, LUG LOW might represent 400 RPM, LUG HIGH might be 900 RPM, LIMIT LOW might be 2000 RPM, and LIMIT HIGH might be 2250 RPM. Still referring to Figure 2, inferred desired fractional manifold vacuum is shown on the vertical axis. Inferred desired fractional manifold vacuum is an estimate of the amount of manifold vacuum which would be desirable in a variable displacement engine operating on a fractional number of cylinders, given the driver's current demand for torque, present engine conditions, and accompanying emissions calibration, as dictated by spark timing and EGR concentration. In a preferred embodiment, inferred desired fractional manifold vacuum is expressed in inches of mercury, with V 1 representing, for example, four inches of mercury, and V 2 representing two inches of mercury. Moving from bottom to top along the vertical axis, vacuum decreases, equalling zero at the point where it matches current barometric pressure. Note that while V 1 and V 2 are shown as constants, they may also be linear or nonlinear functions, or even collections of irregular data values. Fractional operation is recommended when the operating point which corresponds to the inferred desired fractional manifold vacuum and the engine speed is located within the inner area denoted FRACTIONAL OPERATION. Conversely, when the operating point is located in the outer area denoted MAXIMUM OPERATION, maximum mode is recommended. When the point is located within the area marked HYSTERESIS BAND, current engine mode is used to determine which combination of limits should be used, V 1 /LUG HIGH/LIMIT LOW or V 2 /LUG LOW/LIMIT HIGH. A fractional operation indicator stored within controller 18 of Figure 1 is used to track current engine mode. Referring again to Figure 2, maximum-to fractional arrow 30 indicates that the V 1 /LUG HIGH/LIMIT LOW combination should be used when the engine is currently operating in maximum mode. Fractional-to-maximum arrow 32 indicates that the V 2 /LUG LOW/LIMIT HIGH combination should be used when the engine is currently operating in fractional mode. This variability in limits provides a smoothing effect to reduce the likelihood of excessive mode switching. For example, when the engine is first started, engine speed is less than LUG LOW, causing the engine to operate in the maximum mode according to the map. Because of the hysteresis band, a recommendation to operate in fractional mode will not be made until the engine speed is within the LUG HIGH/LIMIT LOW boundaries and the inferred desired fractional manifold vacuum is less than or equal to V 1 . However, once the engine meets these criteria and begins to operate in fractional mode, it will continue this fractional operation until the engine speed falls outside the LUG LOW/LIMIT HIGH boundaries or the inferred desired fractional manifold vacuum exceeds V 2 . The engine mode selection map of Figure 3 shows an alternative embodiment in which the preferred mode is established using nonlinear functions of inferred desired fractional manifold vacuum, engine speed, and current engine mode. Such functions might be derived based on operating characteristics of a particular engine, taking into account a variety of factors including emissions and powertrain features. As in Figure 2, the vertical axis of Figure 3 reflects inferred desired fractional manifold vacuum, which equals zero at barometric pressure and increases in a downward direction. Turning now to Figure 4, a preferred embodiment of the method for selecting the operating mode of a variable displacement engine begins at block 38 with the start of the program. At block 40, the controller infers a desired manifold vacuum for a fractionally operating engine which corresponds to the driver's current demand for torque, present engine conditions, and accompanying emissions calibration, as dictated by spark timing and EGR concentration. This inferred desired manifold vacuum is always determined based on a fractionally operating engine, independent of the engine's real-time operating state, hence the term inferred desired fractional manifold vacuum. Inferring the desired fractional manifold vacuum provides stable decision criteria throughout all operating modes, unlike measuring manifold vacuum, which reflects only the engine's current mode of operation. Inferred desired fractional manifold vacuum is important because it reflects an estimate of the manifold vacuum which the engine will have to achieve in order to operate successfully in fractional mode. If a fractionally operating engine would not be able to meet the driver's demanded torque and specific emissions calibration under the current engine and atmospheric conditions, which are reflected in the inferred desired fractional manifold vacuum, then maximum mode should be recommended. Those skilled in the art will recognise that various methods for inferring manifold vacuum may be chosen. It is the use of inferred desired fractional manifold vacuum as a decision criteria that forms the core of the present invention. Continuing with Figure 4, at block 42 the controller checks the current engine mode to determine which engine map limits should be utilised. If the engine is currently in maximum mode, then maximum-to-fractional limits are used for engine speed and desired fractional manifold vacuum, as shown by block 44. If the engine is currently in fractional mode, then fractional-to-maximum limits are used for engine speed and desired fractional manifold vacuum, as shown by block 46. At block 48 the controller checks to ascertain whether both engine speed and inferred desired fractional manifold vacuum are within the selected limits defined by a stored engine mode selection map. If either engine speed or inferred desired fractional manifold vacuum are outside the defined limits, then maximum operation is recommended as shown at block 50, and the controller continues with block 40. If both are within the defined limits, then at block 56 the controller recommends fractional operation. The controller then continues with block 40. Turning now to Figure 5, an engine mode selection map for an alternative embodiment of the present invention is fundamentally similar to that of Figure 2 but includes a variable limit for the V 1 transition level of inferred desired fractional manifold vacuum, as represented by V 1s , V 1a , V 1b , and V 1c The actual value selected for V 1 on a particular occasion may be a function of time or mode switching frequency, and the amount of variation as represented by δ1, δ2, and δ3 may change with current vehicle speed or other operating conditions. The system begins with V 1 set to the point V 1s and changes this limit each time the engine changes modes, afterwards allowing V 1 to approach the predetermined static value as represented by V 1s . This dynamic limit for V 1 effectively widens the real-time hysteresis band for transitions into fractional mode, and it can be used to add stability and make transitions more smooth under particular environmental conditions where many transitions might ordinarily take place. While this embodiment adjusts the V 1 limit with every mode transition, less frequent changes may also be accomplished if desirable. Similarly, adjusting V 2 may also be desirable. Turning now to Figure 6, a timing diagram illustrates an example of adjustments to an inferred desired fractional manifold vacuum limit over time. Time increases from left to right on the horizontal axis, and manifold vacuum decreases from bottom to top on the vertical axis. Inferred desired manifold vacuum limits V 2 and V 1s initially define the hysteresis band as shown on the left at time t 0 . At time t 1 , a transition is made which causes the system to increase the vacuum limit V 1 by δ1, so it increases from V 1s to V 1a . After the transition, the limit returns to the initial V 1s value, using a restorative function of e -t/τ where τ represents a time constant chosen by the system to achieve the desired smoothing effect. Note that while this preferred embodiment utilises a restorative function of e -t/τ , other restorative functions may also be utilised. Note also that the time constant τ may be varied dynamically to permit faster or slower recovery as circumstances warrant. Continuing with Figure 6, at time t 2 another transition is made, causing the V 1 limit to be increased by δ1 to V 1a . For simplicity, this change has been drawn to mirror the change which took place at t 1 , but this would not necessarily be true under actual operating conditions. Afterwards, the limit once again attempts to restore itself to the original value, but at t 3 another transition occurs before it can do so, causing the limit to be increased by δ2 to the value represented by V 1b . Similarly, the subsequent attempt at restoring V 1 to the level of V 1s is interrupted by yet another transition at t 4 . This transition causes the limit to be increased by δ3 to a still larger vacuum represented by V 1c . Note that at this point, the hysteresis has been dramatically widened to reduce the frequency of transitions for smoother operation. Afterwards, the limit restores itself over time to the original value represented by V 1s .

Claims: A system for determining a number of cylinders to operate in a variable displacement engine, the system comprising: an engine speed sensor (12); means (18) for inferring a desired fractional manifold vacuum, said inferred desired fractional manifold vacuum representing an amount required to accommodate a desired torque and a specific emissions calibration for the variable displacement engine operating on a fractional number of cylinders; and a controller (18) for determining whether the variable displacement engine should be operated on a fractional number of cylinders based on said engine speed sensor and said means for inferring desired fractional manifold vacuum, the controller further comprising storage for one or more engine speed limits, storage for one or more inferred desired fractional manifold vacuum limits, storage for a fractional operation indicator, and means for comparing both said engine speed to said engine speed limit and said inferred desired fractional manifold vacuum to said inferred desired fractional manifold vacuum limit to determine whether the variable displacement engine should be operated on a fractional number of cylinders. A system according to Claim 1, wherein said inferred desired fractional manifold vacuum limit represents a linear function of inferred desired fractional manifold vacuum at varying engine speeds. A system according to Claim 2, wherein said linear inferred desired fractional manifold vacuum limit function includes at least one additional inferred desired fractional manifold vacuum limit function such that said controller uses different inferred desired fractional manifold vacuum limit functions depending on said fractional operation indicator. A system according to Claim 1, wherein the inferred desired fractional manifold vacuum limit represents a nonlinear function of inferred desired fractional manifold vacuums at varying engine speeds. A system according to Claim 4, wherein the nonlinear inferred desired fractional manifold vacuum limit function includes at least one additional inferred desired fractional manifold vacuum limit function such that said controller uses different inferred desired fractional manifold vacuum limit functions depending on said fractional operation indicator. A system according to Claim 1, wherein the controller further comprises means for computing an amount by which to adjust said inferred desired fractional manifold vacuum limit, and means for adjusting said inferred desired fractional manifold vacuum limit by said amount during operation of said variable displacement engine. A method of determining a number of cylinders to operate in a variable displacement engine, comprising the steps of: sensing a current speed of the variable displacement engine; inferring a desired fractional manifold vacuum required to accommodate a desired torque and a specific emissions calibration for the variable displacement engine operating on a fractional number of cylinders at said current engine speed; detecting whether the variable displacement engine is operating on a fractional number of cylinders; selecting limits based on a fractional operation of said variable displacement engine, said limits utilising said current engine speed and said inferred desired fractional manifold vacuum; comparing said current engine speed to said current engine speed limits and said inferred desired fractional manifold vacuum to said inferred desired fractional manifold vacuum limits; and recommending said fractional operation or a maximum operation of the variable displacement engine. A method according to Claim 11, wherein the step of selecting said limits further comprises the steps of evaluating a fractional operation indicator and choosing said limits based on the operation of said indicator. A method according to Claim 11, wherein said method further comprises the steps of determining an amount by which to adjust said inferred desired fractional manifold vacuum limit and adjusting said inferred desired fractional manifold vacuum limit by said determined amount.

Inventors: HIEB BRADLEY J, ROBICHAUX JERRY D, HIEB, BRADLEY J., ROBICHAUX, JERRY D.
Applicants: FORD FRANCE, FORD MOTOR CO, FORD WERKE AG, FORD FRANCE S. A., FORD MOTOR COMPANY LIMITED, FORD-WERKE AKTIENGESELLSCHAFT
Application year: 1996
Main classification: F02D13
IPC codes: F02D11, F02D41, F02D17, F02D45, F02D13