Patent Abstract:
A method for controlling an engine having multiple banks with separate catalysts is described. In particular, coordinate lean and rich operation between the banks is utilized. However, termination of rich operation may be different between the banks to prevent breakthrough of rich exhaust gasses due to lack of stored oxidants. In this situation, the bank that terminated rich operation is operated near stoichiometric. This minimizes breakthrough of emissions, while at the same time minimizing a torque imbalance between the cylinder banks. In particular, the torque imbalance can be further minimized by retarding ignition timing on the rich bank while the other operates near stoichiometry.

Full Description:
BACKGROUND OF INVENTION 
     The field of the invention relates to lean burn engine control in internal combustion engines. 
     lean burn engine systems can have different cylinder groups, each having a close-coupled catalytic converter. These cylinder groups come together in a y-pipe configuration before entering a under-body catalyst. The catalyst can store oxidants (including NOx) when operating lean, and release and reduce the oxidants with incoming reductants when operating rich. In this way, emissions are minimized while operating lean by also periodically operating rich. One such system is described in U.S. Pat. No. 5,970,707. In this system, lean and rich operation of the cylinder groups is generally synchronized during normal operation. 
     The inventors herein have recognized that while the Y-type configuration has some advantages, there may not be enough freedom to optimize exhaust system tuning. In particular, the underbody catalyst typically places a constraint on the location of the Y-pipe to provide optimal temperature window operation for the underbody catalyst. 
     On the other hand, the inventors herein have also recognized that having a dual exhaust system where two underbody catalysts are used with a Y-pipe joining them afterwards, provides more flexibility in positioning the Y-pipe joint. Therefore, there is more freedom for optimizing the exhaust system tuning. 
     Finally, the inventors herein have recognized that maintaining synchronous lean and rich engine operation of the dual catalyst path system may not fully use the catalyst&#39;s storage ability. In particular, due to component variation of the underbody catalysts, bank to bank variation of engine exhaust gas properties, and different aging rates of components, the catalysts on the different banks may not behave identically. The potential difference in catalyst conversion and storage/regeneration, if coupled with synchronous operation of the banks between lean and rich air fuel ratios, may therefore lead to degraded performance. For example, one catalyst may finish releasing or reducing stored NOx and oxygen before the other one does. In this case, if the rich operation of the two banks continue, there may be hydrocarbon and carbon monoxide break through from the catalyst that has already completely released stored oxidants. If the rich operation stops, on the other hand, the storage capacity of the other catalyst may not be fully regenerated, thereby leading to degraded performance in subsequent operation. In either case, the fuel economy and emissions may be negatively impacted. 
     SUMMARY OF INVENTION 
     Disadvantages of prior approaches are overcome by a method for controlling an engine having a first and second group of cylinders, the first group coupled to a first catalyst and the second group coupled to a second catalyst. The method comprises: concurrently operating the first and second cylinder groups rich of stoichiometry; in response to a first indication that said rich operation of at least one of the first and second catalysts should be ended, operating the group coupled to the at least one catalyst near stoichiometry while continuing operation of the other group rich of stoichiometry; and in response to a second indication that said rich operation of the other catalyst should be ended, ending rich operation of the other group. By operating the cylinder group coupled to the catalyst that has depleted stored oxidants near stoichiometry, HC and CO breakthrough are minimized while at the same time minimizing any torque imbalance between the two cylinder groups, i.e., since one bank is operating rich and the other near stoichiometry (with the same amount of air per cylinder), engine torque is substantially maintained since the additional fuel in the rich cylinder does not burn to make torque. Any slight torque increase in torque can be compensated for by ignition retard on the rich cylinder bank. In this way, the other catalyst can also be depleted of stored oxidants. Therefore, the full potential of both catalysts is achieved without sacrificing emission performance or driveability. 
     An advantage of the above aspect of the invention is therefore improved emissions and more efficient use of catalysts in separate exhaust streams. 
     Also note that the indications provided above may be given in a variety of ways such as based on air-fuel ratio sensors coupled downstream of the catalyst, based on estimates using other operating parameters, or various other indications. 
     Other advantages of the present invention will be readily appreciated by the reader of this specification. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     The object and advantages of the invention claimed herein will be more readily understood by reading an example of an embodiment in which the invention is used to advantage with reference to the following drawings wherein: 
     FIGS. 1A and 1B are a block diagrams of an embodiment in which the invention is used to advantage; 
     FIG. 2 is a block diagram of an embodiment in which the invention is used to advantage; 
     FIG. 3 is high level flowchart which perform a portion of operation of the embodiment shown in FIGS. 1A,  1 B, and  2 ; and 
     FIGS. 4A and 4B are graphs depicting results using the present invention. 
    
    
     DETAILED DESCRIPTION 
     Direct injection spark ignited internal combustion engine  10 , comprising a plurality of combustion chambers, is controlled by electronic engine controller  12 . Combustion chamber  30  of engine  10  is shown in FIG. 1A including combustion chamber walls  32  with piston  36  positioned therein and connected to crankshaft  40 . In this particular example, piston  36  includes a recess or bowl (not shown) to help in forming stratified charges of air and fuel. Combustion chamber, or cylinder,  30  is shown communicating with intake manifold  44  and exhaust manifold  48  via respective intake valves  52   a  and  52   b  (not shown), and exhaust valves  54   a  and  54   b  (not shown). Fuel injector  66 A is shown directly coupled to combustion chamber  30  for delivering liquid fuel directly therein in proportion to the pulse width of signal fpw received from controller  12  via conventional electronic driver  68 . Fuel is delivered to fuel injector  66 A by a conventional high pressure fuel system (not shown) including a fuel tank, fuel pumps, and a fuel rail. 
     Intake manifold  44  is shown communicating with throttle body  58  via throttle plate  62 . In this particular example, throttle plate  62  is coupled to electric motor  94  so that the position of throttle plate  62  is controlled by controller  12  via electric motor  94 . This configuration is commonly referred to as electronic throttle control (ETC), which is also utilized during idle speed control. In an alternative embodiment (not shown), which is well known to those skilled in the art, a bypass air passageway is arranged in parallel with throttle plate  62  to control inducted airflow during idle speed control via a throttle control valve positioned within the air passageway. 
     Exhaust gas oxygen sensor  76  is shown coupled to exhaust manifold  48  upstream of catalytic converter  70 . In this particular example, sensor  76  provides signal EGO to controller  12  which converts signal EGO into two-state signal EGOS. A high voltage state of signal EGOS indicates exhaust gases are rich of stoichiometry and a low voltage state of signal EGOS indicates exhaust gases are lean of stoichiometry. Signal EGOS is used to advantage during feedback air/fuel control in a conventional manner to maintain average air/fuel at stoichiometry during the stoichiometric homogeneous mode of operation. 
     Conventional distributorless ignition system  88  provides ignition spark to combustion chamber  30  via spark plug  92  in response to spark advance signal SA from controller  12 . 
     Controller  12  causes combustion chamber  30  to operate in either a homogeneous air/fuel mode or a stratified air/fuel mode by controlling injection timing. In the stratified mode, controller  12  activates fuel injector  66 A during the engine compression stroke so that fuel is sprayed directly into the bowl of piston  36 . Stratified air/fuel layers are thereby formed. The strata closest to the spark plug contains a stoichiometric mixture or a mixture slightly rich of stoichiometry, and subsequent strata contain progressively leaner mixtures. During the homogeneous mode, controller  12  activates fuel injector  66 A during the intake stroke so that a substantially homogeneous air/fuel mixture is formed when ignition power is supplied to spark plug  92  by ignition system  88 . Controller  12  controls the amount of fuel delivered by fuel injector  66 A so that the homogeneous air/fuel mixture in chamber  30  can be selected to be at stoichiometry, a value rich of stoichiometry, or a value lean of stoichiometry. The stratified air/fuel mixture will always be at a value lean of stoichiometry, the exact air/fuel being a function of the amount of fuel delivered to combustion chamber  30 . An additional split mode of operation wherein additional fuel is injected during the exhaust stroke while operating in the stratified mode is also possible. 
     Nitrogen oxide (NOx) absorbent or trap  72  is shown positioned downstream of catalytic converter  70 . NOx trap  72  absorbs NOx when engine  10  is operating lean of stoichiometry. The absorbed NOx is subsequently reacted with HC and CO and catalyzed during a NOx purge cycle when controller  12  causes engine  10  to operate in either a rich homogeneous mode or a near stoichiometric homogeneous mode. 
     Controller  12  is shown in FIG. 1A as a conventional microcomputer, including microprocessor unit  102 , input/output ports  104 , an electronic storage medium for executable programs and calibration values shown as read only memory chip  106  in this particular example, random access memory  108 , keep alive memory  110 , and a conventional data bus. Controller  12  is shown receiving various signals from sensors coupled to engine  10 , in addition to those signals previously discussed, including measurement of inducted mass air flow (MAF) from mass air flow sensor  100  coupled to throttle body  58 ; engine coolant temperature (ECT) from temperature sensor  112  coupled to cooling sleeve  114 ; a profile ignition pickup signal (PIP) from Hall effect sensor  118  coupled to crankshaft  40 ; and throttle position TP from throttle position sensor  120 ; and absolute Manifold Pressure Signal MAP from sensor  122 . Engine speed signal RPM is generated by controller  12  from signal PIP in a conventional manner and manifold pressure signal MAP from a manifold pressure sensor provides an indication of vacuum, or pressure, in the intake manifold. During stoichiometric operation, this sensor can give and indication of engine load. Further, this sensor, along with engine speed, can provide an estimate of charge (including air) inducted into the cylinder. In a preferred aspect of the present invention, sensor  118 , which is also used as an engine speed sensor, produces a predetermined number of equally spaced pulses every revolution of the crankshaft. 
     In this particular example, temperature Tcat of catalytic converter  70  and temperature Ttrp of NOx trap  72  are inferred from engine operation as disclosed in U.S. Pat. No. 5,414,994, the specification of which is incorporated herein by reference. In an alternate embodiment, temperature Tcat is provided by temperature sensor  124  and temperature Ttrp is provided by temperature sensor  126 . 
     Continuing with FIG. 1A, camshaft  130  of engine  10  is shown communicating with rocker arms  132  and  134  for actuating intake valves  52   a ,  52   b  and exhaust valve  54   a ,  54   b . Camshaft  130  is directly coupled to housing  136 . Housing  136  forms a toothed wheel having a plurality of teeth  138 . Housing  136  is hydraulically coupled to an inner shaft (not shown), which is in turn directly linked to camshaft  130  via a timing chain (not shown). Therefore, housing  136  and camshaft  130  rotate at a speed substantially equivalent to the inner camshaft. The inner camshaft rotates at a constant speed ratio to crankshaft  40 . However, by manipulation of the hydraulic coupling as will be described later herein, the relative position of camshaft  130  to crankshaft  40  can be varied by hydraulic pressures in advance chamber  142  and retard chamber  144 . By allowing high pressure hydraulic fluid to enter advance chamber  142 , the relative relationship between camshaft  130  and crankshaft  40  is advanced. Thus, intake valves  52   a ,  52   b  and exhaust valves  54   a ,  54   b  open and close at a time earlier than normal relative to crankshaft  40 . Similarly, by allowing high pressure hydraulic fluid to enter retard chamber  144 , the relative relationship between camshaft  130  and crankshaft  40  is retarded. Thus, intake valves  52   a ,  52   b , and exhaust valves  54   a ,  54   b  open and close at a time later than normal relative to crankshaft  40 . 
     Teeth  138 , being coupled to housing  136  and camshaft  130 , allow for measurement of relative cam position via cam timing sensor  150  providing signal VCT to controller  12 . Teeth  1 ,  2 ,  3 , and  4  are preferably used for measurement of cam timing and are equally spaced (for example, in a V-8 dual bank engine, spaced 90 degrees apart from one another) while tooth  5  is preferably used for cylinder identification, as described later herein. In addition, controller  12  sends control signals (LACT,RACT) to conventional solenoid valves (not shown) to control the flow of hydraulic fluid either into advance chamber  142 , retard chamber  144 , or neither. 
     Relative cam timing is measured using the method described in U.S. Pat. No. 5,548,995, which is incorporated herein by reference. In general terms, the time, or rotation angle between the rising edge of the PIP signal and receiving a signal from one of the plurality of teeth  138  on housing  136  gives a measure of the relative cam timing. For the particular example of a V-8 engine, with two cylinder banks and a five-toothed wheel, a measure of cam timing for a particular bank is received four times per revolution, with the extra signal used for cylinder identification. 
     Sensor  160  provides an indication of both oxygen concentration in the exhaust gas as well as NOx concentration. Signal  162  provides controller a voltage indicative of the O 2  concentration while signal  164  provides a voltage indicative of NOx concentration. 
     Note that FIGS. 1A (and  1 B) merely shows one cylinder of a multi-cylinder engine, and that each cylinder has its own set of intake/exhaust valves, fuel injectors, spark plugs, etc. 
     Referring now to FIG. 1B, a port fuel injection configuration is shown where fuel injector  66 B is coupled to intake manifold  44 , rather than directly cylinder  30 . 
     The engine  10  operates in various modes, including lean operation, rich operation, and “near stoichiometric” operation. “Near stoichiometric” operation refers to oscillatory operation around the stoichiometric air fuel ratio. Typically, this oscillatory operation is governed by feedback from exhaust gas oxygen sensors. In this near stoichiometric operating mode, the engine is operated within one air fuel ratio of the stoichiometric air fuel ratio. 
     As described above, feedback air-fuel ratio is used for providing the near stoichiometric operation. Further, feedback from exhaust gas oxygen sensors can be used for controlling air-fuel ratio during lean and during rich operation. In particular, a switching type HEGO sensor can be used for stoichiometric air-fuel ratio control by controlling fuel injected (or additional air via throttle or VCT) based on feedback from the HEGO sensor and the desired air-fuel ratio. Further, a UEGO sensor (which provides a substantially linear output versus exhaust air-fuel ratio) can be used for controlling air-fuel ratio during lean, rich, and stoichiometric operation. In this case, fuel injection (or additional air via throttle or VCT) is adjusted based on a desired air-fuel ratio and the air-fuel ratio from the sensor. 
     Also note that various methods can be used according to the present invention to maintain the desired torque such as, for example, adjusting ignition timing, throttle position, variable cam timing position, and exhaust gas recirculation amount. Further, these variables can be individually adjusted for each cylinder to maintain cylinder balance among all the cylinder groups. 
     Referring now to FIG. 2, engine  10  is shown in a system including the exhaust system. Engine  10  is shown with first and second cylinder groups  210  and  212 , respectively. In this particular example, each of groups  210  and  212  has two cylinders. However, the engine groups need not have the same number of cylinders and may include even only one cylinder. First cylinder group  210  is coupled to exhaust manifold  48 A, while second cylinder group  212  is coupled to exhaust manifold  48 B. Further, exhaust manifold  48 A is coupled to first catalytic converter  70 A and second catalytic converter  72 A. Also, exhaust gas oxygen sensor  170 A is coupled downstream of catalyst  72 A. Similarly, exhaust manifold  48 B is coupled to catalyst  70 B and  72 B and exhaust gas oxygen sensor  170 B. The outlet of catalysts  72 A and  72 B are coupled to a Y-pipe, which leads to the tailpipe of the vehicle. Sensor  160  is coupled downstream of the Y-pipe. Note that while this is one potential configuration, each cylinder group may be coupled to only a single catalyst. Also, sensor  160  downstream of the Y-pipe may be excluded. Further still, estimates of engine exhaust parameters can be substituted for the measurements provided by sensors  170 A and  170 B. 
     Referring now to FIG. 3, a routine for controlling engine operation is described. First, in step  310 , the determination is made as to whether operating conditions are such that lean engine operation is desired. In particular, these engine operating conditions may include, for example, vehicle speed, engine torque, engine load, engine speed, engine temperature, catalyst temperature, time since engine start, or various other conditions. When the answer to step  310  is no, the routine continues to step  312  where both the first and second cylinder groups are operated near stoichiometry. For example, fuel injected into the first and second cylinder groups via the fuel injectors is adjusted using a proportional integral controller based on feedback from exhaust gas sensors when  70 A,  70 B, and further based on an open-loop estimate of air flow in any of the cylinders. This open-loop estimate of air flowing in the cylinders is based on, for example, engine speed and manifold pressure, or mass airflow from the mass airflow sensor. 
     When the answer to step  310  is yes, the first and second cylinder groups are operated lean of stoichiometry in step  314 . In this case, airflow entering the cylinders is adjusted via the electronically controlled throttle  62 . Then, in step  316 , a set point of NOx grams/mile (tailpipe NOx per distance traveled of the vehicle) is determined based on operating conditions. Note that in an alternative embodiment, a set point amount of NOx stored in the catalysts is determined based on operating conditions. Next, in step  318 , a determination is made as to whether the set point has been exceeded on either cylinder group. In other words, a determination is made as to whether either cylinder group is producing higher NOx out of the tailpipe per distance of the vehicle than the set point. In an alternative embodiment, determination is made as to whether the amount of NOx stored in the catalysts of either group is greater than the set point. Further still, a determination as to whether the total NOx exiting the each of the tailpipes per distance of the vehicle exceeds a threshold. When the answer to step  318  is no, the routine repeats. When the answer to step  318  is yes, the routine continues to step  320 . In other words, a determination is made on a per cylinder (or per catalyst) basis to determine if either of the separate exhaust paths” catalysts needs to be operated with a rich exhaust air-fuel ratio. Note that there are various other ways to trigger rich operation, such as, for example, based on catalyst deterioration and a learned catalyst rich operating duration. 
     In Step  320 , both cylinder groups are operated with a rich air-fuel ratio. Then, in step  322 , sensors  170 A and  170 B are read. Then, in step  324 , a determination is made as to whether either sensor downstream of catalysts  72 A and  72 B indicates a rich air-fuel ratio. In other words, a determination is made as to whether an indication has been provided that at least one of the first and second catalysts has depleted the stored oxidants (e.g., NOx and O 2 ). Note that there are various alternatives for providing this indication, such as, for example: whether exhaust oxygen concentration is below a threshold value, whether exhaust hydrocarbon or CO concentration is greater than a threshold value, and various others. For example, one alternative, which operates in a different way and provides different results than the previous alternatives, is to determine whether the integrated amount of reductant exiting a catalyst is greater than a threshold. 
     When an indication is provided in step  324  that either the first or second catalysts has depleted stored oxidants (or an indication that either first or second catalysts should discontinue operation with a rich air-fuel ratio) the routine continues to step  326 . Otherwise, the routine returns to step  322 . 
     In step  326 , the routine operates the cylinder group coupled to the catalyst whose rich operation should end at a near stoichiometric air-fuel ratio, while continuing rich operation of the other cylinder group. In other words, if, for example, an indication is provided that the first catalyst has depleted stored oxidants (or that the first catalyst should no longer be operated rich) the cylinder group coupled to the first catalyst is operated at the near stoichiometric air-fuel ratio, while continuing operation of the other cylinder group at a rich air fuel ratio to continue the releasing and reducing operation of the second catalyst. In this way, break through of reductants (hydrocarbons and carbon monoxide) is minimized, while maintaining optimal operation of each catalyst. Further, engine torque can be maintained at the desired level (and torque imbalance between the cylinder groups minimized) since the additional fuel injected during the rich operation only minimally may increase engine torque. As described below, if this small torque increase is present, ignition timing retard can be used to further maintain engine torque balance between the two cylinder groups. 
     Continuing with FIG. 3, in step  328 , the sensors downstream of the catalyst are read. Then, in step  330 , a determination is made as to whether the other catalyst (i.e., the catalyst that continued rich operation) has depleted oxidant its storage (or whether rich operation of this catalyst should end). As described above, there are various alternative approaches to providing an indication that rich operation of the cylinder group coupled to the other catalysts should be discontinued, and each of this, as well as other alternatives, can again be used here. 
     When the answer to step  330  is no, the routine continues to step  328  and repeats. When the answer to step  330  is yes, rich operation of the other cylinder group is terminated and the routine proceeds to step  332 . At this time, the engine may operate both cylinder groups near stoichiometry, or may return both cylinder groups to lean operation depending on operating conditions as described above in step of  310 . After step  332 , the routine is complete and is exited. 
     Thus, according to the present invention, it is possible to provide synchronous lean operation of the cylinder groups and a synchronized transition between lean to rich operation of both cylinder groups, but, asynchronous termination of the rich operation of the two cylinder groups. In particular, whichever cylinder group is coupled to a catalyst that has substantially depleted (or depleted to a certain amount) its oxidant storage, rich operation of the cylinder group coupled to that catalyst should be terminated. Further, that cylinder group is operated near stoichiometry while the rich cylinder operation of the other cylinder group is continued. In this way, optimal performance of the two catalysts is obtained even when the catalysts have different storage release and efficiency characteristics. Once rich operation of both catalysts should be terminated, the engine is then returned to lean operation, or near stoichiometric operation. 
     As described above, an alternative embodiment uses a set point amount of NOx stored in the catalysts to determine when rich operation should be commenced. In this embodiment, individual catalyst models can be used to determine the NOx storage of each catalyst individually. Also, in step  320 , when the engine cylinder groups are both operated rich of stoichiometry, adjustment of the throttle and exhaust gas recirculation valves can be used along with fuel and spark scheduling to maintain engine torque at a desired level. Also, in step  324 , as described above, there are various alternatives. Additional alternatives can be used depending on the type of exhaust gas sensor placed downstream of catalysts  72 A and  72 B. For example, a HEGO sensor can be used as well as a UEGO sensor can be used. Further as described above, estimation models can be used to determine rich operating times which are adjusted based on feedback from sensors  170 A and  170 B. Also note that if indications are provided simultaneously that rich operation for both cylinder groups should be terminated, then the ending of the rich operation may be synchronized. 
     Example operation according to the present invention is as now described with respect to the graphs in FIGS. 4A and 4B. First, the Figures show that the engines are concurrently being operated lean of stoichiometry. Note that the engines do not need to be operated at the same lean air fuel ratio, which is shown in the Figure. Rather, the engines may be operated at different lean air-fuel ratios. Further, the banks do not have to operate a fixed lean air-fuel ratios as shown in the Figure. Rather, the lean air-fuel ratios can vary over time and operating conditions. Then, at time T 1 , an indication is provided that both cylinder groups should be operated at a rich air-fuel ratio. Again, note that the cylinder groups do not need to be operated at the same rich air-fuel ratio or constant air-fuel ratios. Rather, the rich air-fuel ratios between the groups can vary, as can the rich air-fuel ratio in one of the groups. As with the lean banks, the variation can be based on time or operating conditions. 
     Continuing with the Figure, the indication provided at time T 1  can be based on NOx stored in the catalysts, NOx stored in only one of the catalysts, NOx exiting the tailpipe of the vehicle per distance of the per distance travel, or any other method as described above herein or suggested by this disclosure. In particular, in one example operation according to the present invention, when the amount of estimated NOx stored in one of the catalysts reaches a predetermined limit, both banks are switched to rich operation even though the amount of NOx stored in the other catalyst has not reached a predetermined NOx limit value. 
     Then, at time T 2 , an indication is provided that the catalysts coupled to group  2  should terminate the rich operation. At this time, cylinder group  2  is operated near stoichiometry. Then, at time T 3 , an indication is provided that the catalysts coupled to cylinder group  1  should terminate rich operation. At this time, both cylinder groups are returned to lean operation. Then, at time T 4 , an indication is provided that both cylinder groups should be operated rich. Then, at time T 5 , both cylinder groups simultaneously indicate that the rich operation should be terminated. At this time, both cylinder groups are returned to normal lean operation. Note, as described above, near stoichiometric operation may be selected after termination of the rich operation of both cylinder groups. 
     Note that there are various other alternatives to practicing the present invention, including those described above. Accordingly, it is intended that the present invention be defined only according to the following claims.

Technology Classification (CPC): 5