Abstract:
A method for determining the effectiveness of a catalyst having both first, relatively high oxidizable material provided to remove emissions from the exhaust of an internal combustion engine and a second, relatively low oxidizable material provided to remove emissions from such exhaust. The method includes measure a difference in oxygen content upstream and downstream of the catalyst while the engine is producing the exhaust to determine the effectiveness of the first material and determining the effectiveness of the second material by comparing time delay in a property of the exhaust as such exhaust passes through the catalyst. In one embodiment, the property of the exhaust is the oxygen content in such exhaust. In one embodiment, the effectiveness of the second material is measured after the first material is determined to be ineffective.

Description:
BACKGROUND 
     The present invention relates to a method and system for determining the efficiency of a catalytic converter based on signals generated by pre-catalyst and post-catalyst exhaust gas oxygen sensors. 
     As is known in the art, increasingly stringent federal regulations limit the permissible levels for emissions. As such, vehicle manufacturers have developed various methods to reduce emissions while improving vehicle performance and fuel economy. Catalytic converters, positioned in the engine exhaust path, are often used to reduce emission levels of regulated exhaust gases. The conversion efficiency of a catalytic converter may be monitored using a pre-catalyst O 2  sensor positioned upstream from the catalytic converter and a post-catalyst O 2  sensor positioned downstream from the catalytic converter. 
     One method known for indicating conversion efficiency of the catalyst is to calculate a ratio of downstream sensor transitions or switches to upstream sensor transitions or switches. An increasing switch ratio is generally indicative of a degrading catalyst. When the switch ratio exceeds a threshold value, a malfunction indicator light (MIL) is illuminated so the vehicle operator will seek service. This method of catalyst monitoring is disclosed in Orzel U.S. Pat. No. 5,357,751, assigned to the assignee of the present invention, and is referred to as the Switch Ratio (SR) method. Another method for indicating conversion efficiency of the catalyst is based on the ratio of the arc lengths of the downstream sensor signal to the arc lengths of the upstream sensor signals identified as an Index Ratio (IR) method in contrast to the SR method. This method is disclosed in U.S. Pat. No. 5,899,062, assigned to the assignee of the present invention, and incorporated herein by reference. 
     The test cycle for catalyst monitoring requires collection of data from each of the sensors while the engine is operating in each of a plurality of inducted airflow ranges or air mass (AM) cells. In each method a predetermined number of transitions or switches of the upstream sensor in each AM cell is required to complete the test cycle. These methods rely on AM cell calibration and assume that sensor signal transitions occurring in a defined AM cell are valid for ratio computation regardless of engine speed and load conditions. The determination of SR and IR based on data taken while the driver is operating the vehicle at a high load, low rpm or low load, high rpm condition results in increased SR and IR variability even though operation is within one of the plurality of inducted airflow ranges. The determination of catalyst conversion efficiency based solely on AM conditions may result in error, and may reduce the ability to discriminate between a good and a failed catalyst. 
     A method of detecting catalytic converter deterioration based on the ratio of the arc length or the number of transitions of signals from sensors upstream and downstream of the converter where ratio determination is restricted to predefined air mass ranges within corresponding predefined engine speed/load ranges in order to avoid areas of engine speed and load instability that might impair test to test repeatability of the deterioration detection is described in U.S. Pat. No. 6,195,986 assigned to the assignee of the present invention, and incorporated herein by reference. 
     The inventors have recognized that all presently known methods are designed to monitor total oxygen storage degradation using different upstream to downstream O 2  sensor signal calculations. Oxygen storage can be found in two different catalyst wash coat components: Ceria (cerium oxides) and precious metal. Total oxygen storage availability is a function of the Ceria and precious metal content in wash coat and as well their dispersions and mutual locations (within the wash coat). The high O 2  storage (Ceria) catalyst has been the standard for monitoring starting in circa 1994 model years. Ceria is the weaker link in the wash coat when compared to the precious metal (PM). Ceria degrades sooner than does the PM when exposed to thermal or chemical (phosphorus) degradation. The current production\Index Ratio (IR) catalyst monitor measures the change in the O 2  sensor signal amplitude, as the catalyst ages. The rear O 2  sensor signal increases in activity as the catalyst loses ability to store oxygen. The Index monitor measures the catalyst O 2  storage (ceria) only and infers the emissions. The ratio of the rear O 2  sensor is compared to the front O 2  sensor, as the ratio approaches 1.0 the catalyst failed. 
     During the catalyst monitor calibration process, the emission and catalyst index relationship are established testing differently aged catalyst. The index vs. Tail Pipe FTP emission function typically referred as a “hockey stick curve”. Monitoring the index in the field allows the catalyst “health” or tailpipe emission from catalyst index. (FIG. 1) to be inferred. For the FIG. 1 hockey stick curve, the “slope” is attributed to the loss of O 2  storage that is measured as an increase in the amplitude of the rear, or CMS O 2  sensor signal compared to the amplitude of front O 2  sensor signal. At the knee of the curve, basically all of cerium oxides (oxygen storage) are gone. After the knee the emissions are still increasing but the Index ratio is constant. This flat portion of the “hockey stick curve” is insensitive to the existing catalyst monitor. The real world failure illustrated in FIG. 1 demonstrates a catalyst that has lost it&#39;s ability to storage oxygen (high Index ratio) yet has good emissions. The cerium oxides based oxygen storage is gone (very susceptible phosphorus contamination) while the precious metal based oxygen storage still stay untracked. This catalyst was phosphorous poisoned in the field and turned on the malfunction indicator light (MIL). The concern is that while the catalyst has lost it&#39;s ability to storage oxygen it may still be a very good emission catalyst. No longer is catalyst monitoring limited to a single measurement of O 2  storage. At the knee of the “hockey stick curve” the A/F signal amplitude entering and exiting the catalyst is almost the same. From this time on, the catalyst has no Ceria based O 2  storage. The precious metal(s) (PM) alone continues to degrade but still carry some O 2  storage due to affinity of oxygen and PM. The PM crystals grow larger (degrade) due to thermal aging thus reducing the active surface area and increase the emissions. The exhaust gas residency time or presence next to the active PM sites with some oxygen storage is the detectable (measured) metric, here time delay, τ (tau) or phase shift through the catalyst. On the flat portion of the hockey stick curve τ (tau) is still changing. τ (tau) is the transport delay (time) between the front and rear O 2  signals which measures the change of catalyst activity. As the (no Ce O 2  storage) catalyst degrades the value of τ (tau) decreases (FIG.  2 ). The measurable O 2  sensor signal change for a catalyst as it ages to low or no cerium oxides based oxygen storage is the time constant tau. Tau is the time, or transport, delay between the upstream and downstream ) O 2  sensor signals. Tau or time delay varies at different rpm, loads, air mass and monitor volume for a given aged catalyst. However, τ decreases over time as the catalyst ages. 
     To put it another way, the inventors have recognized that the are two different types of material in the converter: one highly oxidizable (e.g., Ceria); and the other relatively less oxidizable. Thus, while increases in the amplitude of the oxygen sensed by the downstream converter indicates deterioration in the oxidizable material, and therefore its loss of effectiveness, there may still be effectiveness in the less oxidizable material performing the requisite emission reductions. Applicants further recognized that the effectiveness of the less oxidizable material may be measured by measuring the time delay, or phase shift, between the signals produced by the upstream and downstream sensors. Thus, the applicants have determined that the effectiveness of each of the oxidizable and relatively non-oxidizable materials in the catalytic converter (i.e., the materials making up the catalyst) can be separately evaluated (i.e., measured independently); the former by the relative amplitudes between the oxygen before and after the catalyst; and, the latter by some other measurable parameter, such as time delay through the catalyst. 
     SUMMARY 
     In accordance with the present invention a method is provided for determining the effectiveness of a catalyst having both first, relatively high oxidizable material provided to remove emissions from the exhaust of an internal combustion engine and a second, relatively low oxidizable material provided to remove emissions from such exhaust. The method includes measure a difference in oxygen content upstream and downstream of the catalyst while the engine is producing the exhaust to determine the effectiveness of the first material and determining the effectiveness of the second material by comparing time delay in a property of the exhaust as such exhaust passes through the catalyst. 
     In one embodiment, the property of the exhaust is the oxygen content in such exhaust. 
     In one embodiment, the effectiveness of the second material is measured after the first material is determined to be ineffective. 
     In accordance with the present invention, a method is provided for monitoring efficiency of a catalytic converter during operation of an internal combustion engine coupled to the catalytic converter as exhaust from the engine passes through such converter. The method includes measuring an upstream time history of oxygen content of the exhaust upstream of the converter and a downstream time history of oxygen content of the exhaust downstream of the converter. The difference in such measured amplitudes is determined. A determination is made when the determined difference is less than a predetermined value indicating potential ineffectiveness of the converter. A time, or transport delay is determined between the upstream time history and the downstream time history. The determined time delay is compared with a reference time delay to determine the efficiency of the converter. The converter is determined to be ineffective if the converter as been determined to be potentially ineffective and the time delay is determined to be less than the reference time delay. 
     In one embodiment the converter includes an oxidizable material and a precious metal material. 
     A determination is made when the measured upstream first property and the measured downstream first property differ by a first predetermined value indicating potential ineffectiveness of the converter. An upstream time history of a second property of the exhaust upstream of the converter and a downstream time history of the second property of the exhaust downstream of the converter is measured. A determination is made when the measured upstream second property and the measured downstream second property differ by a second predetermined value. A determination is made when the measured upstream second and the measured downstream second property differ by a second predetermined value. A determination is made that the catalyst is ineffective if the catalyst has been determined to be potentially ineffective and the measured upstream second and the measured downstream second property differ by the second predetermined value. 
     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
    
    
     DESCRIPTION OF DRAWINGS 
     FIG. 1 is a curve showing the relationship between emissions downstream of a catalytic converter and a ratio related to oxygen in the exhaust measured upstream of the converter to oxygen content measured downstream of the converter; 
     FIG. 2 shows relationship between an upstream time history of a property, here time, or transport delay, or time delay τ between an upstream time history and the downstream time history of a property, here oxygen content, of the exhaust as a function of engine rpm, engine load and catalyst efficiency; 
     FIG. 3 is a block diagram of a system for monitoring catalytic converter effectiveness according to the invention; 
     FIGS. 4A is a graph of a signal produced by an upstream exhaust gas sensor as a function of time; 
     FIG. 4B is a graph of a signal produced by a downstream exhaust gas sensor for a catalytic converter having a high exhaust gas conversion efficiency; 
     FIG. 4C as graph of a signal produced by a downstream exhaust gas sensor for a catalytic converter more aged than the converter producing the signal shown in FIG. 4B; 
     FIG. 5 are curves, the upper curve showing the time history of the upstream exhaust gas oxygen sensor of the a catalytic converter and the lower curve showing the time history of the downstream exhaust gas oxygen sensor of the same catalytic converter, such curves being shown with the same time reference; 
     FIGS. 6A-6C are curves useful in understanding a method for determining time delay between the upstream exhaust oxygen sensor and an exhaust gas oxygen sensor downstream of a catalyst being monitored; FIG. 6A showing the time history of the upstream sensor; FIG. 6B showing the time history of the downstream sensor for a good catalytic converter and FIG. 6C showing the time history of the downstream sensor for a good catalytic converter; and 
     FIG. 7 is a flow diagram of the method for evaluating the effectiveness of a catalytic converter according to the invention. 
     Like reference symbols in the various drawings indicate like elements. 
    
    
     DETAILED DESCRIPTION 
     Referring now to FIG. 3, a block diagram illustrating a system for monitoring performance or conversion efficiency of a catalytic converter is shown. System  10  includes an internal combustion engine  12  having an intake manifold  14  and exhaust manifold  16 . Airflow through intake manifold  14  is measured by mass air flow (MAF) sensor  18  and regulated by throttle valve  20 . A throttle position sensor  22  provides a signal (TPS) indicative of position of throttle valve  20  or an associated accelerator pedal  24 . A conventional fuel supply  26  provides fuel which is mixed with the air in intake manifold  14  to provide a combustion mixture which is controlled by an engine controller, such as Engine Control Module (ECM)  28 . An engine coolant temperature sensor  30 , and an engine speed (RPM) sensor  32  communicates engine temperature and engine speed information respectively to the ECM  28 . ECM  28  may also perform control and monitoring functions for various vehicle systems and subsystems in addition to controlling and monitoring engine  12 . 
     An exhaust pipe  34  couples a catalytic converter  36 , preferably a three-way converter (TWC) to the exhaust stream of engine  12 . Catalytic converter  36  is monitored via an upstream (front) exhaust gas sensor  38  and a downstream (rear) exhaust gas sensor  40  each in communication with the engine controller  28 . Upstream sensor  38  is located between engine  12  and catalytic converter  36  whereas downstream sensor  40  is located between catalytic converter  36  and the atmosphere. Upstream sensor  38  is preferably an exhaust gas oxygen sensor, commonly referred to as a HEGO sensor, which provides an indication of presence or absence of oxygen in the exhaust stream. Downstream sensor  40  operates in a similar fashion as upstream sensor  38  but is commonly referred to as a catalyst monitor sensor (CMS) due to its intended function in the exhaust system. Any of a number of exhaust gas sensors may be utilized including lambda sensors, proportional oxygen sensors, and the like, to determine conversion efficiency of the converter according to the present invention. A catalytic converter temperature sensor  42  provides data to the ECM  28  regarding converter temperature. Alternatively, the converter temperature may be inferred, from other sensor data in order to avoid the cost of an additional dedicated temperature sensor. Various other sensors communicate with ECM  28  to facilitate control and monitoring functions. These sensors may include an EGR sensor or other device for exhaust gas recirculation monitoring. 
     The ECM  28  includes a microprocessor and various computer readable storage media, which may include but is not limited to a read only memory (ROM), a random access memory (RAM), and a keep-alive memory (KAM). The computer readable storage media may be implemented by any of a number of known volatile and nonvolatile storage devices including but not limited to PROM, EPROM, EEPROM, flash memory, and the like, all of which are well known in the art. RAM is typically used for temporary data storage of various operating variables which are lost when the engine ignition is turned off, such as counters, timers, status flags, and the like. KAM is generally used to store learned or adaptive values which may change over time. The contents of KAM are maintained as long as some power is provided to ECM  28 . Preferably, one or more ROMs within ECM  28  contains control logic implemented by program instructions executed by the microprocessor along with various system parameter values and calibrations. 
     The ECM  28  receives signals from upstream and downstream exhaust gas sensors  38  and  40 , respectively, which reflect current operating conditions of engine  12  and converter  36 . For example, when at or above operating temperature, upstream sensor  38  provides a continuous signal (preferably a voltage) to ECM  28  based on the presence or absence of oxygen in exhaust pipe  34 . The voltage signal is indicative of the excursion from the stoichiometric combustion mixture of the exhaust gases in exhaust manifold  16 . The upstream sensor signal is a two-state signal having a predetermined high voltage when exhaust gases indicate a rich mixture and a predetermined low voltage when exhaust gases indicate a lean mixture. Downstream sensor  40  monitors catalytic converter  36  by detecting the presence or absence of oxygen downstream from converter  36  and provides a voltage signal to ECM  28 . 
     The ECM  28  uses control logic implemented in hardware and/or software to generate various signals to control and monitor operation of engine  12 . For example, controller  28  generates an output signal to electronic fuel injectors, represented by fuel supply  24 , to control the quantity and timing of fuel delivered to engine  12  in response to a feedback variable derived from an output of the upstream sensor  38 . 
     In the present invention, the ECM  28  is also used to monitor performance of catalytic converter  36  using the signals from upstream sensor  38  and downstream sensor  40 . The sensor signals are filtered, periodically sampled, and stored within ECM  28  to monitor performance of catalytic converter  36 . The amplitude variation or excursion of the signal of the downstream sensor  40  is much less than that of the signal from the upstream sensor  38  due to the operation of the catalytic converter in converting the exhaust gases. As such, catalyst monitors that rely on amplitude variation of the downstream sensor signal are less sensitive to variations induced by catalyst degradation. In contrast, the index ratio metric is based on the arc-length of the signal and the incorporation of a time-based or horizontal component of the sensor signal produces superior sensitivity as explained in the aforementioned U.S. Pat. No. 6,195,986. 
     Referring now to FIGS. 4A-4C, representative voltage signals generated by sensors  38  and  40  are shown. FIG. 4A illustrates an upstream voltage signal  38 ′ from HEGO sensor  38  as a function of time. The voltage  38 ′ from upstream sensor  38  oscillates through a switch point of 0.45 volts between a high voltage and a low voltage in response to the combustion mixture oscillating about the stoichiometric ratio during closed loop control. 
     FIG. 4B shows a representative voltage  40 ′ from downstream sensor  40  as a function of time for a catalyst having a relatively high conversion efficiency. Although the frequency of downstream signal  40 ′ is the same as the frequency of upstream signal  38 ′, downstream signal  40 ′ has a much different variation in amplitude than upstream signal  38 ′ and is time delayed due to the propagation delay of exhaust gases passing through the converter  36 . The amplitude variation or excursion of downstream signal  40 ′ is much less than that of upstream signal  38 ′ to the operation of the catalytic converter in converting the exhaust gases. As such described in the above referenced U.S. Pat. No. 5,899,062, the arc length measuring and ratio method described therein incorporates the time-based or horizontal component of the sensor signal into the catalyst efficiency indicator. 
     FIG. 4C illustrates a representative downstream voltage signal  40 ″ provided by CMS sensor  40  as a function of time. In this case, the amplitude variation of downstream signal  40 ″ is much greater than the variation of downstream signal  40 ′ because the Cerium oxides in the catalyst  36  has be highly oxidized and no longer “absorbs” (i.e., reacts with) oxygen in the exhaust fed to the catalyst. Thus, the arc length ratio described in U.S. Pat. No. 5,899,062 is nearly unity. Detection of this nearly unity arc length ratio while indicating that the Cerium oxides are no longer effective in reducing emissions, does not provide any indication as to whether the precious metals in the catalyst  36  are effective in reducing emissions to within governmental regulations. 
     Applicants have recognized that detection of the time delay through the catalyst of the signals produced by the upstream and downstream sensors  38  and  40  provides a measure of the effectiveness of the precious metals reduction of emissions. 
     More particularly, referring to FIGS. 4A-4C as noted above FIG. 4B shows the voltage produced by the downstream sensor  40  after the Ceruim has lost its effectiveness. Under such condition, there is a reduction in the time delay between the signals produced by the upstream and downstream sensors. Applicants have measured the time delay between such upstream and downstream signal using a new, or green catalyst “poisoned” by phosphorous to remove any emission removal effectiveness of the Cerium oxides. Applicants have determined that this green, or new catalyst is still able to reduce emissions to acceptable levels because of the precious metals in the catalyst. They first measure the time delay of the green but poisoned catalyst, here τ 0 . After many additional hours of use, this now aged catalyst has its emission reduction effectiveness measured along with the time delay between the upstream and downstream sensor  38 ,  40  output signal. The process continued until the catalyst is no longer effective, i.e., the precious metals have lost their effectiveness in removing emissions such that the catalyst no longer met governmental requirement. At this time, the time delay τ 1 , between the upstream and downstream sensors  38 ,  40  is measured. This measured time delay τ 1  becomes a measure of a minimum time delay threshold such that if the actual time delay of a catalyst falls below this level τ 1 , the catalyst is deemed to be ineffective and the MIL is activated. 
     The time delay may be determined a number of different ways. Here, the arc length ratio method described in the above referenced U.S. Pat. No. 5,899,062 is used to measure the effectiveness of the catalyst. Thus, the voltages of the sensors shown in FIGS. 4A and 4B are sampled at regularly known sample times. After the arc length ratio indicates that there is substantially little change in the relationship between the amplitude time history of the upstream sensor  38  output voltage and the downstream sensor  40  output voltage (i.e., the Ceria is no longer effective), the ECM  28  computes, from samples which are continued to be taken, the time delay τ. It is noted that the measurements are performed during a known rpm/load condition, here for example, an idle condition. 
     Thus, referring to FIG. 5, the upper curve shows the time history of the output of the upstream sensor  38  while the lower curve shows, on the same time base, the time history of the downstream sensor  40 . Here samples are shown by the dots in the FIG.  5 . The ECM  28  detects when the voltage goes through a set point level, here for example 0.45 volts. The ECM  28  stores the voltages before and after passing through the set point level and records the times associated with such voltage levels. (Reference is made to U.S. Pat. No. 5,544,481 Davey et al, assigned to the same assignee as the present invention, the entire subject matter thereof being incorporated herein by reference). Thus, here the upstream voltages passes through the 0.45 set point level between times t 1 , and t 2 . The voltage of upstream sensor  38  at time t 1 , here U 1 , is stored in the ECM and the voltage U 2  of the upstream sensor  38  at time t 2  is stored in the ECM. The output of the downstream sensor  40  is also monitored . When the voltage of the downstream sensor  40  falls below the same set point here 0.45 volts after the upstream sensor  38  fell through such set point, here between the times t 3  and t 4 , the voltages at times t 3  and t 4 , here D 1  and D 2 , respectively, are stored in the ECM. A computation of τt is made in the ECM in accordance with:        τ   =     {       (       t   3     +                D   1     -   4.5                   D   2     -     D   1              *            t   4     -     t   3                )     -     (     (       t   1     +                U   1     -   4.5                   U   2     -     U   1              *            t   2     -     t   1                )     }                                
     The ECM determines when the computed τ is less than the minimum time delay threshold described above and if the actual time delay of a catalyst falls below this level τ 1 , the MIL is activated. 
     Another method for determining time delay between the upstream and downstream sensor signals using the arc length data obtained and used for evaluating the effectiveness of the ceria will be described in connection with FIGS. 6A-6C. Thus, here the arc length of the upstream sensor signal is measured as such signal passes between a maximum, here at time t a  and a minimum, here at time t b . The arc length of the signal from the downstream sensor is measured beginning at a time t c  such downstream signal reaches a maximum until the upstream signal indicates that it ha reached its minimum here at time t b . The time delay t is t b −t c . 
     Referring now to FIG. 7 the method described above is summarized in the flow diagram shown, Thus, when the engine is at some predetermined operating condition, here idle the test is performed (Step  702 ). First a comparison is made between the signals produced by the upstream and downstream oxygen exhaust sensors and the ECM processes such signal to determine the oxygen ratio of the oxygen in the downstream of the converter to the oxygen in the exhaust upstream of the converter. If the ratio is less than a predetermined threshold (Step  796 ), the converter is effective and the process continues to make such comparison (returns to Step  704 ). If, on the other hand the ratio is less than the threshold, the time delay between the upstream and downstream oxygen exhaust sensors is measured (Step  708 ). If the measured time delay is greater than a predetermined threshold, the time delay measurement continues. On the other hand if the time delay is less than such predetermined threshold, the catalytic converter is deemed ineffective and the MIL is activated. 
     A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.