Method of controlling an electromagnetic valve actuator in a camless combustion engine

Abstract: A method of controlling valve landing in a camless engine including a valve (12) movable between fully open and fully closed positions, and an electromagnetic valve actuator (14) for actuating the valve (12) is disclosed. The method uses at least one discrete position measurement sensor (28,30,32) to determine when the valve is at a particular position during valve movement and then the velocity of the valve is calculated at the particular position based upon current and rate of change of current in the electromagnetic valve actuator (14) when the valve (12) is at the particular position and then controls valve landing based upon the calculated velocity.

Description: The present invention relates to a method of controlling valve landing in a camless engine which uses current and rate of change of current in an electronic valve actuator with discrete position sensors to calculate valve velocity for controlling valve landing. The use of unthrottled operation enabled by fully actuated valves in a camless engine holds promise for improved fuel economy and drivability. Before this technology becomes production feasible, a number of technical problems need to be resolved. One of the key problems is associated with controlling the contact velocities in the valve actuation mechanism so that a reliable performance without unacceptable noise and vibrations is attained. This problem is often referred to as the soft landing problem (i.e., soft landing of the valve and actuation mechanism at its fully open and fully closed positions). In a typical electromechanical actuator, the valve motion is affected by the armature that moves between two electromagnetic coils biased by two springs. The valve opening is accomplished by appropriately controlling the lower coil, while the upper coil is used to affect valve closing. High contact velocities of the armature as well as of valve seating may result in unacceptable levels of noise and vibrations. On the other hand, if the coils are not appropriately controlled, the valve landing may not take place at all, thereby resulting in engine failure. Because the combustion processes in the engine that determine the magnitude of the disturbance force on the valves are stochastic, the disturbance force may vary from cycle-to-cycle. Consequently, a control system that determines the parameters of the coil excitation must combine both in-cycle compensation for the particular disturbance force profile realized within the present cycle, and slower cycle-to-cycle adaptation of the parameters of the excitation, that compensate for engine and actuator assembly aging as well as various other parameter variations. The solutions proposed in the prior art either do not rely on armature position measurement at all, or they require a position sensing mechanism which continuously senses the location of the valve at all positions. The solutions without a position sensor may not be robust enough as they typically rely on open loop estimation schemes that would be rendered invalid should the engine or actuator assembly parameters change. The main problems with the solutions that rely on a continuous position sensor are the high cost and lack of reliability as the sensor may become inaccurate in the course of operation due to calibration drift. US-A-6 016 778 discloses a magnetically operated valve that has a ferromagnetic coil body with a winding and that defines first and second terminal positions of an armature for driving the valve. A spring urges the armature in the direction of the open position of the valve and a piezoelectric element measures the force of the spring when the valve is opened or closed. The output signal from the piezoelectric element is delivered to a closed loop control circuit and serves to determine the position of the valve and the speed of the armature. The speed of the armature is thereby regulated It is an object of this invention to provide an improved method and system for controlling valve landing in a camless engine. According to a first aspect of the invention there is provided a method of controlling valve landing in a camless engine including a valve moveable between fully open and fully closed positions, and an electromagnetic valve actuator for actuating the valve, wherein the method comprises determining valve velocity by providing at least one discrete position measurement sensor to determine when and if the valve is at a particular position during valve movement, estimating the velocity of the valve at said particular position based upon current and rate of change of current in the electromagnetic valve actuator when the valve is at said particular position and controlling valve landing based upon said estimated velocity, characterised in that; the step of providing at least one discrete position measurement sensor comprises providing a first position measurement sensor at a middle location to sense the movement of the valve at a first position between the fully open and fully closed positions, providing a second position measurement sensor at a nearly-closed location to sense movement of the valve near the fully closed position and providing a third position measurement sensor at a nearly-open location to sense movement of the valve near the fully open position. The step of determining the velocity of the valve at said particular position may comprise estimating the velocity of the valve at the first, second and third positions. The step of controlling valve landing may comprise using the estimated velocity at said first position to control valve landing in the same valve cycle, and using the estimated velocity at the second and third positions to control valve landing in a subsequent valve cycle. Alternatively, the step of determining the velocity of the valve at each of said locations may comprise calculating the velocity of the valve at each location based upon current and rate of change of current in the electromagnetic valve actuator when the valve is at each position and controlling valve landing based upon each calculated velocity. The step of determining the velocity of the valve may be performed by the following formula: where:- z is the armature position (the distance from a fully open or fully closed position), r is electrical resistance of the EVA, V is voltage across the EVA, i is measured current through the EVA, k a and k b are calibrated constants, and ( L·i-ε ) is an estimate of time rate of change of current. The estimated rate of change of current may be derived from the formulas: di dt ( estimate ) = L·i - ε and d ε dt = - L· ( L·i-ε ) where L is an estimator gain. The constants ka and kb may be calibrated from the relation between the force on a movable armature of the electromagnetic valve actuator and the distance of the armature from a fully open position in accordance with the following formula: F mag = k a i 2 ( z + k b ) 2 where: F mag is an electromagnetic field force from an energized coil. The step of controlling valve landing may comprise adjusting a duty cycle of the electromagnetic valve actuator in response to said determined velocity. According to a second aspect of the invention there is provided a camless engine including at least one valve movable between fully open and fully closed positions by an electromagnetic valve actuator and an electronic controller to control actuation of the valve characterised in that the engine further comprises a first position measurement sensor at a middle location to sense the movement of the valve at a first position between the fully open and fully closed positions and arranged to provide a signal indicative of the sensed movement to the controller, a second position measurement sensor at a nearly-closed location to sense movement of the valve near the fully closed position and arranged to provide a signal indicative of the sensed movement to the controller and a third position measurement sensor at a nearly-open location to sense movement of the valve near the fully open position and arranged to provide a signal indicative of the sensed movement to the controller and that the controller is operable to calculate the velocity of the valve at each of said locations based upon current and rate of change of current in the electromagnetic valve actuator when the valve is at each said position and to control valve landing of the or each valve based upon each said calculated velocity. The invention will now be described by way of example with reference to the accompanying drawing of which:- Figure 1 shows a schematic vertical cross-sectional view of an apparatus for controlling valve landing in accordance with the present invention, with the valve in the fully closed position; Figure 2 shows a schematic vertical cross-sectional view of an apparatus for controlling valve landing as shown in Figure 1, with the valve in the fully open position; Figures 3a, 3b and 3c graphically illustrate catching voltage, landing velocity, and velocity at the second sensor, respectively, versus cycle number in a simulation of the present invention; Figures 4a, 4b and 4c graphically illustrate catching voltage, landing velocity and velocity at the second sensor, respectively, versus cycle number in a second simulation of the present invention; and Figure 5 shows a flow chart of a control method in accordance with the present invention. Referring to Figures 1 and 2, an apparatus 10 is shown for controlling movement of a valve 12 in a camless engine between a fully closed position (shown in Figure 1), and a fully open position (shown in Figure 2). The apparatus 10 includes an electromagnetic valve actuator (EVA) 14 with upper and lower coils 16,18 which electromagnetically drive an armature 20 against the force of upper and lower springs 22,24 for controlling movement of the valve 12. Switch-type position sensors 28,30,32 are provided and installed so that they switch when the armature 20 crosses the sensor location. It is anticipated that switch-type position sensors can be easily manufactured based on optical technology (e.g., LEDs and photo elements) and when combined with appropriate asynchronous circuitry they would yield a signal with the rising edge when the armature crosses the sensor location. It is furthermore anticipated that these sensors would result in cost reduction as compared to continuous position sensors, and would be highly reliable. A controller 34 is operatively connected to the position sensors 28,30,32, and to the upper and lower coils 16,18 in order to control actuation and landing of the valve 12. The first position sensor 28 is located around the middle position between the coils 16,18, the second sensor 30 is located close to the lower coil 18, and the third sensor 32 is located close to the upper coil 16. In the following description, only the valve opening control is described, which uses the first and second sensors 28,30, while the situation for the valve closing is entirely symmetric with the third sensor used in place of the second. The key disadvantage of the switch-type position sensor as compared to the continuous position sensor is the fact that the velocity information cannot be obtained by simply differentiating the position signal. Rather, the present invention proposes to calculate the velocity based upon the electromagnetic subsystem of the actuator. Specifically, the velocity is estimated based upon the current and rate of change of current in the electromagnetic actuator 14. Because the disturbance due to gas force on the valve does not directly affect the electromagnetic subsystem of the actuator, this velocity estimation can be done reliably. The velocity estimation (assuming no magnetic field saturation) has the form: where, z and Vel are the armature position (distance from an energized coil) and velocity, respectively, r is the electrical resistance, V and i are voltage and current, respectively, and ε is the dynamic state of the estimator and is derived from the dε / dt formula below. L is an estimator gain and ka and kb are constants that are determined by magnetic field properties and are calibrated from the relation between the force on the armature and the gap distance between the armature and the lower coil: F mag = k a i 2 ( z + k b ) 2 The rate of change of current in the EVA is estimated as ( L · i -ε)) in the velocity formula above, where d ε dt = - L· ( L·i - ε ) and L>0 is an estimator gain and the actual measurement of the current i is an input to the formula. Accordingly, the calculated velocity is based on current and estimated rate of change of current in the EVA. The estimate is implemented on a microprocessor system dedicated to actuator control. The duty cycle of the EVA is the excitation signal on-time divided by total time. The duty excitation signal applied to the lower coil 18 (essentially a fraction of maximum voltage applied to the coil, i.e., V=V max d) during a single cycle is shaped by changing the values of several parameters. One such scheme uses the following parameters: T 2 is the time instant when the duty cycle is applied to effect armature catching; d c is the magnitude of the catching duty cycle; T 3 is the time instant when catching action is changed to holding action; and d h is the magnitude of the holding duty cycle. An algorithm is proposed for adjusting these parameters that uses the information from the first and second sensors 28,30, and accomplishes the tasks of both in-cycle control and cycle-to-cycle adaptation. When the armature passes the location of a switch-type position sensor, a rising signal edge from a sensor is detected, and the position at this time instant is known. Using the above characterization of the electromagnetic subsystem, the armature velocity is backtracked and used for control. Consequently, the velocity of the first sensor crossing can serve as an early warning about the magnitude of the disturbance affecting the valve motion, and this information can be used for in-cycle control. The cycle-to-cycle adaptation aims at regulating the velocity at the second sensor crossing to the desired value. Experiments show that disturbances on the exhaust valves are largest at the beginning of the valve motion and, hence, regulating the velocity to the desired value near the end of the valve travel can be used as an enforcement mechanism for soft landing. Finally, in situations when a valve is about to malfunction, as may be indicated by a serious velocity deficit at the second sensor crossing or a second crossing of the second sensor occurs, it may be necessary to apply the full duty cycle to ensure landing. In other words, voltage is continuously applied to the lower coil 18. The below-described algorithm assumes (for simplicity) that the initial catching part of the duty cycle becomes active only after the first sensor crossing. At higher engine speeds, an earlier activation of the duty cycle may be needed to provide faster responses. In this situation, it is possible to use the crossing information from the third sensor 32 instead of the crossing information from the first sensor 28. It is also possible to modify the algorithm so that it only applies to the part of the active duty cycle profile after the first sensor 28 crossing. Finally, it should be clear that the crossing information from all three sensors 28,30,32 can be used to shape the duty cycle within a single valve opening or valve closing event. The main features of the algorithm described in Figure 5 are as follows. If the estimated velocity at the first sensor crossing, Vel 1 , is below the desired value, Vel 1d , the value of d c (i.e., the duty cycle) is increased from its nominal value d c,0 by a value, f p (Vel 1,d - Vel 1 ), whose magnitude is a faster than linear increasing function of the magnitude of the difference. This calculation is shown at block 40 in Figure 5, where fp is a calibratable gain. The increase in d c assures armature landing since lower than desired velocity indicates larger than expected disturbances counteracting the motion of the valve 12. Disproportionately more aggressive action is provided for a larger velocity deficit. If the estimated velocity at the first sensor crossing is above the desired value, the value of dc may be decreased from its nominal value by a conservative amount that may depend on the magnitude of the difference. Still referring to block 40, the adaptive term is added to the resulting dc value to provide cycle-to-cycle adaptation. This adaptive term is formed by multiplying a gain k times the integrator output è that sums up the past differences between the estimated Vel2 and desired velocity, Vel2,d, at the second sensor crossing. Referring to block 42 of Figure 5, if the resulting dc value exceeds one (i.e., not physically realizable), dc is set to 1 and T 2 is advanced from its nominal value T 2,0 by a value whose magnitude is a monotonic function of the amount by which the originally calculated value of dc exceeds 1. T 2 is the time instant when the duty cycle is applied to effect armature catching. In other words, when greater than 100% duty cycle is demanded, catching current T 2 is initiated sooner to compensate for such demand. Referring to blocks 44 and 46 of Figure 5, if the value of Vel2 is significantly lower than the desired value Vel2,d, or if a second crossing of the second sensor has been detected (indicating the valve 12 starting to move in the opposite direction), an emergency pulse is formed to force the valve landing, wherein the duty cycle dc is set to the maximum value of 1 until a prespecified time T f elapses. After the time T f elapses, the duty cycle dc is set to the holding duty cycle d h . The results of simulating the actuator model in the closed loop with the proposed algorithm of Figure 5 are shown in Table 1 below, and in Figures 3a-3c and 4a-4c. The unmeasured disturbance acting on the valve is assumed to be of initially persistent ultimately exponentially decaying type, to reflect the fact that the disturbance has initially larger size. In the case when the disturbance acts against the valve motion ("-w") applying the nominal duty cycle profile (i.e. with algorithm off) yields no landing at all (in fact, the armature does not make it to the second sensor location). When the disturbance acts in the direction of the valve motion ("+w"), large landing velocity results with the algorithm off. With the algorithm on, landing is ensured in "-w" case and, in addition, the variability in the landing speed in both cases is greatly reduced. Some residual variability is still present despite the fact that the velocity at the second sensor crossing is regulated to the desired value. This is because some disturbance does remain and does affect the armature motion even after the second sensor crossing. w = 0 -w +w With algorithm on 0.45 0.25 0.73 With algorithm off 0.45 No landing, Never crossed 2nd sensor 1.75 Table 1 illustrates steady state (i.e., after ten cycles) landing velocity w (in meters per second) with and without compensation for the nominal case (w=0) and for the cases when the unmeasured disturbance of initially persistent, ultimately exponentially decaying type is acting on the valve. In the "-w" case, the disturbance opposes the valve opening, while in the "+w" case, the disturbance acts in the direction of valve opening. Referring to the Figures 3a-3c, the catching voltage Vc = V max d c (V max equals 200), landing velocity and velocity of the second sensor crossing from one cycle to the next are shown. The desired value of Vel 2,d is shown by the dashed line in Figure 3c. The nominal value of V c is 100. Here, an unknown disturbance force (of initially persistent, ultimately exponentially decaying type) acts on the valve, opposing the armature motion toward the lower coil. The emergency pulse compensation is used on the first and the third cycle to ensure that the armature actually lands. The armature crosses the second sensor location three times on the first and on the third cycle. Aggressive compensation for the difference Vel 1,d - Vel 1 , with f p (Vel 1,d - Vel 1 ) term, is clearly visible on Figure 3a in the first cycle, as well as slower cycle-to cycle adaptation from the difference Vel 2,d - Vel 2 . Referring to Figures 4a-4c, the catching voltage V c = V max d c (V max = 200), landing velocity and velocity at the second sensor crossing from one cycle to the next in the "+w" case are shown. The desired value of Vel 2,d is shown by the dashed line on Figure 4c. The nominal value of V c is 100. Here, an unknown disturbance force (of initially persistent, ultimately exponentially decaying type) acts on the valve, accelerating the armature toward the lower coil. Here (for illustration purposes), the action f p (Vel 1,d - Vel 1 ) on the velocity difference at the first crossing was set to zero, to illustrate the effect of cycle-to-cycle adaptation.

Claims: A method of controlling valve landing in a camless engine including a valve (12) movable between fully open and fully closed positions, and an electromagnetic valve actuator (14) for actuating the valve (12), the method comprising determining valve velocity by providing at least one discrete position measurement sensor (28,30,32) to determine when and if the valve (12) is at a particular position during valve movement, estimating the velocity of the valve (12) at said particular position based upon current and rate of change of current in the electromagnetic valve actuator (14) when the valve (12) is at said particular position and controlling valve landing based upon said estimated velocity, characterised in that ; said step of providing at least one discrete position measurement sensor comprises providing a first position measurement sensor (28) at a middle location to sense the movement of the valve (12) at a first position between the fully open and fully closed positions providing a second position measurement sensor (32) at a nearly-closed location to sense movement of the valve (12) near the fully closed position and providing a third position measurement sensor (30) at a nearly-open location to sense movement of the valve (12) near the fully open position. A method as claimed in claim 1, wherein said step of determining the velocity of the valve (12) at said particular position comprises estimating the velocity of the valve at the first, second and third positions. A method as claimed in claim 2, wherein said step of controlling valve landing comprises using the estimated velocity at said first position to control valve landing in the same valve cycle, and using the estimated velocity at the second and third positions to control valve landing in a subsequent valve cycle. A method as claimed in claim 1, wherein said step of determining the velocity of the valve (12) at each of said locations comprises calculating the velocity of the valve at each location based upon current and rate of change of current in the electromagnetic valve actuator (14) when the valve (12) is at each position and controlling valve landing based upon each calculated velocity. A method as claimed in any of claims 1 to 4 wherein said step of determining the velocity of the valve (12) is performed by the following formula: where:- z is the armature position (the distance from a fully open or fully closed position), r is electrical resistance of the EVA, V is voltage across the EVA, i is measured current through the EVA, ka and kb are calibrated constants, and (L.i-ε .) is an estimate of time rate of change of current. A method as claimed in claim 5 wherein said estimated rate of change of current is derived from the formulas: di dt ( estimate ) = L·i - ε and d ε dt = - L· ( L·i -ε) where L is an estimator gain. A method as claimed in claim 6 wherein said constants ka and kb are calibrated from the relation between the force on a movable armature (20) of the electromagnetic valve actuator (14) and the distance of the armature (20) from a fully open position in accordance with the following formula: F mag = k a i 2 ( z + k b ) 2 where: Fmag is an electromagnetic field force from an energized coil. A method as claimed in any of claims 1 to 7 wherein said step of controlling valve landing comprises adjusting a duty cycle of the electromagnetic valve actuator (14) in response to said determined velocity. A camless engine including at least one valve (12) movable between fully open and fully closed positions by an electromagnetic valve actuator (14) and an electronic controller (34) to control actuation of the valve characterised in that the engine further comprises a first position measurement sensor (28) at a middle location to sense the movement of the valve (12) at a first position between the fully open and fully closed positions and arranged to provide a signal indicative of the sensed movement to the controller (34), a second position measurement sensor (32) at a nearly-closed location to sense movement of the valve (12) near the fully closed position and arranged to provide a signal indicative of the sensed movement to the controller (34) and a third position measurement sensor (30) at a nearly-open location to sense movement of the valve (12) near the fully open position and arranged to provide a signal indicative of the sensed movement to the controller (34) and that the controller (34) is operable to calculate the velocity of the valve (12) at each of said locations based upon current and rate of change of current in the electromagnetic valve actuator (14) when the valve (12) is at each said position and to control valve landing of the or each valve (12) based upon each said calculated velocity.

Inventors: HAGHGOOIE MOHAMMAD, HAMMOUD MAZEN, KOLMANOVSKY ILYA, VAN NIEUWSTADT MICHIEL JACQUES, HAGHGOOIE, MOHAMMAD, HAMMOUD, MAZEN, KOLMANOVSKY, ILYA, VAN NIEUWSTADT, MICHIEL, JACQUES
Applicants: FORD GLOBAL TECH INC, FORD GLOBAL TECHNOLOGIES, INC.
Application year: 2001
Main classification: F01L9
IPC codes: F01L9