Systems and methods for split lambda catalyst heating

Patent metadata

Field	Value
Publication number	US-11300063-B2
Application number	US-202016933122-A
Country	US
Kind code	B2
Filing date	Jul 20, 2020
Priority date	Jul 20, 2020
Publication date	Apr 12, 2022
Grant date	Apr 12, 2022

Abstract

Methods and systems are provided for increasing a temperature of a catalyst of an engine by operating the engine in a split lambda catalyst heating mode. In one example, a method may include, while operating an engine in a split lambda catalyst heating mode, adjusting a magnitude of a lambda split between a rich set of combustion events and a lean set of combustion events based on soot formation in the rich set of combustion events. In this way, catalyst temperature may be increased while maintaining engine efficiency and preventing soot formation in the cylinders.

First claim

The invention claimed is:

1. A method, comprising:
while operating an engine in a split lambda catalyst heating mode, adjusting a magnitude of a lambda split between a rich set of combustion events in a rich set of cylinders and a lean set of combustion events in a lean set of cylinders based on soot formation in the rich set of combustion events and lean combustion tolerance in the lean set of combustion events, wherein operating in the split lambda catalyst heating mode includes:
selecting a cylinder pattern;
advancing spark timing for the lean set of cylinders while retarding spark timing for the rich set of cylinders; and
operating the rich set of cylinders with a rich air-fuel ratio (AFR) and the lean set of cylinders with a lean AFR, the rich AFR and the lean AFR determined based on the lambda split, exhaust gas from both the rich set of cylinders and the lean set of cylinder producing a stoichiometric air-fuel ratio at a catalyst; and

wherein operating the rich set of cylinders with the rich AFR and the lean set of cylinders with the lean AFR includes injecting fuel with early injection timing in the rich set of cylinders, relative to an injection timing for the lean set of cylinders, and performing split fuel injection in the lean set of cylinders, wherein performing split fuel injection in the lean set of cylinders includes:
for each cylinder in the lean set of cylinders, injecting a first amount of fuel during an intake stroke of the cylinder; and
for each cylinder in the lean set of cylinders, injecting a second amount of fuel during a compression stroke of the cylinder prior to spark plug actuation.

2. The method of claim 1 , wherein selecting the cylinder pattern includes determining which of the cylinders of the engine comprise the rich set of cylinders and which of the cylinders of the engine comprise the lean set of cylinders based on an estimated catalyst washcoat storage capacity for the catalyst.

3. The method of claim 2 , wherein the estimated catalyst washcoat storage capacity is based on a catalyst age, a catalyst type, and a catalyst temperature, and wherein the estimated catalyst washcoat storage capacity includes at least one of an estimated catalyst washcoat oxygen storage capacity, an estimated catalyst washcoat hydrogen storage capacity, and an estimated catalyst washcoat hydrocarbon storage capacity.

4. The method of claim 3 , wherein selecting the cylinder pattern further includes increasing a number of consecutive lean firing events as the estimated catalyst washcoat oxygen storage capacity increases, and increasing a number of consecutive rich firing events as the estimated catalyst washcoat hydrocarbon storage capacity increases.

5. The method of claim 1 , wherein the magnitude of the lambda split is further based on a desired amount of catalyst heating.

6. The method of claim 1 , wherein operating the engine in the split lambda catalyst heating mode is responsive to a catalyst front face temperature being above a threshold catalyst front face temperature and a catalyst midbed temperature being below a threshold catalyst midbed temperature.

7. The method of claim 1 , wherein adjusting the magnitude of the lambda split between the rich set of cylinders and the lean set of cylinders based on soot formation in the rich set of cylinders includes determining a threshold rich AFR below which soot formation increases above a threshold amount, and wherein the lambda split is a difference between a lean relative AFR of the lean set of cylinders and a rich relative AFR of the rich set of cylinders.

8. A method, comprising:
responsive to a catalyst midbed temperature below a threshold catalyst midbed temperature and a catalyst front face temperature below a threshold catalyst front face temperature, operating an engine with spark retard;
responsive to the catalyst midbed temperature below the threshold catalyst midbed temperature and the catalyst front face temperature exceeding the threshold catalyst front face temperature:
selecting cylinders of an engine for a first set of cylinders and selecting cylinders of the engine for a second set of cylinders based on an estimated catalyst washcoat storage capacity of a catalyst;
enleaning the first set of cylinders by a first amount of enleanment while enriching the second set of cylinders by a first amount of enrichment;
advancing a spark timing for the first set of cylinders and retarding a spark timing for the second set of cylinders; and
performing split fuel injection in the first set of cylinders and a single fuel injection in the second set of cylinders.

9. The method of claim 8 , wherein enleaning the first set of cylinders by a first amount of enleanment while enriching the second set of cylinders by a first amount of enrichment is responsive to a difference between the first amount of enleanment and the first amount of enrichment determined based on a desired amount of catalyst heating and an estimated soot formation of each cylinder.

10. The method of claim 9 , wherein performing the split fuel injection includes injecting a first portion of fuel during an intake stroke of each cylinder of the first set of cylinders and injecting a second portion of fuel during a compression stroke of each cylinder of the first set of cylinders.

11. The method of claim 8 , wherein selecting cylinders of the engine for the first set of cylinders and selecting cylinders of the engine for the second set of cylinders based on an estimated catalyst washcoat storage capacity includes:
estimating a catalyst washcoat storage capacity based on catalyst age, catalyst type, and catalyst temperature, the catalyst washcoat storage capacity including at least one of a catalyst washcoat oxygen storage capacity, a catalyst washcoat hydrogen storage capacity, and a catalyst washcoat hydrocarbon storage capacity;
selecting a cylinder pattern with a lower number of consecutive lean firing events responsive to the catalyst washcoat oxygen storage capacity decreasing;
selecting a cylinder pattern with a lower number of consecutive rich firing events responsive to the catalyst washcoat hydrocarbon storage capacity decreasing and the catalyst washcoat hydrogen storage capacity decreasing;
assigning each cylinder of the engine to one of the first set of cylinders and the second set of cylinders based on the selected cylinder pattern.

12. The method of claim 11 , wherein assigning each cylinder of the engine to one of the first set of cylinders and the second set of cylinders based on the selected cylinder pattern further includes alternating each cylinder of the engine between the first set of cylinders and the second set of cylinders after a number of engine cycles.

13. The method of claim 8 , wherein exhaust gas from both the first set of cylinders and the second set of cylinders produces a stoichiometric air-fuel ratio at the catalyst.

14. A system, comprising:
a spark ignition engine including a plurality of cylinders;
a catalyst coupled in an exhaust passage of the spark ignition engine; and
a controller with computer readable instructions stored in non-transitory memory that, when executed during engine operation, cause the controller to:
during a first condition, increase a temperature of the catalyst by retarding spark timing by a same amount in every cylinder of the plurality of cylinders; and
during a second condition, increase the temperature of the catalyst by operating a first set of the plurality of cylinders at a rich air-fuel ratio and a second set of the plurality of cylinders at a lean air-fuel ratio while retarding spark timing differently in the first set and the se

Assignees

• Ford Global Tech Llc

Inventors

• Leone Thomas G
• Moilanen Peter C
• Zhang Xiaogang
• Yi Jianwen James
• Schwochert Steven

Classifications

• Y02T10/40

  Engine management systems · CPC title

• Y02T10/12

  Improving ICE efficiencies · CPC title

• F02P5/15

  Digital data processing · CPC title

• F02D41/402

  Multiple injections · CPC title

• F02D41/1473

  characterised by the regulation method · CPC title