Abstract:
An exhaust treatment system comprises M electrically heated substrates and a heater control module. The M electrically heated substrates are coated with a catalyst material and arranged in series to receive exhaust gas of an engine. M is an integer greater than one. The heater control module applies power to N of the M substrates to heat the N substrates during a predetermined period. N is an integer less than M. The engine is turned off and the M electrically heated substrates do not receive exhaust gas during the predetermined period.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is related to U.S. patent application Ser. No. 12/537,384, filed on Aug. 7, 2009. The disclosure of the above application is incorporated herein by reference in its entirety. 
     FIELD 
     The present disclosure relates generally to internal combustion engines and more particularly to exhaust treatment systems. 
     BACKGROUND 
     The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure. 
     Internal combustion engines combust an air and fuel mixture within cylinders to produce drive torque. A byproduct of combustion is exhaust gas. The exhaust gas may include various components such as nitrogen oxides (NOx), carbon monoxide (CO), and hydrocarbons (HC). An exhaust treatment system includes a catalyst that converts the NOx, CO, and HC to carbon dioxide and water. 
     Conversion efficiency of the catalyst refers to the ability of the catalyst to react with or convert one or more components of the exhaust gas. The conversion efficiency of the catalyst is related to the temperature of the catalyst. The catalyst may operate at a reduced conversion efficiency when the catalyst temperature is less than a threshold temperature. The catalyst efficiency may be increased by increasing the catalyst temperature to be greater than or equal to the threshold temperature. 
     The catalyst temperature may be increased using various methods. For example only, heat from the exhaust gas exiting the engine may increase the catalyst temperature. The exhaust gas transfers heat to the catalyst via convection, thereby increasing the catalyst temperature. Fueling to the engine may also be adjusted to increase the catalyst temperature. For example only, unburned fuel from the engine may enter the catalyst where the fuel combusts with oxygen in the catalyst to increase the catalyst temperature. Air may be pumped into the exhaust gas and/or catalyst to increase the amount of oxygen in the catalyst. 
     Hybrid vehicles may include an internal combustion engine and an electric motor. The electric motor may be used more often when vehicle kinetic energy can be recovered by regenerative braking, converted to electric and chemical form, and stored in a battery, from which the motor is driven (e.g. in city driving). The internal combustion engine may be used when wheel braking and opportunities for energy recovery are infrequent, and the engine operates at its greatest efficiency (e.g. in highway driving). In mixed city and highway driving conditions, the electric motor and internal combustion engine may be used together to transmit power to a transmission input shaft, depending on driving conditions and the magnitude of the battery capacity. 
     Hybrid vehicles may experience long periods of engine off-time during idle and driving scenarios. During the periods of engine off-time, the catalyst temperature may decrease below the threshold temperature. Accordingly, catalyst heating may be required to obtain peak efficiency of the catalyst. Maintaining the catalyst temperature at approximately the threshold temperature during engine-off periods increases the conversion efficiency of the catalyst when the engine is started. 
     SUMMARY 
     An exhaust treatment system comprises M electrically heated substrates and a heater control module. The M electrically heated substrates are coated with a catalyst material and arranged in series to receive exhaust gas of an engine. M is an integer greater than one. The heater control module applies power to N of the M substrates to heat the N substrates during a predetermined period. N is an integer less than M. The engine is turned off and the M electrically heated substrates do not receive exhaust gas during the predetermined period. In other features, the engine is disabled during the predetermined period. 
     In other features, the heater control module stops applying power to the N substrates and starts applying power to P other ones of the M substrates to heat the P substrates after the N substrates reach a predetermined temperature. P is an integer less than M. 
     In still other features, N is one and the heater control module applies power to a first one of the M substrates. The heater control module stops applying power to the first one and starts applying power to a second one of the M substrates when a temperature of the first one reaches a threshold temperature. 
     In still other features, N is one and the heater control module applies power to each of the M substrates one at a time. The heater control module stops applying power to each substrate when a temperature of the substrate reaches a threshold temperature during the predetermined period. 
     In still other features, the heater control module applies power to the N substrates for a predetermined period. In yet other features, the M electrically heated substrates include an electrically resistive substrate that generates heat when the heater control module applies power. In still other features, the catalyst material includes a three-way catalyst material. 
     In still other features, the exhaust treatment system includes P non-electrically heated substrates coated with the catalyst material and arranged in series with the M electrically heated substrates that receive the exhaust gas of the engine, wherein P is an integer greater than or equal to one. In still other features, M is three or more and N is one. 
     A method comprises the steps of: providing M electrically heated substrates that are coated with a catalyst material and that are arranged in series to receive exhaust gas of an engine, wherein M is an integer greater than one; and applying power to N of the M substrates to heat the N substrates during a predetermined period, wherein N is an integer less than M. The engine is turned off and the M electrically heated substrates do not receive exhaust gas during the predetermined period. In other features, the method further comprises disabling the engine during the predetermined period. 
     In still other features, the method further comprises stopping application of power to the N substrates; and starting application of power to P other ones of the M substrates to heat the P substrates after the N substrates reach a predetermined temperature, wherein P is an integer less than M. 
     In still other features, the method further comprises applying power to a first one of the M substrates, wherein N is one; stopping application of power to the first one; and starting application of power to a second one of the M substrates when a temperature of the first one reaches a threshold temperature. 
     In still other features, the method further comprises applying power to each of the M substrates one at a time, wherein N is one; and stopping application of power to each substrate when a temperature of the substrate reaches a threshold temperature during the predetermined period. In still other feature, the method further comprises applying power to the N substrates for a predetermined period. 
     In still other features, the method further includes providing M electrically heated substrates that include an electrically resistive substrate that generates heat when power is applied. In still other features, the catalyst material includes a three-way catalyst material. 
     In still other features, the method further comprises providing P non-electrically heated substrates coated with the catalyst material and arranged in series with the M electrically heated substrates that receive the exhaust gas of the engine, wherein P is an integer greater than or equal to one. In still other features, M is three or more and N is one. 
     Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is a functional block diagram of an exemplary hybrid vehicle system according to the principles of the present disclosure; 
         FIG. 2  is an exemplary segmented, cross-sectional perspective view of a catalyst assembly including a plurality of electrically heated catalysts (EHCs) according to the principles of the present disclosure; 
         FIG. 3  is a functional block diagram of an exemplary engine control module according to the principles of the present disclosure; and 
         FIG. 4  is a flowchart depicting exemplary steps performed by the engine control module according to the principles of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical or. It should be understood that steps within a method may be executed in different order without altering the principles of the present disclosure. 
     As used herein, the term module refers to an Application Specific Integrated Circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality. 
     A hybrid vehicle includes an engine and one or more electric motors that control drive torque output to wheels of the vehicle. In some circumstances, the engine is disabled and torque output to the wheels is controlled by the one or more electric motors. The engine may be disabled to, for example, increase the fuel efficiency of the vehicle. 
     An exhaust system that receives exhaust gas output by the engine includes a plurality of electrically heated catalysts (EHCs). The EHCs include a catalyst material that reacts with various components of the exhaust gas to reduce the amount of targeted components of the exhaust gas. The catalyst material of the EHCs, however, reacts with the targeted components of the exhaust gas at temperatures at or above a predetermined (i.e., threshold) temperature, such as 300° C. When the engine is disabled, the temperature of the EHCs may fall below the threshold temperature. 
     Accordingly, power is sequentially applied to electrically resistive substrates of the EHCs to heat the catalyst of the EHCs to or above the threshold temperature while the engine is disabled. Power is applied to heat the EHCs one EHC at a time. Heating a plurality of smaller EHCs, one at a time, rather than a single larger EHC, decreases the period necessary to increase the temperature of the catalyst to the predetermined temperature. Similarly, sequentially heating one EHC at a time, rather than all of the EHCs, decreases the period necessary to increase the temperature. The implementation of more than one smaller EHC rather than the single larger EHC also provides more uniform heating and enables a lesser amount of power to be drawn to heat the EHCs to the predetermined temperature. 
     Referring now to  FIG. 1 , a functional block diagram of an exemplary hybrid vehicle system  100  is presented. The hybrid vehicle system  100  includes an engine  102  that combusts an air/fuel mixture to produce drive torque based on a driver input module  104 . Air is drawn into an intake manifold  110  through a throttle valve  112 . For example only, the throttle valve  112  may include a butterfly valve having a rotatable blade. An engine control module (ECM)  114  may control a throttle actuator module  116 , which regulates opening of the throttle valve  112  to control the amount of air drawn into the intake manifold  110 . 
     Air from the intake manifold  110  is drawn into cylinders of the engine  102 . While the engine  102  may include multiple cylinders, for illustration purposes a single representative cylinder  118  is shown. For example only, the engine  102  may include 2, 3, 4, 5, 6, 8, 10, and/or 12 cylinders. 
     Air from the intake manifold  110  is drawn into the cylinder  118  through an intake valve  122 . The ECM  114  controls a fuel actuator module  124 , which regulates fuel injection to achieve a desired air/fuel ratio. Fuel may be injected into the intake manifold  110  at a central location or at multiple locations, such as near the intake valve of each of the cylinders. In various implementations not depicted in  FIG. 1 , fuel may be injected directly into the cylinders or into mixing chambers associated with the cylinders. 
     The injected fuel mixes with air and creates an air/fuel mixture in the cylinder  118 . A piston (not shown) within the cylinder  118  compresses the air/fuel mixture. Based upon a signal from the ECM  114 , a spark actuator module  126  may energize a spark plug  128  in the cylinder  118 , which ignites the air/fuel mixture. The timing of the spark may be specified relative to the time when the piston is at its topmost position, referred to as top dead center (TDC). In diesel and compression ignition engines, compression by the piston may ignite the air/fuel mixture. 
     The spark actuator module  126  may be controlled by a timing signal indicating how far before or after TDC the spark should be provided. Operation of the spark actuator module  126  may therefore be synchronized with crankshaft rotation. 
     The combustion of the air/fuel mixture drives the piston down, thereby driving a rotating crankshaft (not shown). The piston then begins moving up again and expels the byproducts of combustion through an exhaust valve  130 . The byproducts of combustion are exhausted from the hybrid vehicle via an exhaust system  134 . 
     The exhaust system  134  includes a catalyst assembly  136 . The catalyst assembly  136  includes a plurality of electrically heated catalysts (EHCs). The catalyst assembly  136  may include one or more non-electrically heated catalysts. The catalyst assembly  136  is discussed in detail below. A heater actuator module  138  selectively applies power to one or more EHCs based on signals from the ECM  114 . 
     Exhaust gas exits the engine  102  through the exhaust valve  130  and enters the exhaust system  134 . A temperature sensor  144  may measure a temperature of the exhaust gas before the exhaust gas enters the catalyst assembly  136 . A second temperature sensor  146  may measure a temperature of the exhaust gas after the exhaust gas exits the catalyst assembly  136 . Other temperature sensors (not shown) may measure exhaust gas temperatures in between the temperature sensors  144  and  146  and at various locations in the exhaust system  134 . For example only, multiple temperature sensors may measure catalyst temperatures at multiple locations. The exhaust gas temperatures may be modeled by the ECM  114  based on predetermined tables and/or measured temperatures. The ECM  114  may model the catalyst temperatures. 
     The ECM  114  may use signals from various sensors to make control decisions for the hybrid vehicle system  100 . The ECM  114  also controls operation of the engine  102  and the torque output of the engine  102 . The ECM  114  may communicate with a hybrid control module  196  to coordinate operation of the engine  102  and an electric motor  198 . While only the electric motor  198  is shown, the hybrid vehicle system  100  may include more than one electric motor. 
     In some circumstances, the electric motor  198  may be used to produce drive torque that supplements torque output by the engine  102 . In other circumstances, the engine  102  may be shut down (i.e., disabled) to increase fuel economy of the hybrid vehicle system  100 . The electric motor  198  supplies drive torque when the engine  102  is shut down. 
     The electric motor  198  may also function as a generator. The electric motor  198  may be used to generate electrical energy for use by the various components of the hybrid vehicle system  100  and/or storage. In various implementations, various functions of the ECM  114  and the hybrid control module  196  may be integrated into one or more modules. 
     The ECM  114  selectively operates the hybrid vehicle in a combustion mode. The combustion mode includes using the engine  102  to produce drive torque. The ECM  114  also selectively operates the hybrid vehicle in an electric mode. The electric mode includes using the electric motor  198  to produce drive torque. The ECM  114  may operate the hybrid vehicle in a blended mode by using both the engine  102  and the electric motor  198  to produce drive torque. The ECM  114  may select the mode of operation based on a desired torque output which may be based on driver input. 
     Referring now to  FIG. 2 , an exemplary segmented, cross-sectional perspective view of the catalyst assembly  136  is shown. The catalyst assembly  136  may include a housing  202  that is coupled with the exhaust system  134  to receive exhaust gas output by the engine  102 . The catalyst assembly  136  receives exhaust gas output by the engine  102  at an inlet  204 . 
     A plurality of electrically heated catalysts (EHCs) are implemented within the housing  202  of the catalyst assembly  136 . For example only,  FIG. 2  depicts three EHCs  206 ,  208 , and  210 . While the three EHCs  206 - 210  are described and shown, the catalyst assembly  136  may include two or more EHCs. For example only, the number of EHCs implemented in a vehicle may be based on a battery load, load on the electric motor  198 , an alternator/generator electrical output, and/or other electrical components associated with an electrical system of the vehicle. 
     Each of the EHCs  206 - 210  includes a substrate, such as cordierite, aluminum, and/or another suitable material. The substrates may be formed in a honeycomb arrangement or in another suitable arrangement. A catalyst is applied to each of the substrates of the EHCs  206 - 210 . The catalyst may include, for example, platinum, rhodium, and/or another three-way catalyst. The catalyst reacts with various components of the exhaust gas to reduce the amount of those components in the exhaust gas. 
     A plurality of non-electrically heated catalysts may also be implemented within the housing  202  of the catalyst assembly  136 . For example only, the catalyst assembly  136  may include four passive three-way catalysts (TWCs)  212 ,  214 ,  216 , and  218 . While the four TWCs  212 - 218  are described and shown, the catalyst assembly  136  may include any number of non-electrically heated catalysts. Alternatively, the catalyst assembly  136  may not include any non-electrically heated catalysts. Each of the TWCs  212 - 218  also includes a substrate, such as cordierite, aluminum, and/or another suitable substrate. These substrates may also be formed in a honeycomb arrangement or in another suitable arrangement. 
     A catalyst is also applied to each of the substrates of the TWCs  212 - 218 . The catalyst may include, for example, platinum, rhodium, and/or another suitable three-way catalyst. In some implementations, the same three-way catalyst is applied to both the TWCs  212 - 218  and the EHCs  206 - 210 . The catalyst of the TWCs  212 - 218  also reacts with various components of the exhaust gas to reduce the amount of those components in the exhaust gas. 
     Each of the EHCs  206 - 210  is separated from each of the TWCs  212 - 218 . In other words, a buffer zone is provided between each of the EHCs  206 - 210  and the TWCs  212 - 218 . When no TWCs are present, the buffer zones may be provided between each of the EHCs  206 - 210 . Exemplary buffer zones between the EHCs  206 - 210  and the TWCs  212 - 218  are illustrated by buffer zones  220 . The buffer zones  220  may be implemented to, for example, prevent electrical grounding of the EHCs  206 - 210 . 
     The catalysts of the EHCs  206 - 210  and the TWCs  212 - 218  are effective in reacting with the exhaust gas when the temperature of the catalyst is greater than the threshold temperature (e.g., 300° C.). The heater actuator module  138  selectively applies power to the EHCs  206 - 210  based on signals from the ECM  114 . The heater actuator module  138  applies power to the EHCs  206 - 210  via electrical connectors that are associated with each of the EHCs  206 - 210 . For example only, electrical connectors  222  and  224  are associated with the EHC  206 . Electrical connectors  226  and  228  are associated with the EHC  208 , and electrical connectors  230  and  232  are associated with the EHC  210 . 
     Power is applied to each of the EHCs  206 ,  208 , and  210  via the associated electrical connectors  222 ,  226 , and  230 , respectively. The power may be supplied by, for example, an energy storage device (e.g., a battery), and/or another suitable power source. Power flows through substrates of the EHCs  206 ,  208 , and  210  to the electrical connectors  224 ,  228 , and  232 , respectively. The electrical connectors  224 ,  228 , and  232  are electrically connected to a ground source  234 , such as a ground source that is common to the power source. The substrates provide electrical resistance and function as electrically resistive heaters that generate heat when power is applied. 
     The application of power to the substrates of the EHCs  206 - 210  causes each of the EHCs  206 - 210  to generate (resistive) heat. The ECM  114  selectively applies power to the EHCs  206 - 210  when the engine  102  is disabled (i.e., shut down) and the electric motor  198  is enabled (i.e., outputting torque). In other words, the ECM  114  selectively applies power to the EHCs  206 - 210  during operation in the electric mode. 
     The heater actuator module  138  sequentially applies the power to each of the EHCs  206 - 210 , one at a time. For example only, the heater actuator module  138  may apply power to a first EHC, such as EHC  206 . When the temperature of the first EHC is greater than or equal to the threshold temperature (e.g., 300° C.), the heater actuator module  138  may stop applying power to the first EHC and begin applying power to a second EHC, such as EHC  208 . Each EHC  206 - 210  increases to the threshold temperature at a faster rate than when more than one of the EHCs  206 - 210  are heated at the same time. The heater actuator module  138  may apply a predetermined amount of power to each of the EHCs  206 - 210 . The predetermined power amount may be set based on characteristics of the EHCs  206 - 210 . 
     Resistively heating the EHCs  206 - 210  to or above the threshold temperature enables the catalyst of the heated EHCs  206 - 210  to react with exhaust gas when the engine  102  is started (i.e., turned on). Implementation of more than one smaller EHC rather than a single larger EHC decreases the period necessary to increase the temperature of a portion of the catalyst to the threshold temperature. The implementation of more than one smaller EHC rather than the single larger EHC also provides more uniform heating and enables a lesser amount of power to be drawn to heat the EHCs to the threshold temperature. Smaller EHCs may also be manufactured more easily than larger EHCs. 
     Referring now to  FIG. 3 , an exemplary implementation of the ECM  114  is shown. The ECM  114  may include a drive mode determination module  302  that enables at least one of the engine  102  and the electric motor  198  based on at least one of vehicle speed, driver input, and a desired torque. A vehicle speed sensor (not shown), such as a wheel speed sensor, may measure the speed of the vehicle. A desired torque module  304  may determine the desired torque based on driver input and other engine system signals. 
     When the engine  102  is enabled, the ECM  114  may control actuator values to generate drive torque. For example only, the ECM  114  may control the throttle actuator module  116 , the spark actuator module  126 , and/or the fuel actuator module  124  when the engine  102  is enabled. When the electric motor  198  is enabled, the hybrid control module  196  may control the electric motor  198  to generate drive torque. 
     The ECM  114  may include a catalyst selection module  306  that determines which of the EHCs  206 - 210  to heat when the electric motor  198  is enabled and the engine  102  is disabled. The catalyst selection module  306  may determine to heat each EHC one at a time. Alternatively, the number of EHCs  206 - 210  heated at the same time may be based on an electrical load of the hybrid vehicle system  100 . 
     An electrical load determination module  308  may determine the electrical load on the hybrid vehicle system  100  based on the electrical load of the electric motor  198  and other electrical loads. The hybrid control module  196  may determine the electrical load of the electric motor  198  based on the power output of the electric motor  198 . 
     The ECM  114  may include a heater control module  310  that determines the amount of energy to be applied by the heater actuator module  138  to heat each EHC to the threshold temperature. The amount of energy may be based on the temperature of each EHC. A temperature determination module  312  may determine each EHC temperature based on a measured exhaust temperature. For example only, temperature sensors  144  and  146  may be used to determine the EHC temperature. The EHC temperature may be determined based on an exhaust temperature model generated by an exhaust temperature model module  314 . The exhaust temperature model may be based on the IAT, MAF, fueling, and/or measured exhaust temperatures. 
     When the electric motor  198  is enabled and the engine  102  is disabled, the catalyst selection module  306  may determine which of the EHCs are to be heated by the heater actuator module  138 . The heater control module  310  may determine the amount of energy to be applied to each EHC. The heater actuator module  138  heats the selected EHCs until each of the EHC temperatures are greater than or equal to the threshold temperature. 
     Referring now to  FIG. 4 , a flowchart  400  depicts an exemplary method performed by the ECM  114 . Control begins in step  402  when control determines whether the electric mode is enabled. The electric mode may be enabled when the electric motor  198  is enabled. In step  404 , control determines whether the engine  102  is disabled (shut down). When the electric mode is enabled and the engine  102  is disabled, control continues to step  406 . In step  406 , control selects an EHC to be heated. For example only, the EHC may be the EHC  206 . In step  408 , control determines the EHC temperature. 
     In step  410 , control determines the power to be applied to increase the EHC temperature to the threshold temperature based on the EHC temperature. In step  412 , control applies the power to heat the EHC to the threshold temperature. In step  414 , control compares the EHC temperature with the threshold temperature. When the EHC temperature is less than the threshold temperature, control continues to heat the EHC. When the EHC temperature is greater than or equal to the threshold temperature, control may stop applying power to the EHC and continue to step  416 . 
     In step  416 , control determines whether all of the EHCs have been heated. For example only, control may include a counter that increments when each EHC has been heated to the threshold temperature. When the counter value is greater than or equal to the number of EHCs, control may end. Alternatively, control may continue to maintain the EHC temperatures at the threshold temperature. When one or more EHCs have not been heated, control returns to step  402 . 
     Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.