Method for detecting leakage in a fuel rail

Abstract: A method and apparatus are disclosed for detecting leakage in the fuel supply to the injectors of an engine 10 in which the individual injectors are connected to a fuel supply rail 20 to which fuel from a reservoir 14 is supplied under pressure by a fuel pump 12. The pressure within the fuel rail is monitored and it is determined when a parameter of a pressure surge in the fuel supply rail resulting from a rapid transition from high to low engine load fails to reach a reference value.

Description: The present invention is concerned with an engine in which individual injectors connected to a common fuel supply rail are used to inject fuel directly into the combustion chambers of the engine. In such engines, and especially in diesel engines, the fuel rail needs to be maintained under high pressure by a fuel pump and the present invention seeks to provide a method and apparatus for detecting fuel leakage from the fuel rail and the pipes connected to it. In JP-A-10.089.135, a method for detecting fuel leakage is proposed which compares an expected pressure drop at a given time with a measured pressure drop. In practice, such a method may give rise to inaccurate measurements as it requires a very strict observation of the time-pressure relation. US-A-5.715.786 proposes to detect fuel leakage by observing a pressure rise in a fuel rail. The pressure rise is intentionally generated by the system by means of closing the fuel return line to the tank and allowing the fuel pump to feed fuel to the rail. Active intervention in the normal operation of the engine therefore is required, moreover resulting in high pressure peaks. It is therefore an object of the present invention to overcome the above disadvantages of the prior art by providing a method and means for detecting fuel leakage from a fuel rail in a more reliable and less complicated manner. According to the present invention, there is provided a method of detecting leakage in the fuel supply to the injectors of an engine in which the individual injectors are connected to a fuel supply rail to which fuel from a reservoir is supplied under pressure by a fuel pump, the method comprising the step of monitoring the pressure within the fuel rail. The method comprises the further consecutive steps of : monitoring the engine load and determining when a transition from above a first value of engine load to below a second value of engine load occurs within a predetermined time; turning off the injectors; commanding the fuel pump to close down; and determining when a parameter of a pressure surge in the fuel supply rail resulting from a rapid transition from high to low engine load fails to reach a reference value. In common fuel rail systems, when the load on the engine is reduced (by release of the accelerator pedal), the injectors are immediately turned off and the fuel pump supplying the fuel rail is also commanded to close down. However, because some of the pump chambers will already contain fuel that will be delivered to the rail even after the pump has been commanded to close down, the pressure in the fuel rail increases for a short time and then slowly decays. The invention is predicated on the realisation that this unavoidable pressure surge, which has hitherto been regarded as a nuisance, advantageously can be used to monitor the integrity of the fuel rail. This is because the effect of a leak in the fuel rail of the high pressure lines would be not only to reduce the peak pressure of the surge, but also to reduce the time that it takes to decay. The surge can be measured on such occasions when the accelerator is released suddenly, preferably when the engine is operating at or near full load, as the surge then will be at its maximum level. The peak pressure and decay time of the surge that should occur under these circumstances will depend on the engine speed. By storing the appropriate values of peak pressure and/or decay time, or alternatively the time integral of the pressure surge, in a look-up table, or calculating such reference pressures using a suitable algorithm, it is possible to detect leakage by comparing the respective measured parameter with that stored or calculated for the current engine speed. It is possible to build-in self-learning or adaptation features in the leakage detection algorithm to take into account such factors as variation in the output of the fuel pump. In particular, the algorithm can be made more efficient by allowing the calibration to learn the characteristics of the particular fuel system during the first few hours of operation. As long as the measured values prove to be within an expected range, then they may serve as a baseline from which changes should be measured. The invention will now be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 shows a schematic representation of an engine control system, embodying the present invention; Figure 2 shows a graph of measured rail pressure against time before and after a change in throttle command; and Figure 3 shows part of the graph shown in Figure 2 to an enlarged scale and illustrating the effect of engine speed on the pressure surge in the fuel rail. Figure 1 shows a diesel engine 10 having a fuel pump 12 that draws fuel from a tank 14 by way of a pipe 16 and supplies fuel under pressure to a fuel rail 20 by way of a pipe 18. From the fuel rail 20, fuel flows to the individual injectors (not shown). The pump 12 is controlled by an engine controller 30 which receives inputs from various sensors, amongst them a pressure sensor 24 detecting the pressure in the fuel rail 20, an engine speed/position sensor 32 associated with the crankshaft 22 of the engine 10 and a position sensor 26 sensitive to the position of the accelerator or demand pedal 28. The controller may additionally include a clock to enable it to predict wear in the system. As shown by the graphs in Figures 2 and 3, when the driver suddenly reduces the engine load by removing his foot from the demand pedal 28, that is when there is a step change in the throttle command, the controller 30 after a slight delay sends a signal to the fuel pump 12 to reduce its output. However, when the fuel system has no leaks, there is a temporary surge in the pressure in the fuel rail 20 as sensed by the sensor 24 before the pressure drops to the value corresponding to the reduced engine load condition. The reason for this pressure surge, as earlier explained, is that some of the pump chambers will still contain fuel that is delivered to the fuel rail after the injectors have been shut off. The present invention makes use of this unavoidable pressure surge, to monitor the integrity of the fuel rail because its peak and/or duration would be reduced in the event of a leak in the fuel rail. To avoid errors, it is important to ensure that surge monitoring only takes place when a transition from above a first value of engine load to below a second value of engine load occurs within a predetermined time. In other words, one must ensure that a significant and sudden drop in engine load has occurred. In Figure 3, the curve A shows the pressure variation in the fuel rail when the accelerator pedal is released with the engine running at 2500 rpm while the curve B shows the pressure variation if the release of the accelerator pedal occurs with the engine running at 700 rpm. Because of these variations, it is not possible to specify a fixed limit for the magnitude and/or duration of these pressure surges as they will depend on other operating parameters such as engine speed. Instead, therefore, the engine controller 30, which is itself a micro-computer serving several other functions, may be used to store or calculate tables of expected pressure surge magnitude and duration occurring at different speeds (or other engine control parameters affecting the fuel rail pressure surge) and to compare the expected values with actual values sensed by the sensor 24. When the difference between expected and measured surge peaks and/or surge durations drops below a threshold, then the controller 30 can issue a warning of a suspected leak in the fuel rail. The values of surge pressure and duration may vary between fuel systems and it is possible to compensate for such variation by adopting a self-learning algorithm in the controller 30. To further improve the accuracy and reliability of the fuel leak control, the time integral of the pressure during the surge also may be used as the decisive parameter.

Claims: A method of detecting leakage in the fuel supply to the injectors of an engine (10) in which the individual injectors are connected to a fuel supply rail (20) to which fuel from a reservoir (14) is supplied under pressure by a fuel pump (12), the method comprising the step of monitoring the pressure within the fuel rail (20); and characterized in that the method further comprises the consecutive steps of : monitoring the engine load and determining when a transition from above a first value of engine load to below a second value of engine load occurs within a predetermined time; turning off the injectors; commanding the fuel pump (12) to close down; and determining when a parameter of a pressure surge in the fuel supply rail (20) resulting from a rapid transition from high to low engine load fails to reach a reference value. A method according to claim 1, characterized in that the monitored parameter of the pressure surge is the maximum pressure reached during the surge. A method according to claim 1, characterized in that the monitored parameter of the pressure surge is the duration of the surge. A method according to claim 1, characterized in that the monitored parameter is the time integral of the pressure during the surge. A method according to any of the preceding claims, characterized in that surge monitoring takes place only when a transition from above a first value of engine load to below a second value of engine load occurs within a predetermined time. A method according to any of the preceding claims, characterized in that the reference value is varied as a function of the engine speed during the pressure surge. A method according to claim 6, characterized in that a correction factor is applied to the reference value to compensate for variations in fuel system production. A method according to claim 6 or 7, characterized in that the reference value is varied as a function of an operating condition of the engine (10) such as coolant temperature, ambient temperature and fuel temperature during the pressure surge. A method according to any of the preceding claims characterized in that the method comprises the further step of calculating or looking up from a stored table a reference value appropriate to the prevailing engine operating conditions. A method according to any of the preceding claims, characterized in that the method comprises the further step of applying a correction to the reference value to compensate for variations in the output of the fuel pump (12).

Inventors: ANDREWS ERIC B, BOWLING STACEY A, FLETCHER THOMAS E, SWEETLAND EMMA, ANDREWS, ERIC B., BOWLING, STACEY A., FLETCHER, THOMAS E., SWEETLAND, EMMA
Applicants: CNH UK LTD, CUMMINS ENGINE CO LTD, IVECO UK LTD, CNH U.K. LIMITED, CUMMINS ENGINE COMPANY, LTD., IVECO (UK) LTD.
Application year: 2001
Main classification: F02M65
IPC codes: F02D41, F02M65, F02M55, F02D45