Spark plug fouling detection for ignition system

Patent metadata

Field	Value
Publication number	US-10054101-B2
Application number	US-201715722867-A
Country	US
Kind code	B2
Filing date	Oct 2, 2017
Priority date	Dec 19, 2013
Publication date	Aug 21, 2018
Grant date	Aug 21, 2018

Abstract

Methods and systems are provided for determining a type of spark plug fouling. In one example, a method may include differentiating spark plug fouling due to soot accumulation from spark plug fouling due to fuel additive accumulation based on a current on a control wire of the spark plug following application of a dwell command. Further, exhaust oxygen sensor degradation and/or exhaust catalyst degradation may be determined based on switching frequencies of one or more exhaust oxygen sensors and the type of spark plug fouling.

First claim

The invention claimed is:

1. A method for an engine comprising:
for each combustion event of a cylinder of the engine, outputting a dwell command on a control wire of a spark plug ignition coil; estimating an ignition current switching time taken for a current of the control wire to drop below a pre-determined value; counting a fraction of combustion cycles of the cylinder over a given vehicle drive cycle that have the ignition current switching time longer than a threshold duration; and indicating fouling of the cylinder's spark plug due to fuel additive accumulation on the spark plug based on the fraction being larger than a threshold percentage.

2. The method of claim 1 , further comprising estimating an average ignition current switching time for the cylinder over a number of combustion cycles of the given vehicle drive cycle.

3. The method of claim 2 , further comprising, in response to the estimated average ignition current switching time being longer than a threshold time, indicating spark plug fouling due to fuel additive accumulation on the spark plug of the cylinder.

4. The method of claim 3 , wherein the duration is a threshold duration based on the dwell command applied and an operational status of a current sink.

5. The method of claim 3 , wherein the threshold percentage is based on an average percentage in an engine operating with a fuel not including fuel additives.

6. The method of claim 3 , further comprising operating with the fraction smaller than the threshold percentage, and in response to the fraction being smaller than the threshold percentage, increasing an engine idling speed and engine load, and advancing spark ignition timing of the cylinder to maintain a tip temperature of the spark plug above a threshold temperature for a threshold duration.

7. The method of claim 6 , further comprising; after the threshold duration, reassessing the fraction of combustion cycles of the cylinder.

8. The method of claim 7 , further comprising in response to the reassessed fraction being smaller than the threshold percentage, indicating spark plug fouling due to soot accumulation.

9. The method of claim 1 , further comprising, in response to the indication of spark plug fouling due to fuel additive accumulation, decreasing an engine load, and disabling fuel and spark for an adjacent cylinder configured to receive exhaust residuals from the cylinder coupled to the fouled spark plug.

10. The method of claim 1 , further comprising estimating a response time of an exhaust oxygen sensor coupled upstream of an exhaust catalyst.

11. The method of claim 10 , further comprising, based on the estimated response time being lower than a threshold, indicating degradation of the exhaust oxygen sensor due to fuel additive accumulation and confirming spark plug fouling due to fuel additive accumulation.

12. The method of claim 1 , wherein the engine is a boosted engine.

13. The method of claim 1 , wherein the engine is a direct injection fueled engine.

14. A method for an engine comprising:
boosting intake air delivered to the engine with a turbocharger; and
for each combustion event of a cylinder of the engine, direct injecting fuel to the engine and outputting a dwell command on a control wire of a spark plug ignition coil; estimating an ignition current switching time taken for a current of the control wire to drop below a pre-determined value; counting a fraction of combustion cycles of the cylinder over a given vehicle drive cycle that have the ignition current switching time longer than a threshold duration; and indicating fouling of the cylinder's spark plug due to fuel additive accumulation on the spark plug based on the fraction being larger than a threshold percentage.

15. The method of claim 14 , further comprising estimating an average ignition current switching time for the cylinder over a number of combustion cycles of the given vehicle drive cycle, and in response to the estimated average ignition current switching time being longer than a threshold time, indicating spark plug fouling due to fuel additive accumulation on the spark plug of the cylinder.

16. The method of claim 15 , wherein the duration is a threshold duration based on the dwell command applied and an operational status of a current sink, and wherein the threshold percentage is based on an average percentage in an engine operating with a fuel not including fuel additives.

17. The method of claim 16 , further comprising operating with the fraction smaller than the threshold percentage, and in response to the fraction being smaller than the threshold percentage, increasing an engine idling speed and engine load, and advancing spark ignition timing of the cylinder to maintain a tip temperature of the spark plug above a threshold temperature for a threshold duration.

18. The method of claim 17 , further comprising; after the threshold duration, reassessing the fraction of combustion cycles of the cylinder.

19. The method of claim 18 , further comprising in response to the reassessed fraction being smaller than the threshold percentage, indicating spark plug fouling due to soot accumulation.

20. The method of claim 14 , further comprising, in response to the indication of spark plug fouling due to fuel additive accumulation, decreasing an engine load, and disabling fuel and spark for an adjacent cylinder configured to receive exhaust residuals from the cylinder coupled to the fouled spark plug.

Assignees

• Ford Global Tech Llc

Inventors

• Glugla Chris Paul
• Huberts Garlan J
• Morrow Nelson William
• Qu Qiuping

Classifications

• F02B2075/125

  Direct injection in the combustion chamber for spark ignition engines, i.e. not in pre-combustion chamber · CPC title

• F02D2041/227

  Limping Home, i.e. taking specific engine control measures at abnormal conditions · CPC title

• F02D41/1441

  Plural sensors · CPC title

• F01N11/00 Primary

  Monitoring or diagnostic devices for exhaust-gas treatment apparatus · CPC title

• F02D41/1454

  the characteristics being an oxygen content or concentration or the air-fuel ratio · CPC title