Patent Publication Number: US-4317434-A

Title: Preheating apparatus for Diesel engines

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a preheating apparatus for Diesel engines, which is designed to ensure a rapid glow plug temperature rise characteristic. 
     In the past, certain types of Diesel engines, known as pre-combustion chamber engines, have been mostly equipped with glow plugs such that during the engine starting the glow plugs are heated red hot and the fuel is burned by contacting it with the glow plugs to thereby facilitate the starting of the engine, and there has been a desire that the time required for heating the glow plugs red hot be reduced as far as possible. In particular, passenger cars equipped with Diesel engines have recently been used for a variety of purposes due to the improved fuel economy of the Diesel engines. However, the vehicles equipped with Diesel engines have been found inferior in starting performance to those equipped with gasoline engines, thus making the necessity of preheating the Diesel engine particularly important in the case of passenger cars. 
     On the other hand, in order to start the Diesel engine smoothly, it has been necessary to preheat the glow plugs to a temperature of 700° to 1000°C., and in the past the time required for attaining such temperature (hereinafter referred to as a &#34;preheating time&#34;) has been considerably long. 
     In view of these background circumstances, systems have been proposed in which as shown, for example, in Japanese Utility Model Publication No. 48262/77, a resistance unit having a very high positive temperature coefficient of resistance, such as, a resistance unit made from molybdenum disilicide is connected in series with a parallel circuit of glow plugs so that during the starting period a large current is supplied to the glow plugs through the action of the resistance unit and the temperature of the glow plugs is rapidly increased. 
     However, the prior art apparatus of this type has the following disadvantages. 
     (1) The resistance value of the resistance unit linearly increases with temperature so that the ratio of change in resistance between the lower and higher temperature ranges is about 6 times and consequently the resistance value at the normal temperature becomes 1/6 of the resistance value in the higher temperature range. Thus, the normal temperature resistance value cannot be set so small that the amount of starting current supplied to the glow plugs is limited considerably depending on the resistance unit and the resulting preheating time is 15 seconds as compared with the conventional time of 20 seconds showing only an improvement by 25%. 
     (2) When current is being supplied to the glow plugs, the current always flows to the molybdenum disilicide resistance unit so that the resistance unit always generates heat and it is always kept at elevated temperatures with the resulting large change of its characteristics with time. As a result, no matter how accurately the initial resistance value is set, the resistance value is subject to variation with the accumulated period of service time of the glow plugs, thus giving rise to such troubles as burnout failure, faulty heat generation, etc., of the glow plugs. 
     SUMMARY OF THE INVENTION 
     With a view to overcoming the foregoing deficiencies in the prior art, it is the object of the present invention to provide an improved preheating apparatus for Diesel engines, which is capable of remarkably reducing the preheating time of glow plugs than previously and also preventing burnout failure of the glow plugs. 
     To accomplish the above object, the preheating apparatus provided in accordance with the present invention preferably includes a starting resistor unit made from a barium titanate ceramic material having a positive temperature coefficient and whose resistance value abruptly increases at a specified temperature, the resistor unit being connected in the energization circuit of glow plugs, an ordinary resistor unit connected in parallel with the starting resistor unit and having a resistance value which is greater than that of the starting resistor unit when the temperature of the glow plugs themselves is relatively low and which is smaller than that of the starting resistor unit when the glow plug temperature is relatively high, and a bypass energization circuit for applying the power from a battery to the glow plugs without passing the ordinary resistor unit and the starting resistor unit during the cranking period of the engine. 
     To accomplish the above object, preferably the starting resistor unit used in the apparatus of the present invention has a honeycomb structure in which a plurality of passages are isolated from each other by a plurality of isolating walls and an electrode film is formed on each of the surfaces of the isolating walls so as to cause the flow of current through the isolating walls at right angles thereto. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a wiring diagram showing a first embodiment of a preheating apparatus according to the present invention. 
     FIGS. 2 to 6 show the construction of the resistor unit 7 of FIG. 1, with FIG. 2 showing its plan view, FIG. 3 its front sectional view, FIG. 4 its half-sectional side view, FIG. 5 its sectional view showing in detail the electrode films 13, and FIG. 6 a perspective view of the resistor unit 7. 
     FIG. 7 is a characteristic diagram of the resistor unit 7 of FIG. 1. 
     FIG. 8 is a characteristic diagram useful in explaining the effects of the apparatus of this invention. 
     FIG. 9 is a sectional view showing another form of the resistor unit 7 of FIG. 1. 
     FIG. 10 is a sectional view looked in the direction of the arrow line X--X of FIG. 9. 
     FIG. 11 is a left side view of FIG. 9. 
     FIG. 12 is a wiring diagram showing a second embodiment of the apparatus according to the invention. 
     FIG. 13 is a wiring diagram showing a third embodiment of the apparatus according to the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In accordance with the present invention a starting resistor unit is mainly composed of barium titanate (BaTiO 3 ) and it is produced by adding to this main component such impurities as manganese (Mn), strontium (Sr), cerium (Ce), etc., forming the material into a honeycomb shape (according to the first embodiment of the invention), baking the honeycomb structure, and then applying and baking an electrode film on each of the inner surfaces of a plurality of isolation walls forming the honeycomb structure. 
     This barium titanate type starting resistor unit has a positive temperature coefficient of resistance such as shown in FIG. 7, and it has a resistance value which becomes 0.0076 ohms at the normal temperature (25° C.) and which at a temperature of about 210° C. abruptly increases to 700 ohms. This ratio of change of resistance value is about 100,000 times. While the temperature at which the resistance value increases abruptly (hereinafter referred to as a Curie point) and the ratio of change of resistance are adjustable in dependence on the amounts of impurities added to barium titanate, generally the Curie point and the ratio of resistance change of this type of resistor units are mostly on the order of 100° to 300° C. and 100,000 times, respectively. 
     In accordance with the present invention, the ordinary resistor unit is composed for example of an ordinary metal resistance wire such as a tungsten wire or nichrome wire. This resistor unit is used in the form of a bare wire or it is incorporated in a ceramic body. 
     In accordance with the present invention, the following relationship exists between the resistance values of the ordinary and starting resistor units. In other words, when the temperature of the glow plugs themselves is the lower range, the starting resistor unit has a resistance value which is smaller than that of the ordinary resistor unit, whereas when the glow plug temperature is the higher range, the starting resistor unit has a resistance value which is greater than that of the ordinary resistor unit. To cite a specific example, if it is selected so that the resistance value of the starting resistor unit becomes 1/10 of that of the ordinary resistor unit when the glow plug temperature is in the lower range and the resistance value of the starting resistor unit becomes over 10 times that of the ordinary resistor unit when the glow plug temperature is in the higher range, it is possible to ensure a satisfactory rapid glow plug heating effect and it is also possible to provide the glow plugs with the necessary current for normal operation through the ordinary resistor unit when the normal condition is established or when the glow plugs are heated to a temperature high enough for preheating purposes. Consequently, the resistance ratio between the two resistor units must be at least 100 times. 
     With the present invention, &#34;the higher temperature range of the glow plugs themselves&#34; represents in fact the surface temperatures of the glow plug heat coil which are higher than 800° C. and &#34;the lower temperature range&#34; represents the surface temperatures lower than 800° C. Of course, the necessary glow plug temperature for preheating purposes ranges from 700° to 1000° C. depending on the types of engines as mentioned previously and thus the temperatures represented by the higher and lower temperature ranges vary correspondingly. Thus, if they are defined for purposes of discussion, the higher temperature range represents the temperatures higher than that required for engine preheating purposes and the lower temperature range represents the temperatures lower than the required engine preheating temperature. 
     In this connection, since the preheating time required for increasing the glow plug temperature to a value necessary for engine preheating purposes coincides with the time required for the starting resistor unit to attain the Curie point, considering from the standpoint of the starting resistor unit the lower temperature range represents the temperatures lower than the Curie point and the higher temperature range represents those higher than the Curie point. 
     The present invention is also applicable to single-cylinder Diesel engines. Of course, where the present invention is applied to a multi-cylinder Diesel engine, a starting resistor unit may be provided for each of the glow plugs in the respective cylinders. 
     The present invention will now be described in greater detail with reference to the illustrated embodiments. 
     Referring to FIG. 1, numeral 1 designates a vehicle-mounted power source or battery, 2 a starter switch, 2a a preheating contact, 2b a starting contact, and 2c and auxiliary contact. Numeral 3 designates a glow plug relay, 3a a normally open contact, and 3b a coil. Numeral 4 designates a starter relay, and 5 a starter. Numeral 6 designates glow plugs of the known sheathed structure (not shown in detail) in which a heat coil is contained within a heat resisting metal tube through the intermediary of electrical insulating powder. The forward end of each of the metal tubes is reduced in diameter so as to reduce the heat capacity. The glow plugs 6 are each disposed in one of the pre-combustion chambers of cylinder-head of a Diesel engine, and a plurality, e.g., four, of the glow plugs 6 are connected in parallel. Numeral 7 designates a starting resistor unit composed of the previously mentioned barium titanate type ceramic and it has a characteristic as shown in FIG. 7. Its Curie point is about 210° C. and it has a resistance value of about 0.0076 ohms until reaching the Curie point at which the resistance value abruptly increases to 700 ohms. The single resistor unit 7 is connected in series with the parallel circuit of the glow plugs 6. Numeral 8 designates an ordinary resistor unit of the previously mentioned type having a resistance value of 0.068 ohms, and it is composed for example of a small diameter (1 to 2 mm) nichrome wire wound 2 to 5 times in loop shape and having a structure which is likely to be exposed to and cooled by the air (i.e., the same structure as a preheating indicating glow plug controller 19 disposed within the vehicle compartment). The ordinary resistor unit 8 is contained in a case and mounted inside the engine room. 
     Next, the construction of the starting resistor unit 7 will be described in detail with reference to FIGS. 2 to 6. In the Figures, the starting resistor unit 7 is contained and held in place by means of metal plate springs 10a, 10b, 10c and 10d in a case 9 made from a material having good heat conductive and heat resisting properties, such as aluminum. Formed on the outer surface of the case 9 are fins 11a, 11b, 11c and 11d. As shown in FIG. 6, the resistor unit 7 is shaped to form a honeycomb structure in which a plurality of isolation walls 7a and a frame member 7c are arranged to define a plurality of passages 7b. This structure is produced by for example assemblying barium titanate ceramic green sheets and then baking the assembly. An electrode 12 in thin film form is formed all over each of the surfaces of the isolation walls 7a of the resistor unit 7 which face the passages 7b. The electrodes 12 are each composed for example of a baked silver paste. The electrodes 12 on the respective isolation walls 7b are electrically isolated from each other by the isolation walls 7b, since no electrode 12 is formed on the end faces of the isolation walls 7a. Inserted within each of the passages 7b of the resistor unit 7 is a positive electrode plate 13a or negative electrode plate 13b having its forward end portion formed into a loop shape and contacted electrically with the electrodes 12 on the isolation walls 7a. These positive and negative electrode plates 13a and 13b are disposed alternately in the passages 7b of the resistor unit 7. As a result, each of the positive and negative electrode plates 13a and 13b is assembled as a separate unit. Also, the positive and negative electrode plates 13a and 13b are respectively connected electrically to positive and negative terminal strips 14a and 14b. Thus, if conduction is established between the alternate positive and negative electrode plates 13a and 13b, current flows through the isolation walls 7a in a direction perpendicular to the axes of the passages 7b. The terminal strips 14a and 14b and the electrode plates 13a and 13b are held between insulating plates 15a and 15b having heat resisting and electrical insulating properties and the insulating plates 15a and 15b are secured to a metal mounting base 16. Each of the terminal strips 14a and 14b has its one end projected to the outside of the case 9 and these ends are electrically connected to the terminals of the battery 1. The metal mounting base 16 is formed with integral mounting stays 16a, 16b and 16c and the mounting base 16 is mounted inside the engine room by means of screws and the mounting stays 16a, 16b, 16c and 16d.  The case 9 is secured to the mounting base 16 by screws. 
     With the construction described above, the operation of the apparatus is as follows. When the switch 2 is operated so that the preheating contact 2a is closed, the current flows from the battery 1 to the coil 3b of the glow plug relay 3 so that an attractive force is produced in the coil 3b and the normally open contact 3a is closed. At this time, since the engine must be preheated and hence the temperature of the glow plugs 6 is low as a matter of course, as shown in FIG. 7 the resistance value of the starting resistor unit 7 is 0.0076 ohms and this is considerably smaller than that of the ordinary resistor unit 8 which is 0.068 ohms. As a result, the current from the battery 1 flows to the glow plugs 6 through the normally open contact 3a and mainly through the starting resistor unit 7, causing the glow plugs 6 to generate heat. In this case, due to the fact that just after the beginning of the current flow the resistor unit 7 is not generating heat and that the electrodes 12 have a large area and a very small resistance value due to the honeycomb structure, a large current flows to the glow plugs 6. While the resistor unit 7 generates heat as the conduction time passes, as will be seen from the characteristic diagram of FIG. 7, the resistance value of the resistor unit 7 remains practically unchanged until its self-heated temperature reaches the Curie point of 210° C. and the large current continuously flows to the glow plugs 6. As a result, the energized temperature rise time of the glow plugs 6 becomes faster considerably. While the large current flowing continuously to the glow plugs 6 tends to cause their heat coils to burn out, the resistor unit 7 generates heat as the conduction time passes and its temperature eventually attains the Curie point of FIG. 7. As a result, the resistance value of the resistor unit 7 increases abruptly and the current flowing in the resistor unit 7 rapidly decreases, thus preventing the heat coils of the glow plugs 6 from being burnt out. 
     When the resistance value of the resistor unit 7 abruptly increases (up to 700 ohms), the resistance value (0.068 ohms) of the ordinary resistor unit 8 connected in parallel with the resistor unit 7 now becomes smaller than that of the latter and consequently the current from the battery 1 is supplied to the glow plugs 6 mainly through the ordinary resistor unit 8. As a result, the temperature of the glow plugs 6 is maintained at the required value for the normal operation of the engine. 
     Due to its honeycomb structure, the resistor unit 7 has a very large heat transfer surface area. Also, the heat dissipation of the resistor unit 7 is improved by placing it in the case 9 having the fins 11a, 11b, 11c and 11d. Thus, the supply of current to the glow plugs 6 through the resistor unit 7 is adjusted in accordance with the time constant which is determined by the amount of heat generated and the amount of heat dissipated by the resistor unit 7. 
     Then, as the switch 2 is operated so that the starting contact 2b is closed and the starter 5 is energized, the starter 5 consumes a large amount of current and thus the terminal voltage of the battery 1 drops from about 12 volts to about 5 volts. In accordance with the present embodiment, however, the auxiliary contact 2c is closed simultaneously with the closing of the starting contact 2b, so that the current is directly supplied from the battery 1 to the glow plugs 6 through a bypass energization circuit 17 and thus the heated temperature of the glow plugs 6 is not decreased even if the terminal voltage of the battery 1 drops while the starter 5 is in operation. In this case, if the rated voltage of the glow plugs 6 is about 6.5 volts and the terminal voltage of the battery 1 is 7 volts, there is the danger of the glow plugs 6 being burnt out. However, this difficulty is overcome by the provision of a resistor unit 18 of a small value (e.g., 0.028 ohms) in the bypass energization circuit 17 so as to decrease the terminal voltage of 7 volts to about 6.5 volts. 
     In this connection, the results of the experiments conducted by the inventor showed that a comparison between the prior art apparatus and the present embodiment of the invention in terms of the time required for increasing the plug temperature from -20° C. up to 1000° C. resulted as shown in FIG. 8. In the prior art apparatus in which the glow plugs were connected directly to the battery by way of the switch, the rated voltage of the glow plugs was 11 volts (9 A) as compared with 6 volts (18 A) in the present embodiment. In the prior art apparatus the resistance value of the glow plugs 6 themselves was 1.2 ohms and that of the present embodiment was 0.33 ohms. The resistance value of the known molybdenum disilicide resistor unit was the same as disclosed in Japanese Utility Model Publication No. 48262/77. In FIG. 8, the line a shows the result of the prior art apparatus, the line b the result obtained with the known molybdenum disilicide and the line c the result of the present embodiment of the invention. As will be apparent from FIG. 8, the line c representing the embodiment of this invention shows that the rise time required for the glow plug temperature to rise from -20° C. to 1000° C. is about 3.0 seconds and this is remarkably fast as compared with 30 seconds of the line a and 25 seconds of the line b. Further, in accordance with the present embodiment the required energized temperature for operating the engine can be maintained through the action of the ordinary resistor unit 8 in the same manner as in the case of the prior art apparatus. 
     With the thusly constructed starting resistor unit 7 of this embodiment, by virtue of the provision of the electrodes on the surfaces of the isolation walls, the total electrode area is proportional to the number of the isolation walls, with the result that the electrode area can be increased easily by increasing the number of isolation walls and that the gap between the electrodes through which the current flows through the isolation walls at right angles thereto can be reduced by reducing the thickness of the isolation walls. In this case, due to the entire unit being of the honeycomb structure, even if the thickness of the isolation walls is reduced, there is no danger of deteriorating the strength. 
     As a result, the resistance value of the starting resistor unit 7 decreases considerably in accordance with the following equation 
     
         Ω=ρ×l=S 
    
     where 
     Ω is the resistance, 
     ρ is the specific resistance, 
     l is the electrode gap, 
     S is the electrode area. 
     Thus, the honeycomb barium titanate starting resistor unit provided in accordance with this invention has a very small resistance value at the normal temperature as compared with that of the prior art molybdenum disilicide resistor unit and it is also very small in size as compared with the known barium titanate resistor units having shapes other than the honeycomb structure, thus ensuring the supply of a large current (e.g., about 80 A) to the glow plugs and remarkably reducing the preheating time of the glow plugs. 
     Further, since the starting resistor unit of this invention has a honeycomb structure with a large surface area, even if it reaches the Curie point temperature through the generation of heat by itself, it has an excellent heat dissipating property so that when the engine fails to start and the current is supplied again to the glow plugs to start the engine again, the reenergization time of the glow plugs can be reduced considerably. 
     The embodiments of the present invention are not intended to be limited to the starting resistor unit 7 of the honeycomb structure shown in FIG. 6 and the honeycomb structure of any of many other shapes may of course be used. Also, the electrodes 12 may be formed by a plating method. 
     The starting resistor unit 7 can be formed into a plate shape. FIGS. 9 to 11 show a specific structure of the plate type. In the Figures, the starting resistor unit 7 has a rectangular plate shape and it is placed in a metallic case 9&#39; made from brass or the like having a good heat conducting property. An electrode film is formed on each side of the resistor unit 7 by applying and baking silver paste. The metallic case 9&#39; includes a threaded portion 9a for securing the case 9&#39; to the cylinder head or the cylinder block of the engine. In the case of this embodiment, the case 9&#39; is screwed into the cylinder head. Electrodes 13a&#39; and 13b&#39; in thin sheet form are mounted on the sides of the resistor unit 7. The resistor unit 7 placed between the electrodes 13a&#39; and 13b&#39; is supported inside the case 9&#39; by support members 15&#39; made from a heat resisting and electrical insulating material. In the Figures, numerals 14a&#39; and 14b&#39; designate terminals of the electrodes 13a&#39; and 13b&#39;. 
     When used with the first embodiment shown in FIG. 1, the resistor unit 7 of the structure shown in FIGS. 9 to 11 operates in the same manner as mentioned previously and the temperature rise time required for the temperature of the glow plugs 6 to rise from -20° C. to 1000° C. is about 7.5 seconds as shown by the line d in FIG. 8. This rise time is somewhat slower than that of the resistor unit 7 of the honeycomb structure shown in FIGS. 2 to 6 but is still faster than those of the lines a and b representing the prior art techniques as will be seen from FIG. 8. 
     Referring now to FIG. 12, there is illustrated a second embodiment which differs from the first embodiment of FIG. 1 in that the auxiliary contact 2c of the starter switch 2 is replaced with a relay 20, so that when the engine is cranked, a coil 20b of the relay 20 is energized through the starting contact 2b and a contact 20a is closed, thus directly applying the battery voltage to the glow plugs 6 through the bypass energization circuit 17 upon closing of the contact 20a. 
     Referring to FIG. 13, there is illustrated a third embodiment of the invention which differs from the first embodiment of FIG. 1 in that the auxiliary contact 2c of the starter switch 2 and the bypass energization circuit 17 (including the resistor 18) are eliminated and that the starting contact 2b of the starter switch 2 is connected to a coil 3c of the glow plug relay 3 and the coils 3b and 3c are connected to each other through diodes 3d. In this third embodiment the resistance value of the ordinary resistor unit 8 is selected 0.3056 ohms. 
     In FIG. 13, when the switch 2 is closed to the preheating contact 2a, the current flows from the battery 1 to the coil 3b of the glow plug relay 3 and the normally open contact 3a is closed. In this case, the flow of the current from the battery 1 to the starter relay 4 is prevented by the diodes 3d. The remaining operation is the same with that which took place when the switch 2 was closed to the preheating contact 2a in FIG. 1. 
     Then, as the switch 2 is closed to the starting contact 2b, the starter 5 is energized. 
     The remaining operation of this embodiment is the same as mentioned previously. Thus, if, for example, the starting resistor unit 7 of the plate shape shown in FIGS. 9 to 11 is used, the temperature rise time required for the temperature of the glow plugs 6 to rise from -20° C. to 1000° C. becomes about 7.5 seconds as shown by the line d in FIG. 8.