U.S. patent application number 10/957500 was filed with the patent office on 2005-03-17 for spark generating apparatus having strain gage cylinder pressure measurement feature.
This patent application is currently assigned to DELPHI TECHNOLOGIES, INC.. Invention is credited to Bell, Matthew W., Boyer, James Alva, Kiess, Ronald J., Noel, Robert A., Wright, James Tordt.
Application Number | 20050056087 10/957500 |
Document ID | / |
Family ID | 25175702 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050056087 |
Kind Code |
A1 |
Kiess, Ronald J. ; et
al. |
March 17, 2005 |
Spark generating apparatus having strain gage cylinder pressure
measurement feature
Abstract
An ignition coil, spark plug, and pressure sensor for an
internal combustion engine are, in a preferred embodiment,
integrated into a single assembly and mounted directly on a plug
hole of an internal combustion engine. A hard spark plug shell
serves as a pressure member and on which a strain gage is affixed.
Changes in the pressure in the combustion chamber deform the shell,
causing a corresponding change in the resistance of the strain
gage. A bridge circuit or the like is used to measure the
resistance change thereby providing a direct indication of cylinder
pressure.
Inventors: |
Kiess, Ronald J.; (Decatur,
IN) ; Noel, Robert A.; (Anderson, IN) ;
Wright, James Tordt; (Anderson, IN) ; Boyer, James
Alva; (Anderson, IN) ; Bell, Matthew W.;
(Plymouth, MI) |
Correspondence
Address: |
Jimmy L. Funke
DELPHI TECHNOLOGIES, INC.
Legal Staff, Mail Code: 480-410-202
P.O. Box 5052
Troy
MI
48007-5052
US
|
Assignee: |
DELPHI TECHNOLOGIES, INC.
|
Family ID: |
25175702 |
Appl. No.: |
10/957500 |
Filed: |
October 1, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10957500 |
Oct 1, 2004 |
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09799362 |
Mar 5, 2001 |
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6799451 |
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Current U.S.
Class: |
73/114.19 |
Current CPC
Class: |
G01L 23/18 20130101;
G01L 23/22 20130101 |
Class at
Publication: |
073/116 |
International
Class: |
G01L 003/26 |
Claims
1. A spark generating assembly for initiating combustion and
detecting a pressure in a cylinder of an internal combustion
engine, said assembly comprising: an outer housing; a control
circuit interface portion coupled to a first end of said outer
housing; a central electrode having a main axis and a first end
configured for connection to a relatively high voltage source; an
insulator radially outwardly of said central electrode, said
central electrode further having a second, exposed end axially
opposite said first end; a conductive shell outwardly of said
insulator and coupled to a second end of said outer housing, said
shell having a center portion and an engagement portion, said
engagement portion being having threads and configured to engage a
corresponding aperture of said engine that is in communication with
said combustion cylinder; a second electrode spaced apart from said
second end of said central electrode to define a spark gap
therebetween, said second electrode being electrically connected to
said shell; a strain gage directly affixed to said center portion
of said conductive shell whereby the strain gage strains with the
shell due to direct affixation, said strain gage configured to
detect deformations of said shell indicative of said pressure; said
assembly further comprising an ignition coil disposed within said
outer housing configured to be connected to a low voltage source
through said control circuit interface to selectively energize said
ignition coil, said ignition coil being coupled to said first end
of said central conductor and further configured to generate said
relatively high voltage; said assembly further comprising a bridge
circuit electrically connected to said strain gage configured to
generate a pressure signal indicative of said pressure; wherein
said outer housing, said control circuit interface portion, said
ignition coil, said conductive shell and said strain gage are
formed as an integrated assembly, and said strain gage and
electrical connections to said bridge circuit are formed in a flex
circuit comprising a multi-layer circuit including a ground plane
layer and subsequent outer layers having leads disposed thereon
sandwiched between insulating layers, all of which provide
electromagnetic interference (EMI) shielding.
2. (Cancelled).
3. (Cancelled).
Description
TECHNICAL FIELD
[0001] The present invention relates to a spark generating
apparatus with a pressure sensor.
BACKGROUND OF THE INVENTION
[0002] An ignition coil for an internal combustion engine that is
installed directly on an engine and that is directly coupled with
spark plugs is known. However, such conventional ignition coils
and/or spark plugs do not generally incorporate a pressure sensor
and often are large and costly to produce. A pressure sensor
mounted on a spark plug is known as disclosed in U.S. Pat. No.
5,672,812 to Meyer.
[0003] Meyer discloses a magnetostrictive pressure sensor device
attached to a spark plug shell. The disclosed approach, however,
requires a magnetized spark plug shell. This increases cost, and
subjects the resulting signal to noise due to environmental factors
(e.g., magnetic and electrical noise in an automotive
environment).
[0004] U.S. Pat. No. 6,119,667 to Boyer et al. disclose an
integrated spark plug/ignition coil with a pressure sensor for an
internal combustion engine. The sensor is disclosed as a
magnetostrictive sensor, and is further disclosed as using a
radially polarized biasing magnet and a sensing winding. As with
the Meyer device, additional components such as a magnet are
needed, which increase cost and complexity.
[0005] Additionally, piezoelectric devices have been used in a
laboratory environment but are not feasible for mass production.
ION sense methods of detecting cylinder pressure are also known;
however, such methods are indirect approaches for determining
pressure.
[0006] There is therefore a need for an improved spark generating
apparatus with pressure sensing for an internal combustion engine
that minimizes or eliminates one or more problems as set forth
above.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to solve one or more
of the problems as set forth in the Background. An advantage of an
apparatus according to the invention is that it provides a high
quality signal indicative of a pressure detected in a combustion
chamber of an internal combustion engine. The high quality signal
is generated at a comparatively higher value than certain other
pressure sensors conventionally used. Conventional pressure sensing
arrangements provide reduced signal output under conditions of low
cylinder pressure (i.e., idle or deceleration). The present
invention provides a high signal to noise ratio under all operating
conditions. Another advantage of the present invention involves
flexibility of application. That is, a strain gage sensor portion
of the present invention may be mounted in a variety of different
locations and orientations.
[0008] An apparatus according to the present invention includes a
central electrode, an insulator, a conductive shell, a second
electrode, and a strain gage. The central electrode has a main axis
and a first end configured for connection to a relatively high
voltage source. The insulator is located outwardly of the central
electrode. The central electrode further includes a second, exposed
end opposite the first end. The conductive shell is located
outwardly of and surrounds the insulator. The second electrode is
spaced apart from the exposed end of the central electrode to
define a spark gap therebetween. The second electrode is
electrically connected to the shell. According to the invention, a
strain gage is affixed to the shell. In operation, the shell
becomes a pressure member wherein the stress applied to the shell
during, for example, piston strokes, will flex the shell. The
strain gage converts the deformation to a resistance change
measurable by way of, for example, a bridge circuit, in one
embodiment.
[0009] In an alternate embodiment, a spark generating assembly is
provided that integrates an ignition coil with a spark plug
configured to include a strain gage as described above. In still
further embodiments, the strain gage is incorporated (i.e., applied
to) into one or more fuel injectors of a Direct Gasoline Injection
(DGI) engine, the glow plugs in a diesel engine, or any other
component protruding into the combustion chamber. Additionally, the
strain gage can be incorporated onto a cylinder head, head bolt,
engine block, and/or main bearing cap or bolt. Moving parts could
also be the subject of (destination for) the strain gage including
the piston, connecting rod, crankshaft, and valve train components
or the like.
[0010] A method of making a spark generating apparatus according to
the invention is also presented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Additional objects and advantages of the present invention
will be more readily apparent from the following detailed
description of preferred embodiments thereof when taken together
with the accompanying drawings in which:
[0012] FIG. 1 is a sectional view of the integrated spark plug and
coil with pressure sensor according to the present invention;
[0013] FIG. 2 is a side view of the coil case of the integrated
spark plug and coil with pressure sensor of FIG. 1 showing a flex
circuit;
[0014] FIG. 3 is a sectional view of an alternate embodiment of the
present invention illustrating a stand alone spark plug with a
pressure sensor;
[0015] FIG. 4 is an exploded view of the integrated spark plug and
coil with pressure sensor together with an engine and a control
unit; and
[0016] FIG. 5 is a schematic view of an exemplary bridge circuit
for use with a pressure sensor of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring now to the drawings wherein like reference
numerals are used to identify identical components in the various
views, FIG. 1 shows a preferred embodiment of an integrated
ignition coil, spark plug and pressure sensor assembly 10 in
accordance with the present invention. The assembly 10 is adapted
for installation to a conventional internal combustion engine 64
through a spark plug shell and in threaded engagement with a spark
plug opening 62 into a combustion cylinder. This arrangement is
best shown in FIG. 4.
[0018] FIG. 1 illustrates assembly 10 having a transformer portion
12 comprising a core 14, a primary coil 16, a secondary spool 18
and a secondary coil 20, a connection portion 22 comprising a
high-voltage boot 24, a control circuit portion 26 comprising an
assembled connector portion 28 and a circuit interface portion 30,
a coil case 32, an outer housing or shield 34 comprising a
fastening head 36, a spark plug assembly 38, and a pressure sensor
assembly comprising a strain gage 40. As further shown in FIG. 1,
spark plug assembly 38 comprises a central electrode 42 having a
first end 44 and a second end 46, an insulator portion 48, and a
shell 50 comprising a second electrode portion 52, a threaded
portion 54 and a center portion 56.
[0019] With continued reference to FIG. 1, assembly 10 has a
substantially rigid outer housing 34 at one end of which is the
spark plug assembly 38 and at the other end of which is the control
circuit interface portion 30 for external electrical interface with
a control unit 66, such as an engine control unit. The primary and
secondary windings 16, 18 are arranged in a substantially coaxial
fashion along with a high permeability magnetic core 14. All high
voltage ignition system components are housed or are part of the
integrated ignition coil, spark plug, and pressure sensor assembly
10. Generally, the structure is adapted for drop in assembly of
components and sub-assemblies as later described.
[0020] Transformer portion 12 and control-circuit portion 26 (which
are provided) for high-voltage generation, are inserted into outer
housing 34. The control-circuit portion 26 responds to instruction
signals from an external circuit (not shown) to cause a primary
current to initially flow through primary coil 16 and then be
interrupted when a spark is desired. The control circuit 26 may be
external to the integrated coil/spark plug assembly 10. Connecting
portion 22, which supplies a relatively high secondary voltage
generated by the transformer portion 12 to the spark plug 38, is
provided in a lower portion of the outer housing 34.
[0021] The outer housing 34 may be formed from round tube stock for
example comprising nickel-plated 1008 steel or other adequate
magnetic material. Where higher strength may be required, such as
for example in unusually long cases, a higher carbon steel or a
magnetic stainless steel may be substituted. A portion of the outer
housing 34 at the end adjacent to the control circuit interface
portion 30 may be formed by a conventional swage operation to
provide a plurality of flat surfaces, thereby providing a fastening
head 36, such as a hexagonal fastening head for engagement with
standard sized drive tools. Additionally, the extreme end is rolled
inward to provide necessary strength for torque applied to the
fastening head 36 and perhaps to provide a shelf for trapping a
ring clip between the outer housing 34 and the connector body 30.
The previously assembled primary and secondary sub-assemblies are
loaded into the outer housing 34 from the spark plug end to a
positive stop provided by the swaged end acting on a top end
portion of the connector body.
[0022] The transformer portion 12 is formed around the central
magnetic core 14. The magnetic core 14 may be manufactured from
plastic coated (insulated) iron particles in a compression molding
operation. After the core 14 is molded, it is finish machined such
as by grinding to provide a smooth surface absent, for example,
sharp mold parting lines otherwise detrimental to the intended
direct primary coil winding thereon.
[0023] Core 14 may also be formed using laminated thin
silicon-steel plates of differing widths so that a cross section
thereof becomes substantially circular. Optionally, magnets may be
included as well in the core circuit. If included, the magnets may
have polarity of reversed directions of magnetic flux generated by
excitation by the primary coil 16 and are disposed on both ends of
core 14.
[0024] The primary coil 16 may be, as shown, wound directly on the
surface of the core 14. Coil 16 may be formed from insulated wire,
which may be wound directly upon the outer cylindrical surface of
the core 14. The winding of the primary coil 16 directly upon the
core 14 provides for efficient heat transfer of the primary
resistive losses and improved magnetic coupling which is known to
vary substantially inversely proportionally with the volume between
the primary coil 16 and the core 14. The core 14 is preferably
assembled to the interior end portion of the connector body to
establish positive electrical contact between the core 14 and a
core-grounding terminal. However, the specific grounding of the
core 14 is not essential to the operation of the present invention.
Terminal leads of primary coil 16 may be connected to insert molded
primary terminals by conventional processes such as soldering.
Alternative constructions are possible, for example, via use of
steel laminations for core 9 in combination with the primary coil
wound on a primary coil spool (not shown). The foregoing is
exemplary only and not limiting in nature.
[0025] The primary sub-assembly is inserted into the secondary coil
spool 18. A secondary coil 20 may then be wound onto the outer
periphery of the secondary spool 18. The secondary coil 20 may be
either a segment wound coil or a layer (progressive) wound coil in
a manner that is known to one of ordinary skill in the art.
[0026] The control-circuit portion 26 may contain circuitry for
processing the strain gage signal and may be made up of a
molded-resin switching element which controls a conduction current
through the primary coil 16 to be intermittent, and a control
circuit which is an igniter that generates the control signals of
this switching element. Additionally, a heat sink, which may be a
separate body, may be glued or otherwise adhered to the
control-circuit portion 26 for heat radiation of circuit elements
such as the switching element. However, as previously mentioned,
the control-circuit portion 26 may be external to the spark plug
assembly 38.
[0027] The interior of housing 34 retains the transformer portion
12, connector portion 28, and a high voltage boot 24. The coil case
32 is disposed within the outer housing 34 and is added for support
and to support the coil. For the assembly process, the wound
primary coil 16 with assembled connector 28 is assembled to the
wound secondary spool 18 and then into the coil case 32.
[0028] The above-described ignition coil and spark plug assembly 10
is inserted in a plug hole of an internal combustion engine and is
fixed to an engine. The spark plug assembly 38 that is mounted on a
bottom portion of the plug hole is received within the connecting
portion 22, and a high voltage terminal portion 44 of the spark
plug 38 electrically contacts high voltage connector portion. The
steel shield 34 may be welded to the spark plug to form a
pre-assembled unit. The pre-assembled unit is then screwed into the
spark plug hole in the engine head in the conventional manner. The
unit may then be self-supporting with no attachment bolts
required.
[0029] It is preferable that the ignition coil have a
cross-sectional configuration and dimensions that are housable
within the plug hole 62. According to this embodiment of the
invention, a tube-portion cross section of the outer housing 34 is
formed to be circular so that an inner-diameter dimension
accommodates a plug hole 62, and an outer diameter thereof is
established to be a suitable dimension as recognized by those
skilled in the art.
[0030] As previously mentioned the coil case 32 is disposed within
the outer housing 34. The coil case 32 extends from the spark plug
shell 50 to the circuit interface portion 30. The coil case 32 also
contains the core 14, primary coil 16, secondary spool 18, and
secondary coil 20. Strain gage 40 is affixed to shell 50,
particularly the center portion 56 thereof. Strain gage 40 may be
affixed in an axial (i.e., tension) arrangement, or, in an
alternate embodiment, in a circumference (i.e., hoop stress) manner
to center portion 56 of shell 50. Conventional adhesives known for
the purpose of affixing strain gages may be used, with due regard
for the expected elevated temperature of an engine In the
embodiment illustrated in FIG. 1, strain gage 40 is electrically
connected to a bridge circuit (see FIG. 5 for example), by way of a
flex circuit 58, which is more clearly shown in FIG. 2. The use of
flex circuit 58 eliminates what would otherwise involve individual
termination/wiring to/from the strain gage 40. Using, for example,
a resistive bridge, and attaching the strain gage 40 to the spark
plug shell 50, the described arrangement will indicate the cylinder
pressure of a running or motoring heat engine. The pressure applied
to the center insulator of the spark plug during the piston strokes
will cause a stress which will flex or deform the spark plug shell
50. Such flexure will result in a change of resistance of the
strain gage 40, and hence serve to vary the output of the bridge. A
direct correlation of cylinder pressure to resistance change is
measurable during the cycles of the heat engine.
[0031] The location of strain gage 40 on spark plug shell 50 is
important for optimum performance. For example, axially oriented
strain gage elements placed close to the rollover crimp will
indicate a strong negative tensile output, as opposed to a strong
positive tensile output if axially oriented and placed away from
the crimp. The circumferentially oriented gage located away from
the crimp produces a strong negative hoop indication. This is the
Poisson effect. These facts may be utilized to advantage by those
skilled in the art by placing strain gage elements onto the spark
plug shell 60, and configuring the elements into a full bridge to
produce an output significantly higher than a single strain gage
element acting alone in a bridge made with three passive
resistors.
[0032] The flex circuit 58 may comprise a multi-layer circuit. A
ground plane layer thereof is disposed adjacent the coil case.
Leads are then disposed on subsequent outer layers sandwiched
between insulating layers. The ground plane, together with the
insulating layers protect the connection leads from the high
voltage of the coils and therefore reduces or eliminates noise
coupling (i.e., electromagnetic interference or EMI). The circuit
interface portion 30 connects to the electrical system of the
vehicle to both provide an electrical input and control of the
coils, and communication of the engine control unit with the
pressure sensing assembly.
[0033] FIG. 3 shows an alternate embodiment of the present
invention, namely spark plug assembly 38a. Spark plug assembly 38a
is particularly adapted for stand-alone use (i.e., is not
integrated with an ignition coil), although could be used with a
conventional pencil coil. Spark plug assembly 38a is substantially
identical to spark plug assembly 38 shown in FIG. 1, with the
exception that shell 50a is modified to include a nut portion 60
adapted to receive a tool for installing the same in a threaded
aperture 62 of an engine 64. Nut portion 60 may be either above or
below location of strain gage 40.
[0034] FIG. 4 depicts several integrated spark plug coil and
pressure assemblies 10 connected to a plug hole 62 of an engine 64.
The assemblies are in turn connected to the engine control unit 66
that may include appropriate control logic to use the pressure
information detected by gage 40. As described above, the present
invention is configured to detect cycle-to-cycle pressure
information and generate a respective pressure signal indicative of
the detected pressure for each cylinder. Such plurality of pressure
signals may be used by engine control unit 66 for calibrating
engines to achieve improved performance with regard to fuel economy
and exhaust emissions, while reducing indicated mean effective
pressure (IMEP) variation. The output pressure signals are useful
for closed-loop feedback control of combustion. Such control
includes locating a peak cylinder pressure (e.g., with respect to
top dead center--TDC), controlling cycle-by-cycle variation in IMEP
and monitoring rate of pressure rise for each cylinder. In
addition, one or more of the pressure signals may be used to detect
misfire, knocking, or pre-ignition for a cylinder on an
event-by-event basis. Additionally, positive control of spark
timing, spark energy, air-fuel ratio, and charge dilution are
possible using one or more of the pressure signals to thereby
provide improvements in engine stability while reducing fuel
consumption and exhaust emissions.
[0035] FIG. 5 shows an exemplary resistive bridge 68 including
strain gage 40, and a plurality of resistors 70, 72, and 74. As
arranged in FIG. 5, an input voltage designated E is applied to the
bridge, as known to those of ordinary skill in the art. An output
pressure signal E.sub.o is indicative of the detected pressure in
the cylinder of engine 64 to which the embodiment of the invention
is installed. Of course, it should be understood that the resistive
bridge shown in FIG. 5 is simplified and is illustrated and
described in exemplary terms only. More sophisticated arrangements,
as well as calibration and scaling considerations, all such factors
being well known to those of ordinary skill in the art, may be
included and are considered within the spirit and scope of the
present invention. Moreover, other conditioning circuits for
detecting the resistance change presented by strain gage 40 may be
used, and also remain within the spirit and scope of the present
invention.
[0036] A strain gage is located on a shell portion of a spark plug
assembly for monitoring in-cylinder pressure variation which occurs
as a result of piston position, sweep volume, gas compression and
expansion, rate of pressure rise, and combustion mixture burn
characteristics. The present invention provides a high quality
output signal indicative of detected pressure sensed in-cylinder
pressure variation. The present invention provides a high
signal-to-noise ratio under a wide variety of operating conditions,
including idle or deceleration. Inasmuch as the strain gage has a
low impedance, improved noise immunity is provided compared with
other known pressure measurement devices.
[0037] Although the present invention has been fully described in
connection with the preferred embodiment thereof with reference to
the accompanying drawings, it is to be noted that various changes
and modifications will become apparent to those skilled in the art.
Such changes and modifications are to be understood as being
included within the scope of the present invention as defined by
the appended claims.
* * * * *