Patent ID: 12247512

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising.” “including.” and “having.” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The terms “first,” “second,” “third,” etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

In this application, including the definitions below, the term “module” may be replaced with the term “circuit.” The term “module” may refer to, be part of, or include an Application Specific Integrated Circuit (ASIC): a digital, analog, or mixed analog/digital discrete circuit: a digital, analog, or mixed analog/digital integrated circuit: a combinational logic circuit: a field programmable gate array (FPGA): a processor (shared, dedicated, or group) that executes code: memory (shared, dedicated, or group) that stores code executed by a processor: other suitable hardware components that provide the described functionality: or a combination of some or all of the above, such as in a system-on-chip.

The term “code,” as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, and/or objects. The term “shared processor” encompasses a single processor that executes some or all code from multiple modules. The term “group processor” encompasses a processor that, in combination with additional processors, executes some or all code from one or more modules. The term “shared memory” encompasses a single memory that stores some or all code from multiple modules. The term “group memory” encompasses a memory that, in combination with additional memories, stores some or all code from one or more modules. The term “memory” may be a subset of the term “computer-readable medium.” The term “computer-readable medium” does not encompass transitory electrical and electromagnetic signals propagating through a medium, and may therefore be considered tangible and non-transitory memory. Non-limiting examples of a non-transitory memory include a tangible computer readable medium including a nonvolatile memory, magnetic storage, and optical storage.

The apparatuses and methods described in this application may be partially or fully implemented by one or more computer programs executed by one or more processors. The computer programs include processor-executable instructions that are stored on at least one non-transitory tangible computer readable medium. The computer programs may also include and/or rely on stored data.

A software application (i.e., a software resource) may refer to computer software that causes a computing device to perform a task. In some examples, a software application may be referred to as an “application,” an “app.” or a “program.” Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

The non-transitory memory may be physical devices used to store programs (e.g., sequences of instructions) or data (e.g., program state information) on a temporary or permanent basis for use by a computing device. The non-transitory memory may be volatile and/or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM)/programmable read-only memory (PROM)/erasable programmable read-only memory (EPROM)/electronically erasable programmable read-only memory (EEPROM) (e.g., typically used for firmware, such as boot programs). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM) as well as disks or tapes.

These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, non-transitory computer readable medium, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor.

Various implementations of the systems and techniques described herein can be realized in digital electronic and/or optical circuitry, integrated circuitry, specially designed ASICS (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

The processes and logic flows described in this specification can be performed by one or more programmable processors, also referred to as data processing hardware, executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by special purpose logic circuitry. e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit). Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data. e.g., magnetic, magneto optical disks, or optical disks. However, a computer need not have such devices. Computer readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks: magneto optical disks; and CD ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

To provide for interaction with a user, one or more aspects of the disclosure can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touch screen for displaying information to the user and optionally a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide interaction with a user as well: for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to and receiving documents from a device that is used by the user: for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.

Referring toFIGS.1-4, a vehicle100includes an engine system102controlled by an anti-lag controlled ignition system10that is configured to model oxidation within the engine system102to harness heat within the engine system102and improve the speed of the vehicle100, as described in more detail below: The engine system102includes a turbocharger104fluidly coupled with cylinders106and an exhaust manifold108. The engine system102cycles a fuel mixture110ato be burned, primarily, in the cylinders106to produce exhaust gas110. The fuel mixture110aincludes a combination of fuel and air. The exhaust gas110may contain the residual fuel mixture110aincluding residual fuel and air that passes from the cylinders106to the exhaust manifold108. Ultimately, the exhaust gas110is directed toward a turbine112of the turbocharger104, which is configured to extract energy, or enthalpy, to power a compressor114of the turbocharger104.

The residual fuel mixture110aincluding residual fuel and air of the exhaust gas110may be harnessed by the engine system102to generate additional, free energy for the turbine112by burning the oxidizable component of exhaust gas110within the exhaust manifold108, as described herein. This process results in increased energy available for the turbine112of the turbocharger104and, thus, provides the turbine112with maximized energy capture to power the compressor114. The burning of the exhaust gas110within the exhaust manifold108, described in more detail below, is determined by the anti-lag controlled ignition system10through modeling of oxidation within the exhaust manifold108. The harnessing of the exhaust gas110within the exhaust manifold108may provide an added advantage of improving the overall combustion efficiency of the engine system102by maximizing the combustion potential of the exhaust gas within the engine system102.

With further reference toFIGS.1-3, the engine system102may be calibrated with an electronic control unit (ECU)12of the vehicle100that is utilized as part of the anti-lag controlled ignition system10. The ECU12includes data processing hardware14and memory hardware16that cooperate with sensors116of the engine system102to gather engine data18. For example, the ECU12monitors a fuel mass that is utilized within the engine system102and determines a volume of exhaust gas110within the engine system102after in-cylinder combustion. The volume of exhaust gas110may include an exhaust equivalence ratio120, described below; that may reflect the residual fuel mixture110a(i.e., residual fuel and air) of the exhaust gas110.

The ECU12also monitors, via the engine data18, a flow rate122and gas temperature124of the exhaust gas110. The sensors116also detect a wall temperature126of the exhaust manifold108. Each of the heat release118, the equivalence ratio120, the flow rate122, the gas temperature124, and the wall temperature126may be categorized as the engine data18captured by the sensors116and stored in the memory hardware16of the ECU12. The gas temperature124and the wall temperature126may collectively be stored as temperature data128within the memory hardware16. The memory hardware16may be regularly updated with the engine data18during operation of the engine system102via the data processing hardware14.

Referring still toFIGS.1-3, the fuel mixture110ais initially combusted within the cylinders106, which results in the heat release118from the in-cylinder combustion. The heat release118may be dependent upon the chemical composition of the exhaust gas110in the cylinders106and, subsequently, the exhaust manifold108. While a majority of the fuel mixture110ais combusted, or burned, within the cylinders106, the exhaust gas110expelled from the cylinders106may contain some residual fuel mixture110a, as mentioned above. The residual fuel mixture110ais calculated via the ECU12, after combustion within the cylinders106, to determine the equivalence ratio120. The equivalence ratio120reflects the stoichiometric condition of the exhaust gas110and is utilized by the anti-lag controlled ignition system10to model the oxidation within the exhaust manifold108, described in more detail below: In addition to the equivalence ratio120, the anti-lag controlled ignition system10may also receive oxidation data130from the ECU12. The oxidation data130is related to the residual air contained in the exhaust gas110and may be used by the anti-lag controlled ignition system10when modeling the oxidation within the exhaust manifold108.

The exhaust manifold108has a high temperature associated with the metallic composition of the walls of the exhaust manifold108. The high temperature of the exhaust manifold108is captured as the wall temperature126, mentioned above, and may be monitored for a peak temperature. As a result of the high temperature, the exhaust gas110may undergo additional combustion reactions within the exhaust manifold108, which is determined by the anti-lag controlled ignition system10and executed by the ECU12. The anti-lag controlled ignition system10utilizes the exhaust manifold108to achieve complete combustion of the residual fuel mixture110aof the exhaust gas110by reacting with the residual air (i.e., oxygen) and harnessing the wall temperature126of the exhaust manifold108for activation energy.

An engine system model42utilizes a kinetics reaction mechanism20to evaluate a performance of the engine system102while solving for the oxidation of the exhaust gas110at a correlated level of fidelity to the engine data18based on the wall temperature126, the gas temperature124, the residual fuel and oxygen110a, and the equivalence ratio120of the exhaust gas110. The calibration tables22may be generated by various physics-based predictive models that may correlate the gas temperature124and the wall temperature126, as well as unseen data. In addition, the anti-lag controlled ignition system10utilizes the flow rate122of the exhaust gas110to determine an airflow24within the exhaust manifold108for optimized, complete combustion. The exhaust gas110, including the residual fuel mixture110a(i.e., residual fuel and air), is burned within the exhaust manifold108based on calibration tables22generated as part of the anti-lag controlled ignition system10, described below; to achieve complete combustion.

With reference toFIGS.2-4, the anti-lag controlled ignition system10further includes a virtual optimization system40that is configured to generate the calibration tables22for the ECU12and engine system102. The virtual optimization system40includes the exhaust system model42that may be utilized to generate the calibration tables22based on the engine data18received from the ECU12. In other examples, the exhaust system model42may receive the engine data18from an engine performance model, which is physics-based and predictive. In one example illustrated inFIG.4, the exhaust system model42receives the equivalence ratio120, the gas temperature124, and the flow rate122of the exhaust gas110. The exhaust system model42is configured to determine an optimized combustion of the exhaust gas110within the exhaust manifold108based on the engine data18. In addition, the exhaust system model42utilizes the oxidation data130, the wall temperature126of the exhaust manifold108, and a desired speed output of the turbocharger104.

The exhaust system model42may be developed by the virtual optimization system40) as a three-dimensional model that may be blocked into one-dimension to capture the interface between the exhaust gas110and the exhaust manifold108. For example, the virtual optimization system40may utilize a three-dimensional or one-dimensional computational fluid dynamics code with a conjugate heat transfer model to solve for a target exhaust gas flow rate, thermodynamic performance, and structural temperatures. The virtual optimization system40is configured to, ultimately, provide a one-dimensional exhaust system model42designed to imitate a detailed chemical kinetic mechanism of the engine system102to provide time-feasible control designs and feedback via the calibration tables22. Thus, the one-dimensional exhaust system model42imitates a more detailed mechanism by using a smaller, even single-step, mechanism to an acceptable approximation of the detailed results. In developing the calibration tables22, the exhaust system model42determines a burn duration of the exhaust gas110relative to a defined temperature.

The defined temperature may, in some examples, correspond to the wall temperature126of the exhaust manifold108. The burn duration of the exhaust gas110may be modeled relative to the wall temperature126on a log scale versus the reciprocal of the wall temperature126to define a linear trend. Thus, the exhaust system model42may have a correlation of auto-ignition time based on the modeled burn duration. The correlation and the modeled burn duration may be incorporated as part of one or more of the calibration tables22for use with the engine system102via the ECU12, as described below: The modeled burn duration incorporated in the calibration tables22may assist in reducing the real-time reaction mechanism of the engine system102, which may assist in maximizing the speed of the engine system102as a whole.

The exhaust system model42may further utilize the temperature data128to control the conditions of the heat release118by, for example, comparing the equivalence ratio120) with the temperature data128and the flow rate122of the exhaust gas110. For example, the exhaust system model42may identify a viable temperature for post-cylinder oxidation from the temperature data128of the exhaust manifold108, which may be utilized in generating a calibration table22that includes combustion control parameters44. The calibration table22may also include exhaust manifold temperature estimations based, at least in part, on the wall temperature of the exhaust manifold108received from the ECU12. The calibration tables22are provided to the ECU12from the virtual optimization system40for execution by the engine system102within the exhaust manifold108, pre-turbine112.

Thus, the engine system102may execute additional heat release118within the exhaust manifold108before the exhaust gas110reaches the turbine112of the turbocharger104. The added heat release118advantageously increases the energy available for the turbocharger104. Thus, the turbine112has increased energy available, which results in an anti-lag effect and increased efficiency of the engine system102. The engine system102utilizes the added energy resulting from the burning of the exhaust gas110within the exhaust manifold108to sustain the reactions within the engine system102and control an instantaneous manifold energy to a limiting target temperature126aof the exhaust manifold108. For example, the temperature126of the exhaust manifold108decreases over time, so the engine system102is calibrated, via the calibration tables22, to operate to a minimum limited target temperature126aof the exhaust manifold108. The limited target temperature126agenerally corresponds to the wall temperature126of the exhaust manifold108as the exhaust manifold108cools after the in-cylinder106combustion.

With further reference toFIGS.2-4, the engine system102is repeatedly calibrated by the ECU12based on the calibration tables22generated by the exhaust system model42in the virtual optimization system40of the anti-lag controlled ignition system10. The calibration tables22may include calibrations for various aspects of the engine system102including, but not limited to, injector calibrations, cam calibrations, and spark calibrations. The calibration tables22are utilized for combustion control within the exhaust manifold108by predicting an exotherm from excess or stoichiometric fueling conditions of the engine system102. For example, the injector and cam calibrations may be utilized to control kinetically limited open flow reactions within the exhaust manifold108and cylinders106by targeting a range of gas temperatures124of the exhaust gas110and wall temperatures126of the exhaust manifold108. The spark calibrations may be utilized to control the gas temperature124of the exhaust gas110after the in-cylinder combustion and entering the exhaust manifold108. By calibrating the sparks, a pumping and mixing of the engine system102can be maintained while achieving the anti-lag function through burning of the exhaust gas110within the exhaust manifold108.

The integration of the calibration tables22with the ECU12and the engine system improves the performance of the turbocharger104by increasing the overall speed of the turbocharger104. For example, the turbocharger104may resume a boosting effect faster based upon the wall temperature126of the exhaust manifold108. The exhaust system model42can be utilized to estimate various conditions of the engine system102to identify an optimized burn duration of the exhaust gas110and heat release118from one or both of the in-cylinder combustion and the exhaust manifold108. In some examples, when the exhaust gas110is in a single environment for a period of time, the exhaust gas110releases a cumulative amount of enthalpy.

In execution, the one-dimensional application of the exhaust system model42would utilize dithering spark and inversely dithering a command airflow ratio for one or more cylinders106opposite another cylinder106. In some three-dimensional examples, with respect to a multi-phase injection, a stratified charge can shift the combustion reaction by controlling the equivalence ratio120in the cylinder106. Thus, the stratified charge may, through an exhaust stroke, promote mixing of the unburnt charge for oxidation in the exhaust manifold108based on the wall temperature126and the flow rates122. This one-dimensional exhaust system model42would assist in maintaining a global stoichiometry for the engine system102. The variances between the cylinders106utilizing the command airflow ratio and the global stoichiometry collectively assists in defining a target mixture composition46of the exhaust gas110and added airflow within the engine system102. The target mixture composition46is designed by the exhaust system model42to promote additional heat release118within the exhaust manifold108to maximize the energy available to the turbine112of the turbocharger104. For example, the additional heat release118assists in maintaining the energy available for the turbine112.

Referring still toFIGS.2-4, the engine system102is designed and calibrated by the ECU12based on the wall temperature126of the exhaust manifold108. The wall temperature126should be sufficiently high so as to execute an auto-ignition and have a chemical-based oxidation of the residual fuel mixture110awithin the exhaust manifold108. The exhaust system model42is configured to model the oxidation data130associated with the oxidation of the residual fuel mixture110a. The calibration table22including the modeled oxidation data130is configured to reduce lag of the turbocharger104by using the modeled oxidation data130to maximize the amount of exhaust gas110burned in the exhaust manifold108. The generated calibration tables22from the exhaust system model42provide the engine system102with the capability to continually, nominally increase the turbo-speed generated by the turbocharger104. Thus, the increased turbo-speed is achieved through the oxidation within the exhaust manifold108during which the residual oxygen within the fuel mixture110ais burned.

The calibration tables22are loaded onto the ECU12from the virtual optimization system40as part of the anti-lag controlled ignition system10. The calibration tables22provide the ECU12with instructions and strategies to be executed using the engine system102. The calibration tables22may be stored in the memory hardware16of the ECU12and may be leveraged by the data processing hardware14for implementation into the engine system102. For example, the calibration tables22may provide a spark-fuel-injection strategy48that may be executed by the engine system102. The calibration tables22are configured to provide the engine system102with a method of increased fuel combustion by leveraging the wall temperature126of the exhaust manifold108to burn the exhaust gas110within the exhaust manifold108using one or more strategies48, such as the spark-fuel-injection strategy48.

Thus, the ECU12, through execution of one or more of the calibration tables22, is configured to leverage the exhaust manifold108as an ignition source. The cylinders106are utilized as a primary ignition source of the engine system102, as generally described above, and the exhaust manifold108may supplement the cylinders106by burning the residual fuel mixture110a(i.e., residual fuel and air). For example, the ECU12may execute enthalpy calibrations using one or more of the calibration tables22to specify the burning of the exhaust gas110within the exhaust manifold108until the defined limited target temperature126ais reached. During operation of the engine system102, the wall temperature126of the exhaust manifold108reaches such high temperatures that the engine system102is able to achieve near complete combustion of the residual fuel mixture110aof the exhaust gas110.

With reference again toFIGS.1-5, an example flow diagram of the anti-lag controlled ignition system10is illustrated. At400, the exhaust system model42gathers the engine data18from the engine system102via the ECU12. The virtual optimization system40receives the engine data18and executes, at402, the exhaust system model42for the anti-lag controlled ignition system10. The exhaust system model42generates, at404, calibration tables22for the engine system102, and the ECU12, at406, enables the calibration tables22to be used with the engine system102. The ECU12, at408, can select the calibration table22that will maximize the turbo-speed based on the engine data18. As a result, the anti-lag controlled ignition system10provides, at410, excess enthalpy to the turbocharger104resulting in the maximized turbo-speed.

The anti-lag controlled ignition system10is advantageously designed to minimize lag associated with the turbocharger104and may also increase the overall efficiency of the engine system102as a result. The minimized lag of the turbocharger104is achieved by the virtual optimization system40executing the exhaust system model42. Specifically, the modeling of the oxidation data130from the exhaust manifold108pertaining to the exhaust gas110is utilized in generating the calibration tables22. The generated calibration tables22are incorporated into the ECU12and may be stored in the memory hardware16. Thus, the calibration tables22are static tables incorporated into the ECU12. While the calibration tables22are pre-executed by the exhaust system model42, if there was a physical temperature measurement as feedback, a closed-loop control routine may be utilized to learn potential offsets that may be unique to the engine system102(i.e., unique injector performance or component aging, such as spark plug fowling or electrode gap growth).

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.