Abstract:
A fuel injection control apparatus of an internal combustion engine is provided with a fuel injection valve that injects fuel directly into a combustion chamber and a controller. When the engine is cold started (i.e., YES in step S 10 ), a first fuel injection is performed and the injected fuel is spark ignited during the compression stroke, and a second fuel injection is performed during the expansion stroke. The controller selects, according to exhaust emissions, one of a first fuel injection rate and a second fuel injection rate that is lower than the first fuel injection rate as a fuel injection rate during at least the expansion stroke and injects fuel at the selected fuel injection rate. The second fuel injection rate is selected as the fuel injection rate of the second fuel injection and the start timing of the injection is advanced compared with the conventional injection start timing (i.e., when a reference fuel pressure is used) (steps S 11  to S 16 ). As a result, smoke, NOx, and HC are simultaneously reduced, thereby improving emissions.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The invention relates to a fuel injection control apparatus of an internal combustion engine, and more specifically, to a fuel injection control apparatus and fuel injection control method of an internal combustion engine, which can improve emissions by simultaneously reducing particulate matter (smoke), nitrogen oxides (NOx), and hydrocarbons (HC). 
         [0003]    2. Description of the Related Art 
         [0004]    Japanese Patent Application Publication No. JP-A-2002-295277 and Japanese Patent Application Publication No. JP-A-10-122015, for example, describe fuel injection control apparatuses of an internal combustion engine which are provided with a fuel injection valve that injects fuel directly into the combustion chamber. These control apparatuses aim to increase the temperature of a catalyst when the engine is cold started by performing a first fuel injection and spark igniting the injected fuel during the compression stroke, and performing a second fuel injection during the expansion stroke. 
         [0005]    With these technologies, however, if the injection timing is advanced, as shown in  FIG. 11 , the period before the exhaust valve opens becomes longer so the amount of unburned fuel decreases which in turn results in less HC. On the other hand, the temperature in the cylinder is high so combustion takes place rapidly. As the combustion temperature rises, so too does the amount of NOx. Further, when the fuel is combusted without being sufficiently mixed with air, the amount of smoke increases.  FIG. 11  is a conceptual diagram showing the relationship between the start timing of the second injection and emissions. 
         [0006]    On the other hand, if the injection timing is retarded, the period before the exhaust valves open becomes shorter, which results in unburned fuel being exhausted, thus increasing the amount of HC. Further, the temperature in the cylinder is low so combustion takes place slowly. As a result, the combustion temperature drops so the amount of NOx decreases. In addition, the mixture of fuel and air is promoted which improves combustion and thus reduces the amount of smoke. 
         [0007]    Thus, advancing the second injection timing during the expansion stroke reduces HC but increases smoke and NOx, while retarding that injection timing reduces smoke and NOx but increases HC. That is, smoke, NOx, and HC were unable to be simultaneously reduced. Therefore, a fuel injection control apparatus of an internal combustion engine was desired that could improve emissions by simultaneously reducing smoke, NOx, and HC. 
       SUMMARY OF THE INVENTION 
       [0008]    In view of the foregoing problems, this invention thus provides a fuel injection control apparatus and fuel injection control method of an internal combustion engine which improves emissions by simultaneously reducing smoke, NOx, and HC. 
         [0009]    A first aspect of the invention relates to a fuel injection control apparatus of an internal combustion engine, which includes a fuel injection valve that injects fuel directly into a combustion chamber, and a controller which, when the internal combustion engine is cold started, performs a first fuel injection and spark ignites the injected fuel during a compression stroke and performs a second fuel injection during an expansion stroke. The controller selects, according to exhaust emissions, one of a first fuel injection rate (e.g. a reference injection rate) and a second fuel injection rate that is lower than the first fuel injection rate as a fuel injection rate to be used during at least the expansion stroke and injects fuel via the fuel injection valve at the selected fuel injection rate. 
         [0010]    Thus, according to this first aspect, the fuel injection rate during the expansion stroke is set according to the exhaust emissions. More particularly, the fuel injection rate is reduced from a reference fuel injection (e.g. the first fuel injection rate) to the second fuel injection rate which inhibits rapid combustion so that less NOx and smoke are generated even when the injection quantity is the same. Therefore, the injection timing can be advanced which ensures a longer time until the exhaust valve opens, thereby promoting the combustion of unburned HC during that time. As a result, the amounts of NOx and smoke, as well as HC can be reduced. 
         [0011]    Also, in the first aspect, the elected fuel injection rate may be realized by adjusting the fuel pressure of the fuel injection valve. 
         [0012]    Accordingly, for example, reducing the fuel pressure reduces the injection rate which slows combustion of the fuel injected during the second fuel injection thus reducing smoke and NOx. Further, advancing the injection timing increases the time until the exhaust valve opens, giving the unburned HC time to be combusted. 
         [0013]    Also, in the first aspect, the fuel injection valve may be structured such that a lift amount of the fuel injection valve can be variably controlled, and the controller may realize the fuel injection rate to be used during the expansion stroke by adjusting the lift amount. 
         [0014]    Accordingly for example, atomization of the fuel is not adversely affected by fuel being injected at the reference injection rate achieved by using the reference valve lift in the first injection during the compression stroke so the required torque can be ensured by the ignition of that fuel. Also, a cylinder internal temperature is reached which enables the fuel of the fuel of the second injection to be diffusively combusted. Injecting the fuel at a low injection rate achieved by a small valve lift in the second injection during the expansion stroke slows combustion so less smoke and NOx are generated. In addition, advancing the start timing of the injection compared to the start timing when the reference valve lift is used reduces the amount of HC generated. That is, good emissions can be achieved while avoiding the possibility of adversely affecting torque and making torque fluctuation worse. 
         [0015]    Also, a second aspect of the invention relates to a fuel injection control apparatus of an internal combustion engine, which includes a fuel injection valve that injects fuel directly into a combustion chamber; and a controller which, when the internal combustion engine is cold started, performs a first fuel injection and spark ignites the injected fuel during a compression stroke and performs a second fuel injection during an expansion stroke. The controller determines an octane rating of the fuel; and selects, according to the octane rating, one of a first fuel injection timing and a second fuel injection timing that is later than the first fuel injection timing as a fuel injection timing to be used during the expansion stroke, and injects fuel via the fuel injection valve at the selected fuel injection timing. 
         [0016]    Therefore, according to the second aspect, the octane rating when knock occurs is estimated or learned and the injection timing of the second injection is changed according to the determined octane rating to improve emissions when the engine is cold started the next time. For example, when high octane fuel is used, the injection timing of the second injection may be retarded compared with when fuel having a lower octane rating is used in order to minimize the generation of smoke, NOx, and HC. Accordingly, good emissions can be realized. That is, good emissions can be achieved by changing the injection timing of the second injection depending on the octane rating of the fuel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The foregoing and further objects, features and advantages of the invention will become apparent from the following description of preferred embodiments with reference to the accompanying drawings, wherein like numerals are used to represent like elements and wherein: 
           [0018]      FIG. 1  is a flowchart of a control method according to a first example embodiment of the invention; 
           [0019]      FIG. 2  is a sectional view schematically showing the structure of an engine; 
           [0020]      FIG. 3  is a sectional view of an engine having a spray-guide structure; 
           [0021]      FIG. 4  is a conceptual diagram showing the relationship between emissions and the start timing of a second injection having the injection rate and injection quantity as parameters; 
           [0022]      FIG. 5  is a map showing the relationship between fuel pressure and injection rate; 
           [0023]      FIG. 6  is a map showing the relationship between lift amount and injection rate; 
           [0024]      FIG. 7  is a time chart showing the concept of injection at a reference fuel pressure and ignition; 
           [0025]      FIG. 8  is a time chart showing the concept of injection at a low fuel pressure and ignition; 
           [0026]      FIG. 9  is a time chart showing the concept of injection and ignition according to a second example embodiment of the invention; 
           [0027]      FIG. 10  is a conceptual diagram showing the relationship between emissions and the start timing of a second injection according to a third example embodiment; and 
           [0028]      FIG. 11  is a conceptual diagram showing the relationship between emissions and the start timing of the second injection. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0029]    Hereinafter, example embodiments of the fuel injection control apparatus of an internal combustion engine according to the invention will be described in more detail with reference to the accompanying drawings. 
         [0030]    First the schematic structure of an engine (i.e., an internal combustion engine) to which a first example embodiment of the invention can be applied will be described with reference to  FIG. 2 . Here,  FIG. 2  is a sectional view schematically showing the structure of an engine having a so-called wall-guide structure which promotes the mixture of air and fuel with a cavity provided in the top surface of the piston. 
         [0031]    As shown in  FIG. 2 , the engine  10  is a direct injection type four cycle gasoline engine in which fuel spray  23   a  is injected from a fuel injection valve  23  directly into a combustion chamber  10   a.    
         [0032]    That is, the combustion chamber  10   a  of the engine  10  is formed of a cylinder bore  11 , a cylinder head  13 , and a piston  12  arranged so as to be able to move up and down inside the cylinder bore  11 . Also, a depressed cavity  12   a  for achieving stratified-charge combustion is formed in a portion on the intake side of the top surface of the piston  12 . 
         [0033]    Also, a spark plug  14  for igniting the air-fuel mixture is disposed in substantially the top center of the combustion chamber  10   a . Also, an intake valve  16  is provided in an intake port  15  that opens into the combustion chamber  10   a , and an exhaust valve  20  is provided in an exhaust port  18  that also opens into the combustion chamber  10   a . These valves  16  and  20  are controlled open and closed by a variable valve timing mechanism. 
         [0034]    Also, although not shown, a catalyst device for purifying smoke, NOx, and HC and the like in the exhaust gas is provided in an exhaust passage of the engine  10 . 
         [0035]    Each structural element such as the valves  16  and  20 , the spark plug  14 , and the fuel injection valve  23  and the like is controlled by an electronic control unit (ECU), not shown. 
         [0036]    The engine  10  having a wall-guide structure is shown in  FIG. 2  as the object to which the invention is applied, but the engine is not limited to this structure. 
         [0037]    For example, as shown in  FIG. 3 , the invention may also be applied to an engine  10  having a so-called spray-guide structure in which the spark plug  14  is arranged near the fuel injection valve  23  and the air-fuel mixture formed by this fuel injection valve  23  is ignited.  FIG. 3  is a sectional view of an engine having a spray-guide structure. 
         [0038]    Also, although not shown in the drawings, the invention may also be applied to an engine having another structure in which the air-fuel mixture is led near the spark plug by the flow of air and then ignited. 
         [0039]    Next, a control method will be described with reference to  FIG. 1 .  FIG. 1  is a flowchart of a control method according to the first example embodiment of the invention. The following control is executed by the ECU (which serves as the fuel injection control apparatus of an internal combustion engine) described above. 
         [0040]    First it is determined whether the catalyst needs to be warmed up (step S 10 ). If it is determined that the catalyst needs to be warmed up (i.e., YES in step S 10 ), then a required torque T necessary for idling when warming up the catalyst, as well as a required exhaust temperature E necessary to warm up the catalyst are calculated and determined (step S 11 ). 
         [0041]    The required torque T and required exhaust temperature E are calculated comprehensively taking into account, for example, the time passed after the engine was started up, the temperature of the engine coolant, the temperature of the engine oil, the electrical load of auxiliary devices such as the alternator, and the load of power steering and the like. 
         [0042]    If, on the other hand, it is determined that the catalyst does not need to be warmed up (i.e., NO in step S 50 ), step S 10  is repeated until it is determined that the catalyst does need to be warmed up. 
         [0043]    Next, fuel injection quantities (injection periods) and injection timings of first (written as “1st” in the drawing) and second (written as “2nd” in the drawing) fuel injections are tentatively determined (step S 12 ). 
         [0044]    That is, the parameters of the first injection can be tentatively determined using a map, not shown, for example, from the required torque T determined in step S 11 . 
         [0045]    Also, for the parameters of the second injection, the required exhaust temperature E described above can be ensured at the reference fuel pressure and an injection timing which minimizes emissions (i.e., the amounts of smoke, NOx, and HC generated) can be tentatively determined using the map shown in  FIG. 4 . 
         [0046]    Here,  FIG. 4  is a conceptual diagram showing the relationship between emissions and start timing of the second injection with the injection rate and injection quantity as parameters. In the drawing, the broken line indicates a case in which the reference fuel pressure is used and the solid line indicates a case in which low fuel pressure is used, while the chain double-dashed line indicates an emissions target value. Also, the ignition timing is shown to be before TDC after the first injection. The opening timing Tevo of the exhaust valve  20  is also shown in the drawing. 
         [0047]    Next, the emissions (the total amount for the first and second injections) are calculated using the map in  FIG. 4  based on the value that was tentatively determined in step S 12  (step S 13 ). It is then determined whether the calculated value of the emissions has reached the target value (step S 14 ). 
         [0048]    If the calculated value of the emissions has reached the target value (i.e., YES in step S 14 ), then the injection timing and injection period and the like that were tentatively determined in step S 12  are established (step S 17 ) and the control ends. 
         [0049]    If, on the other hand, the calculated value of the emissions has not reached the target value (i.e., NO in step S 14 ), then it is necessary to correct the injection timing and injection period that were tentatively determined in step S 12 . Therefore, as shown in  FIG. 4 , the injection rate of the second injection (i.e., the fuel injection quantity per unit time) is decreased so that the amount of emissions attributed to the second injection (reference character a) at the reference fuel pressure tentatively set in step S 12  falls below (reference character b) the emissions target value (the chain double-dashed line) with an equivalent injection quantity (step S 15 ). 
         [0050]    This injection rate can be decreased by reducing the fuel pressure of the fuel injection valve  23  a predetermined amount from the reference fuel pressure so that it becomes a low fuel pressure.  FIG. 5  is a map showing the relationship between the fuel pressure and the injection rate. 
         [0051]    The fuel pressure from the fuel injection valve  23  with a constant lift amount is the same for the first and second injections so when step S 15  is executed, the first injection rate also decreases simultaneously. 
         [0052]    The injection rate of the second injection can also be decreased by reducing the lift amount of the fuel injection valve  23  a predetermined amount from the reference lift amount so that it becomes a low lift amount, as shown in  FIG. 6  for example (see the second example embodiment described later). 
         [0053]    In this case, the lift amount of the fuel injection valve  23  for the second injection can be controlled independently from the lift amount for the first injection. Therefore the lift amount of the fuel injection valve  23  for the second injection will not affect the injection rate for the first injection so in step S 16 , which will be described later, the injection timing and injection period of the first injection do not need to be reset.  FIG. 6  is a map showing the relationship between the lift amount and the injection rate. 
         [0054]    Continuing on, the injection rate was decreased by reducing the fuel pressure in step S 15  so the injection timing and injection period are reset and the determined value is calculated (step S 16 ). That is, for the first injection, the injection period is extended to make up for the reduction in the injection rate realized by the decrease in fuel pressure and the start timing of the injection is advanced along with that extension of the injection period. 
         [0055]    For example, as shown in  FIG. 8  in comparison with  FIG. 7 , the start timing T 1   n  (see  FIG. 7 ) of the first injection at the reference fuel pressure is advanced to the start timing T 1  (see  FIG. 8 ) at a predetermined low fuel pressure, and the injection period shown by T 1   n  to T 1   ne  when the reference fuel pressure is used is extended to the injection period as shown by T 1  to T 1   ne  when the predetermined low fuel pressure is used. 
         [0056]      FIG. 7  is a time chart showing the concept of injection at the reference fuel pressure and ignition, and  FIG. 8  is a time chart showing the concept of injection at the low fuel pressure and ignition. In these drawings, top dead center during the compression stoke of the piston  12  is denoted by TDC. Also, the first injection is denoted by “1st Inj” and the second injection is denoted by “2nd Inj”, both of which are shown by black portions in the drawings. 
         [0057]    Further, the area of those black portions represents the injection quantity, the horizontal axis represents the injection time, and the vertical axis represents the injection rate. Also, the region where a large amount of smoke tends to be produced is indicated by the excessive smoke region shown with hatching (i.e., slanted lines), and the timing at which the exhaust valve  20  opens is indicated by Tevo. 
         [0058]    Moreover, the start timing of the first injection at the reference fuel pressure is denoted by T 1   n , the end timing of that first injection is denoted by T 1   ne , the start timing of the second injection is denoted by T 2   n , and the end timing of that second injection is denoted by T 2   ne . Also, the start timing of the first injection at the low fuel pressure is denoted by T 1   n , the end timing of that first injection is denoted by T 1   ne  (the same as at the reference fuel pressure), the start timing of the second injection is denoted by T 2 , and the end timing of that second injection is denoted by T 2   ne  (the same as the reference fuel pressure). 
         [0059]    Also, the parameters of the second injection are determined based on the emissions map in  FIG. 4  described above. That is, as shown in  FIGS. 4 ,  7 , and  8 , the required exhaust temperature E is established with the low pressure set in step S 15  and the start timing T 2   n  (see  FIG. 7 ) of the second injection at the reference fuel pressure is advanced to the start timing T 2  (see  FIG. 8 ) at the predetermined low fuel pressure, while the injection period shown by T 2   n  to T 2   ne  when the reference fuel pressure is used is extended to the injection period shown by T 2  to T 2   ne  when the predetermined low fuel pressure is used to minimize the emissions (i.e., the amounts of smoke, NOx, and HC generated) (step S 16 ). 
         [0060]    As described above, with the fuel injection control apparatus of an internal combustion engine according to this first example embodiment, the amount of smoke and NOx generated is reduced by slowing combustion of the fuel injected during the second fuel injection which is done by the reducing the fuel pressure and decreasing the injection rate. At the same time, the amount of HC generated is also reduced by advancing the start timing of the injection so that it is earlier than the reference start timing (i.e., when the reference fuel pressure is used). 
         [0061]      FIG. 9  is a time chart showing the concept of injection and ignition according to a second example embodiment of the invention. In the following description, members which are the same as or correspond to members that have already been described are denoted by the same reference characters and redundant descriptions thereof will be omitted or simplified. 
         [0062]    With the structure and control method of the first example embodiment, when the second injection fuel pressure is decreased, the first fuel pressure also decreases due to the structure of the fuel injection valve  23 . Therefore, atomization of the fuel spray  23   a  is inhibited which may adversely affect the torque and make torque fluctuation worse, both of which depend largely on the first injection and the spark timing. The second example embodiment thus avoids this adverse affect on the torque and the like by reducing only the injection rate of the second injection. 
         [0063]    That is, the second example embodiment employs a fuel injection valve  23  in which the lift amount of the needle, not shown, can be varied. Thus, as shown in  FIG. 9 , fuel injected in the first injection during the compression stroke is injected at the reference injection rate achieved with the reference valve lift and ignited, while the injection rate of the second injection is reduced by reducing the valve lift in only the second injection during the expansion stroke. 
         [0064]    The other structure and control operations are substantially the same as in the first example embodiment so a redundant description thereof will be omitted. However, the lift amount of the fuel injection valve  23  during the second injection can be controlled independently from the lift amount during the first injection and thus does not affect the injection rate of the first injection. Therefore, in step S 16  (i.e., controlling the injection rate of the second injection by reducing the fuel pressure) in the flowchart shown in  FIG. 1  described above, it is not necessary to reset the injection timing and injection period of the first injection as it was in the first example embodiment. 
         [0065]    As a result, atomization of the fuel is not adversely affected by fuel being injected at the reference injection rate achieved by the reference valve lift in the first injection during the compression stroke so the required torque can be ensured by the ignition of that fuel. Also, a cylinder internal temperature is reached which enables the fuel of the second injection to be diffusively combusted. 
         [0066]    Injecting the fuel at a low injection rate achieved by a small valve lift in the second injection during the expansion stroke slows combustion so less smoke and NOx are generated. In addition, advancing the start timing of the injection so that it is earlier than the conventional start timing (i.e., when the reference valve lift is used) reduces the amount of HC generated. 
         [0067]    As described above, the fuel injection control apparatus of an internal combustion engine according to the second example embodiment enables good emissions to be achieved while avoiding adversely affecting torque and making torque fluctuation worse. 
         [0068]      FIG. 10  is a conceptual diagram showing the relationship between emissions and the start timing of the second injection according to a third example embodiment of the invention. The drawing takes high octane gasoline with a high octane rating and regular gasoline with a normal octane rating, for example, and shows the concept of how the injection timing (i.e., the optimal point) of the second injection changes depending on the octane rating. In this third example embodiment as well, the invention can be applied to an engine  10  having the structure shown in  FIG. 2  or  FIG. 3  of the first example embodiment, for example. 
         [0069]    The fuel spray  23   a  injected in the second injection during the expansion stroke described above autoignites and combusts from the heat inside the cylinder. It is commonly known that a higher octane rating of the fuel results in a longer ignition retard period which means that the period from the start of injection until autoignition will become longer. That is, the higher the octane rating the more fuel that will combust at the time of ignition so combustion is rapid. Therefore, when the start timing of the injection is the same, more smoke and NOx tend to be generated. 
         [0070]    Thus in the third example embodiment, knock is detected by a knock sensor or the like when the engine  10  is operating at a low speed under a high load, and the octane rating when knock occurs is estimated or learned by an ECU (octane rating determining means), not shown. Then the next time the engine  10  is started at a low temperature, the injection timing of the second injection is changed according to the octane rating to improve emissions. 
         [0071]    For example, as shown in  FIG. 10 , the injection timing of the second injection when high octane gasoline (fuel with a high octane rating) is used is retarded compared to when regular gasoline (i.e., fuel with a low octane rating) which has a lower octane rating than high octane gasoline is used, and the optimal point RP for the regular gasoline is set to the optimal point HP for the high octane gasoline in order to minimize smoke, NOx, and HC. 
         [0072]    As described above, the fuel injection control apparatus of an internal combustion engine according to the third example embodiment can achieve good emissions by changing the injection timing of the second injection according to the octane rating of the fuel. 
         [0073]    As described above, the fuel injection control apparatus of an internal combustion engine according to the invention is useful in a direct injection type four cycle gasoline engine, and is particularly well suited for an engine that aims to improve emissions by simultaneously reducing the amounts of smoke, NOx, and HC generated.