Method and system for exhaust heat exchanger diagnostics

Patent metadata

Field	Value
Publication number	US-9909541-B1
Application number	US-201615296950-A
Country	US
Kind code	B1
Filing date	Oct 18, 2016
Priority date	Oct 18, 2016
Publication date	Mar 6, 2018
Grant date	Mar 6, 2018

Abstract

Methods and systems are provided for carrying out on-board diagnostics of a plurality of components of an exhaust heat exchange system. In one example, degradation of one or more of a heat exchanger and a coolant system fluidically coupled to the heat exchanger may be detected based on a first temperature estimated upstream of the heat exchanger, a second temperature sensor estimated downstream of the heat exchanger, a coolant temperature, and a pressure estimated upstream of the heat exchanger. Also, degradation of a diverter valve of the heat exchange system may be detected based on inputs of a position sensor coupled to the diverter valve.

First claim

The invention claimed is:

1. A method, comprising:
indicating degradation of a heat exchange system diverting exhaust, via a diverter valve, from downstream of an exhaust catalyst into a heat exchanger in an exhaust bypass, the indicating based on each of a first exhaust temperature and an exhaust pressure estimated upstream of the heat exchanger, a second exhaust temperature estimated downstream of the heat exchanger, and a temperature of coolant circulating through the heat exchanger.

2. The method of claim 1 , further comprising, responsive to the indication of degradation, disabling the diverting of exhaust through the heat exchanger in the exhaust bypass; and enabling direct flow of exhaust to a tailpipe via a main exhaust passage, bypassing the heat exchanger.

3. The method of claim 1 , wherein the indicating is further based on an actual position of the diverter valve relative to a commanded position, the actual position estimated via a position sensor coupled to the diverter valve, the commanded position based on engine heating demand, the diverter valve coupled to a junction of an outlet of the exhaust bypass and a main exhaust passage.

4. The method of claim 3 , wherein the heat exchange system further includes an exhaust gas recirculation (EGR) passage for recirculating exhaust from the exhaust bypass, downstream of the heat exchanger, to an engine intake manifold via an EGR valve, and wherein the indicating is further based on an actual position of the EGR valve.

5. The method of claim 4 , further comprising:
operating the heat exchange system in a first, heat recovery mode by actuating the EGR valve to a closed position and actuating the diverter valve to a first position to enable exhaust flow to the tailpipe via the heat exchanger;
operating the heat exchange system in a second, EGR mode by actuating the EGR valve to an open position and actuating the diverter valve to a second position to enable exhaust flow to the engine intake manifold via the heat exchanger; and
operating the heat exchange system in a third, bypass mode by actuating the EGR valve to the closed position and actuating the diverter valve to the second position to enable direct exhaust flow to the tailpipe, bypassing the heat exchanger, wherein the indicating is performed during each of the first, second, and third modes.

6. The method of claim 5 , wherein the indicating includes:
when operating the heat exchange system in one of the first mode and the second mode, indicating degradation of the heat exchanger responsive to each of the second exhaust temperature being lower than an expected second exhaust temperature and the estimated exhaust pressure being higher than an expected exhaust pressure;
when operating the heat exchange system in one of the first mode and the second mode, indicating degradation of a coolant system circulating coolant through the heat exchanger responsive to the estimated coolant temperature being lower than an expected coolant temperature; and
when operating the heat exchange system in one of the first, second, and third mode, indicating degradation of the diverter valve responsive to an actual position of the diverter valve differing from an expected position of the diverter valve.

7. The method of claim 6 , wherein the expected second exhaust temperature is modeled based on one or more of engine load, engine temperature, engine speed, exhaust flow-rate, and coolant flow-rate through the heat exchanger, wherein the expected exhaust pressure is modeled based on one or more of engine load, engine temperature, engine speed, and exhaust flow-rate, and wherein the expected coolant temperature is modeled based on one or more of exhaust temperature, exhaust flow-rate, and coolant flow-rate.

8. The method of claim 6 , wherein the expected position of the diverter valve includes the first position during the first mode, and the second position during each of the second and third mode, the first position enabling exhaust flow from downstream of the catalyst to the tailpipe via the exhaust bypass, and the second position disabling exhaust flow from downstream of the catalyst to the tailpipe via the exhaust bypass.

9. The method of claim 6 , wherein the first exhaust temperature is estimated via a first temperature sensor coupled to the exhaust bypass, upstream of the heat exchanger, wherein the second exhaust temperature is estimated via a second temperature sensor coupled to the exhaust bypass, downstream of the heat exchanger, wherein the exhaust pressure is estimated via a pressure sensor coupled to the exhaust bypass, upstream of the heat exchanger, wherein the coolant temperature is estimated via a third temperature sensor coupled to a coolant line of the coolant system.

10. The method of claim 9 , wherein the indicating further includes:
while operating in the third mode,
indicating degradation of the pressure sensor responsive to a higher than threshold pressure difference between the estimated exhaust pressure and atmospheric pressure;
indicating degradation of at least one of the first temperature sensor and the second temperature sensor responsive to a higher than threshold difference between the first exhaust temperature and the second exhaust temperature; and
indicating degradation of the third temperature sensor responsive to the estimated coolant temperature being higher than the expected coolant temperature.

11. The method of claim 6 , wherein indicating degradation of the heat exchanger includes indicating the heat exchanger is clogged, wherein indicating degradation of the coolant system includes indicating one or more coolant lines are clogged, wherein indicating degradation of the diverter valve includes indicating the diverter valve is stuck in one of the open position, the closed position, and a partially open position.

12. A method, comprising:
while operating a heat exchange system to flow an entire volume of exhaust from downstream of an exhaust catalyst to a tailpipe via an exhaust bypass housing a heat exchanger,
indicating degradation of the heat exchanger responsive to each of an exhaust pressure measured upstream of the heat exchanger being higher than a first threshold pressure, and a temperature difference between a first exhaust temperature measured upstream of the heat exchanger and a second exhaust temperature measured downstream of the heat exchanger being higher than a first threshold difference;
indicating degradation of a coolant system circulating coolant through the heat exchanger responsive to coolant temperature measured at an outgoing line of the coolant system being lower than a first threshold coolant temperature; and
indicating a diverter valve coupled at a junction of the exhaust bypass and a main exhaust passage is stuck closed or partially open responsive to an actual position of the diverter valve differing from a fully open position.

13. The method of claim 12 further comprising:
based on EGR demand, recirculating a portion of the exhaust from downstream of the heat exchanger to an engine intake manifold via an exhaust gas recirculation (EGR) valve; and
during the recirculating, while the EGR valve is not degraded,
indicating degradation of the heat exchanger responsive to each of the exhaust pressure measured upstream of the heat exchanger being higher than a second threshold pressure, and the temperature difference between the first exhaust temperature measured upstream of the heat exchanger and the second exhaust temperature measured downstream of the heat exchanger being higher than a second threshold difference;
indicating degradation of the coolant system responsive to coolant temperature me

Assignees

• Ford Global Tech Llc

Inventors

• Bevan Karen Evelyn
• Pursifull Ross Dykstra
• Uhrich Michael James
• Ulrey Joseph Norman

Classifications

• F01N2560/06

  the means being a temperature sensor · CPC title

• F02M26/15

  in relation to engine exhaust purifying apparatus · CPC title

• F01N2900/1404

  Exhaust gas temperature · CPC title

• F01N2410/00

  By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device · CPC title

• F01N3/005

  for draining or otherwise eliminating condensates or moisture accumulating in the apparatus (F01N3/02 takes precedence) · CPC title