Abstract:
A booster circuit installed in a fuel injection device of an internal combustion engine, wherein malfunctions and characteristic changes of the booster circuit are detected, among which the detection distinguishes between decreases in capacity caused by deterioration or broken wires in a booster capacitor, and failures of a current monitor circuit, coil, externally connected fuel injection valve, and other components. The range of decrease in boost voltage when the fuel injection valve is opened is monitored, as is the range of increase per switch performed in order to restore the boost voltage. This makes it possible to detect malfunctions and characteristic changes of the booster circuit.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a booster circuit of a fuel injection system of an inter al combustion engine. 
       BACKGROUND ART 
       [0002]    Examples of background art of the present field include JP 2011-247192 A. In this publication, in a booster circuit of a fuel injection system, the number of times of boost switching until restoration to a set voltage after a booster capacitor discharges is measured; and, when the criteria of a set number of times of switching is exceeded, drive of a fuel injection valve is permitted. It is not an object of this publication to carry out deterioration judgment, but is to wait for recovery of the capacitor having lowered capability in initial usage and restart operation of the booster circuit. 
         [0003]    Moreover, examples of background art of the present field also include JP 2011-247192 A. In this publication, in a booster circuit of a fuel injection system, a steady-state value of a charge voltage for a booster capacitor is monitored. If it is normal, a fuel injection valve is driven by a control signal indicating a normal injection pulse width and injection timing; and, if it is not normal, the injection pulse width and injection timing are corrected. In this publication, the stead-state value is monitored for the charge voltage for the booster capacitor. However, since no change is generated in the steady-state value, it is difficult to detect the deterioration of the booster capacitor. 
       CITATION LIST 
     Patent Literature 
       [0004]    PTL1: JP 2011-47192 A 
       SUMMARY OF INVENTION 
     Technical Problem 
       [0005]    It is an object of the present invention to distinguish and detect capacity decrease due to deterioration or a broken wire of a booster capacitor and failure of a current monitor circuit, a coil, an externally connected fuel injection valve, etc. among malfunctions and characteristic changes of a booster circuit in the booster circuit used in fuel injection. 
       Solution to Problem 
       [0006]    The object of the present invention can be achieved, for example, by monitoring charge/discharge of a booster capacitor. 
       Advantageous Effects of Invention 
       [0007]    According to the present invention, capacity decrease due to deterioration or a broken wire of a booster capacitor and failure of a current monitor circuit, a coil, an externally connected fuel injection valve, etc. can be distinguished and detected among malfunctions and characteristic changes of a booster circuit in the booster circuit used in fuel injection. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0008]    [ FIG. 1 ]  FIG. 1  shows an outline of a fuel injection system related to the present invention. 
           [0009]    [ FIG. 2 ]  FIG. 2  is a control unit block diagram for carrying out the present invention. 
           [0010]    [ FIG. 3 ]  FIG. 3  is a circuit block diagram of boost voltage generation. 
           [0011]    [ FIG. 4 ]  FIG. 4  shows voltage and current waveforms of boost voltage generation. 
           [0012]    [ FIG. 5 ]  FIG. 5  shows a booster circuit configuration of the present invention. 
           [0013]    [ FIG. 6 ]  FIG. 6  shows boost voltage waveforms in a case in which a booster capacitor is deteriorated. 
           [0014]    [ FIG. 7 ]  FIG. 7  is a flow chart of a method of monitoring the range of decrease in boost voltage when a fuel injection valve is opened. 
           [0015]    [ FIG. 8 ]  FIG. 8  is a flow chart of a method of monitoring the range of increase in boost voltage per 1 boost switching. 
           [0016]    [ FIG. 9 ]  FIG. 9  is a method of distinguishing locations of malfunctions in the booster circuit. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0017]    Hereinafter, an embodiment according to the present invention will be described in detail based on drawings. 
         [0018]    First, a configuration of an internal combustion engine system in which a fuel-injection controlling device according to the present embodiment is installed will be described by using  FIG. 1 . An engine  1  is provided with a piston  2 , an air intake valve  3 , and an air exhaust valve  4 . Intake air passes through an air flow meter (AFM)  20 , enters a throttle valve  19 , and is supplied from a collector  15  serving as a branching part to a combustion chamber  21  of the engine  1  via an air intake pipe  10  and an air intake valve  3 . Fuel is supplied from a fuel tank  23  to an internal combustion engine by a low-pressure fuel pump  24 , and the pressure thereof is further increased by a high-pressure fuel pump  25  to a pressure required for fuel injection. The fuel subjected to pressure increase by the high-pressure fuel pump  25  is injected and supplied from a fuel injection valve  5  to the combustion chamber  21  of the engine  1  and is ignited by an ignition coil  7  and an ignition plug  6 . The pressure of the fuel is measured by a fuel pressure sensor  26 . 
         [0019]    An exhaust gas after combustion is discharged to an air exhaust pipe  11  via an air exhaust valve  4 . The air exhaust pipe  11  is provided with a three-way catalyst  12  for exhaust gas purification. A fuel-injection controlling device  27  is built in an ECU (engine control unit)  9 ; and signals of a crank angle sensor  16  of the engine  1 , air-volume signals of the AFM  20 , signals of an oxygen sensor  13  which detect the oxygen concentration in the exhaust gas, an accelerator opening degree of an accelerator opening degree sensor  22 , signals of a fuel pressure sensor  26 , etc. are input thereto. The ECU  9 , for example, calculates the torque required for the engine from the signals of the accelerator opening-degree sensor  22  and judges an idle state. The ECU  9  is provided with a rotating-speed detecting means, which computes an engine rotating speed from the signals of the crank angle sensor  16 . 
         [0020]    Moreover, the ECU  9  calculates an intake air volume required for the engine  1  and outputs an opening-degree signal corresponding to that to the throttle valve  19 . Moreover, the fuel-injection controlling device  27  of the ECU  9  calculates a fuel quantity corresponding to the intake air volume, outputs a current for the fuel injection valve  5  to carry out fuel injection, and outputs an ignition signal to the ignition plug  6 . 
         [0021]    The air exhaust pipe  11  and the collector  15  are connected to each other by an EGR passage  18 . An EGR valve  14  is provided at an intermediate part of the EGR passage  18 . The opening degree of the EGR. valve  14  is controlled by the ECU  9 , and, in accordance with needs, the exhaust gas in the air exhaust pipe  11  is flowed back to the air intake pipe  10 . 
         [0022]      FIG. 2  shows a circuit block diagram of fuel-injection-system drive circuit. A fuel injection system is generally built in the ECU  9  shown in  FIG. 1 . The voltage of a battery  41  is supplied to the ECU  9 , and this voltage is supplied to a power source IC  43 , a driver IC  47 , a fuel-injection-system driving booster circuit  51 , a high-side driver  52 , etc. Moreover, voltages are supplied by the power source IC  43  to a microcomputer  44 , the driver IC  47 , etc. The driver IC  47  has a communication unit  49  for the microcomputer  44 , a booster-circuit driving unit  50 , and a driver driving unit  48 . A switching signal is transmitted from the booster-circuit driving unit  50  to the booster circuit  51 , and the voltage increased by the booster circuit is supplied to a high-side driver  52 . Meanwhile, the voltage increased by the booster circuit  51  is fed back to the booster-circuit driving unit  50 , and whether a switching signal is to be transmitted again or not is determined by the driver IC  47 . Meanwhile, the voltage increased by the booster circuit  51  can be fed back to an A/D converter  45  of the microcomputer  44 , and, based on an A/D value, a signal can be transmitted from a communication unit  46  in the microcomputer  44  to the driver IC  47 . Meanwhile, other than boost voltages, signals from a fuel pressure sensor, a temperature sensor, etc. can be input to and monitored by the A/D converter owned by the microcomputer  44 . Other than that, the microcomputer  44  has an input/output port  42 , which drives an external load and/or monitors signals from outside. The high-side driver  52  can obtain power supplies from the booster circuit  51  and the battery  41  and has a driver  52   a  driven by the boost voltage and a driver  52   b  driven by the battery voltage. It has a role to cause a current to flow to a load  54 , which has a coil, by drive signals (A, B) of the driver driving unit  48 . A low-side driver  53  has a role to cause the current from the load  54 , which has the coil, to flow to a ground electric potential by a drive signal (C) from the driver driving unit  48 . Meanwhile, either one of or both of the high-side driver  52  and the low-side driver  53  has a current detecting function and a terminal voltage detecting function using a shunt resistance, etc., wherein driver driving is carried out by detecting the values of the currents which flow to the driver and the load  54  and feeding back the current values. Meanwhile, by these functions, overcurrent to the driver, power-source short circuit and ground short circuit of terminals can be also detected. Herein, the booster circuit  51 , the high-side driver tit, and the low-side driver  53  may be provided inside or outside the driver IC  47 , and the driver IC  47  may be used as either role as a driver or a pre-driver. 
         [0023]      FIG. 3  is a diagram describing details of the booster circuit  51 . When a gate voltage Vg of a booster driver  63  is turned on, a current I flows from the battery  41  to GND via a shunt resistance  61 , a booster coil  62 , and the booster driver  63 . The current at this point is detected as a both-end voltage of the shunt resistance  61  by the booster-circuit driving unit  50 . When a set maximum current value is detected, the booster driver  63  is turned off. At that point, the current I flows to a booster diode  64  because of back electromotive force of the booster coil  62 . A booster capacitor  65  functions to temporarily store the current, which has flowed to the diode. Then, when the current flowing through the shunt resistance  61  becomes small, the booster driver  63  is turned on again, and the current value is increased. By repeating this, the current. is kept flowing to the booster diode  64  and storing the current in the booster capacitor  65 , thereby generating a boost voltage. Moreover, a circuit  66  which monitors the boost voltage is provided in the booster circuit; wherein, voltage boosting is carried out when the voltage is low, and the boost voltage is monitored in order to stop voltage boosting when the voltage reaches a predetermined value. The waveforms of a voltage boosting operation are shown by a diagram in  FIG. 4 . The gate signal for turning on the booster driver  63  is Vg. When this is turned on, a drain voltage Vd of the booster driver  63  is reduced to the vicinity of 0 V, and the current I is increased. When the current I reaches the set Max current, the gate signal Vg of the booster driver  63  is turned off. At that point, Vd reaches a voltage equivalent to the boost voltage, the current I flows to the booster diode  64  side and is stored in the booster capacitor  65 ; however, the current value per se is reduced along with time. Since the booster driver  63  is turned on again when the current reaches a set Min current, the operation of  FIG. 4  is carried out by repeating this operation. This operation is carried out until the boost voltage reaches a set value. Note that hatched parts in the diagram represent the currents which actually flow through the booster diode  64  and represent the currents which are used in boosting. When this operation is carried out, the booster circuit has a waveform like that of the boost voltage of  FIG. 4 . When injection to a fuel drive valve is started, the boost voltage is reduced until a fuel injection current reaches a peak current. After the fuel injection current reaches the peak current, the boost voltage is not used. Therefore, the boost voltage is gradually recovered by switching drive of the booster circuit. When Vg is off, the current flows to the booster capacitor, and the boost voltage is therefore increased. When Vg is on, the current does not enter the booster capacitor, and the boost voltage is therefore not increased (is slightly reduced since natural discharge is carried out). Voltage boosting is carried out by Vg switching until the boost voltage becomes a predetermined value as a result of the repetition thereof. 
         [0024]    It is an object of the present invention to check the deterioration state of the booster circuit by monitoring the movement in the boost voltage. 
         [0025]      FIG. 5  and  FIG. 6  are diagrams described as embodiments of claims  1  to  3  of the present invention.  FIG. 5  is a diagram in which a determination unit  67  for read boost signals and boost voltages is provided with respect to  FIG. 3 . The determination unit  67  is provided inside or outside the driver IC  47  and is a part which monitors and diagnoses differences in the boost voltage and on/off drive of the booster circuit two times at measurement points. In  FIG. 6 , a boost voltage waveform of a case in which the capacity of the booster capacitor  65  has been reduced is added to  FIG. 4  (broken line in the diagram). If the capacity is reduced due to deterioration or a broken wire of the booster capacitor  65 , the range of reduction of the boost voltage in valve opening of the fuel injection valve is increased (normal case (1)→capacity reduced case (1)′). When it is reduced largely from that of the normal case, diagnosis is carried out by reading the difference between a voltage Va of a point when injection of the fuel injection valve is started and a boost voltage Vb of a point when the current to the fuel injection valve reaches the peak. 
         [0026]    Then, after the current to the fuel injection valve reaches the peak, a boost-voltage restoring operation is started; wherein, the voltage Vb of a point immediately before the booster driver  63  is turned off in order to check the voltage value increased by one time of switching and a voltage Vc at a point it is turned on are monitored. The difference is increased if the capacity is reduced due to deterioration or a broken wire of the booster capacitor  65  (normal case (2)→capacity reduced case (2)′). As a result of reading the booster voltage difference therebetween, if the difference has been largely increased from the normal case, diagnosis is carried out. 
         [0027]      FIG. 7  and  FIG. 8  are flow charts of the contents of the description in  FIG. 6 . In  FIG. 7 , the boost voltage Va before fuel injection is monitored ( 101 ), and the boost voltage Vb at the point when the fuel injection current reaches the peak is monitored ( 102 ). Then, the difference (1) is obtained ( 103 ). If the difference is equal to or less than a predetermined value V1, normal drive is carried out ( 104 ). If the difference is equal to or more than V1, diagnosis is carried out ( 105 ). In  FIG. 8 , the voltage Vb at the point immediately before the booster driver  63  is turned off (when Max current is detected) is monitored ( 201 ), and the voltage Vc at the point immediately before the booster driver  63  is turned on (when Min current is detected) is also monitored ( 202 ). Then, the difference (2) therebetween is obtained ( 203 ). If the difference is equal to or less than a predetermined value V2, normal drive is carried out ( 204 ). If the difference is equal to or more than V2, diagnosis ms carried out ( 205 ). 
         [0028]    When the measurement method as described above is carried out, diagnosis can be carried out when there is a difference from a normal case. In a case of a diagnosis method by  FIG. 7  or  FIG. 8 , distinguishment from deterioration and characteristic variations of other elements cannot be made in some cases. Therefore, when both of  FIG. 7  and  FIG. 8  are used, characteristic changes due to deterioration, broken wire, etc. of the booster capacitor  65  can be specified. A diagram thereof is shown in  FIG. 9 , and this is the diagram described as embodiments of claims  1  and  4 . Examples of characteristic changes include, other than the capacity value of the booster capacitor  65 , the resistance value of the shunt resistance  61  for current monitoring, inductance of the booster coil  62 , and the resistance value of an externally-connected fuel injection valve. The changes of the voltage (1) and voltage (2) in the cases in which the numerical values thereof become large or small are shown in the diagram. For example, if the change of the voltage (1) is larger than that in the normal operation and is larger than the threshold value V1 and if the change of the voltage (2) is larger than that in the normal operation and is larger than the threshold value V2 it can be distinguished as abnormality (deterioration, broken wire, etc.) of the booster capacitor  65 . Moreover, if the change of the voltage (1) is not different from that in the normal operation, but the change of the voltage (2) is larger than that in the normal operation and is larger than the threshold value V2, the resistance value of the shunt resistance  61  has been reduced, or the inductance of the booster coil  62  has been increased. In this manner, if either one of (1) and (2) is monitored, there is a part that cannot be distinguished from other characteristic changes. However, if both of (1) and (2) are monitored, it can be distinguished from the other characteristic changes. (Effects of the Invention) As described above, according to the present invention, in a fuel injection system of an internal combustion engine driven to be opened/closed by a boost voltage higher than a battery voltage and by the boost voltage, the system having a drive circuit configured to control electric power distribution to a coil driven to open/close a fuel injection valve, the range of decrease in the boost voltage when the fuel injection valve is opened and the range of increase per 1 switching carried out for restoring the boost voltage are monitored. As a result, malfunctions and characteristic changes of the booster circuit can be detected, and, among them, capacity decrease due to deterioration or a broken wire of the booster capacitor and malfunctions and characteristic changes of the current monitor circuit, the coil, and the externally connected fuel injection valve, etc. can be distinguished and detected. 
       REFERENCE SIGNS LIST 
       [0000]    
       
           1  engine 
           2  piston 
           3  air intake valve 
           4  air exhaust valve 
           5  fuel injection valve 
           6  ignition plug 
           7  ignition coil 
           8  water temperature sensor 
           9  ECU (Engine Control Unit) 
           10  air intake pipe 
           11  air exhaust pipe 
           12  three-way catalyst 
           13  oxygen sensor 
           14  EGR valve 
           15  collector 
           16  crank angle sensor 
           18  EGR passage 
           19  throttle valve 
           20  AFM 
           21  combustion chamber 
           22  accelerator opening-degree sensor 
           23  fuel tank 
           24  low-pressure fuel pump 
           25  high-pressure fuel pump 
           26  fuel pressure sensor 
           27  fuel-injection controlling device 
           41  battery 
           42  input/output port of microcomputer 
           43  power source IC 
           44  microcomputer 
           45  A/D converter 
           46  communication unit in microcomputer 
           47  driver IC (or pre-driver) 
           48  driver driving unit 
           49  communication unit in driver IC 
           50  booster-circuit driving unit 
           51  booster circuit 
           52  high-side driver 
           53  low-side driver 
           54  coil load (fuel injection system) 
           61  shunt resistance 
           62  booster coil 
           63  booster driver 
           64  booster diode 
           65  booster capacitor 
           66  boost-voltage monitoring circuit 
           67  determination unit for boost voltage