U.S. patent application number 14/300012 was filed with the patent office on 2014-09-25 for diagnosing a cooling subsystem of an engine system in response to dynamic pressure sensed in the subsystem.
The applicant listed for this patent is BorgWarner Inc.. Invention is credited to Olaf Weber, Wolfgang Wenzel.
Application Number | 20140283588 14/300012 |
Document ID | / |
Family ID | 41550969 |
Filed Date | 2014-09-25 |
United States Patent
Application |
20140283588 |
Kind Code |
A1 |
Weber; Olaf ; et
al. |
September 25, 2014 |
DIAGNOSING A COOLING SUBSYSTEM OF AN ENGINE SYSTEM IN RESPONSE TO
DYNAMIC PRESSURE SENSED IN THE SUBSYSTEM
Abstract
A method of diagnosing a cooling subsystem of an engine system
in response a parameter extracted from dynamic hydraulic pressure
sensed in the cooling subsystem, and products and systems using
same.
Inventors: |
Weber; Olaf; (Bloomfield
Hills, MI) ; Wenzel; Wolfgang; (Stuttgart,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BorgWarner Inc. |
Auburn Hills |
MI |
US |
|
|
Family ID: |
41550969 |
Appl. No.: |
14/300012 |
Filed: |
June 9, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13003377 |
Jan 10, 2011 |
8751101 |
|
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PCT/US2009/049740 |
Jul 7, 2009 |
|
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14300012 |
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61081160 |
Jul 16, 2008 |
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Current U.S.
Class: |
73/114.68 |
Current CPC
Class: |
G01M 15/042 20130101;
F01P 2025/04 20130101; F02B 29/0493 20130101; Y02T 10/146 20130101;
F01P 11/18 20130101; F01P 2031/00 20130101; Y02T 10/12
20130101 |
Class at
Publication: |
73/114.68 |
International
Class: |
G01M 15/04 20060101
G01M015/04 |
Claims
1. An engine system comprising: an engine; a cooling subsystem
coupled to the engine to cool at least a portion of the engine and
including at least one hydraulic pressure sensor to sense dynamic
hydraulic pressure in the cooling subsystem; and said cooling
subsystem comprising a HT cooling subsystem and a LT cooling
subsystem; and a control subsystem to extract a parameter from the
sensed dynamic hydraulic pressure, and to evaluate the extracted
parameter to diagnose a condition of the cooling subsystem.
2. The engine system of claim 1 wherein the extracted parameter is
at least one of acceleration, period, amplitude, frequency,
wavelength, intensity, velocity, or direction.
3. The engine system of claim 1 wherein the at least one condition
includes at least one of a device malfunction, device failure,
device position, coolant leakage, coolant boiling, coolant volume
flow, coolant volume flow splits, coolant pressure differential, or
coolant temperature.
4. The engine system of claim 1 wherein the cooling subsystem
further comprises at least one pump, and said hydraulic pressure
sensor is located in proximity to said at least one pump to assess
at least one condition of said at least one pump.
5. The engine system of claim 4 wherein the wherein said cooling
subsystem further comprises at least one thermostat valve, and at
least one hydraulic pressure sensor is also located in proximity to
the thermostat valve to assess at least one condition of the
thermostat valve.
6. A method comprising: sensing dynamic hydraulic pressure in a
cooling subsystem of an engine system; said cooling subsystem
comprising a HT cooling subsystem and a LT cooling subsystem;
extracting a parameter from the sensed dynamic hydraulic pressure;
and evaluating the extracted parameter to diagnose a condition of
the cooling subsystem.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/003,377 filed on Jan. 10, 2011, which is a
371 of international Application No. PCT/US2009/049740 filed on
Jul. 7, 2009, which claims the benefit of U.S. Provisional
Application No. 61/081,160 filed Jul. 16, 2008.
TECHNICAL FIELD
[0002] The field to which the disclosure generally relates includes
internal combustion engine systems and, more particularly,
indicating conditions of or amount of coolant in engine cooling
subsystems.
BACKGROUND
[0003] An internal combustion engine system is typically equipped
with a cooling subsystem that basically circulates liquid coolant
between coolant passages in an engine and a heat exchanger located
remotely from the engine. The coolant absorbs heat produced by the
engine and is carried to the heat exchanger, which dissipates the
heat from the coolant into the air. A conventional cooling
subsystem also typically includes one or more pumps, filters,
thermostats and other valves, and conduit interconnecting such
devices. Conventional cooling subsystems also usually include
static temperature sensors that monitor static coolant temperature
to diagnose thermostat valve failures.
SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0004] One exemplary embodiment of the invention may include a
method comprising sensing dynamic hydraulic pressure in a cooling
subsystem of an engine system, extracting a parameter from the
sensed dynamic hydraulic pressure, and evaluating the extracted
parameter to diagnose a condition of the cooling subsystem.
[0005] Another exemplary embodiment of the invention may include an
engine system comprising an engine, a cooling subsystem coupled to
the engine to cool at least a portion of the engine and including a
hydraulic pressure sensor to sense dynamic hydraulic pressure in
the cooling subsystem, and a control subsystem to extract a
parameter from the sensed dynamic hydraulic pressure, and to
evaluate the extracted parameter to diagnose a condition of the
cooling subsystem.
[0006] A further exemplary embodiment of the invention may include
an engine system comprising an internal combustion engine, and an
engine breathing system coupled to the engine. The breathing system
includes an induction subsystem coupled to the engine, an exhaust
subsystem coupled to the engine, and a high-pressure (HP) exhaust
gas recirculation (EGR) subsystem in communication across the
exhaust and induction subsystems, and including a HP
high-temperature (HT) EGR cooler. The breathing system also
includes a turbocharger between the induction and exhaust
subsystems and having a turbine in the exhaust subsystem and a
compressor in the induction subsystem. The breathing system further
includes a low-pressure (LP) EGR subsystem in communication across
the exhaust subsystem downstream of the turbine and upstream of the
compressor, and including a LP HT EGR cooler. The engine system
also comprises a cooling subsystem coupled to the engine to cool at
least a portion of the engine, and including a plurality of
hydraulic pressure sensing devices to sense dynamic hydraulic
pressure, and a high-temperature (HT) cooling subsystem in fluid
communication with the internal combustion engine and the engine
breathing system, and including an HT radiator, an HT coolant pump,
a thermostat valve, the HP and LP HT EGR coolers, an HT coolant
valve. A control subsystem extracts a parameter from the sensed
dynamic hydraulic pressure, and to evaluate the extracted parameter
to diagnose a condition of the cooling subsystem.
[0007] Other exemplary embodiments of the invention will become
apparent from the detailed description provided hereinafter. It
should be understood that the detailed description and specific
examples, while disclosing exemplary embodiments of the invention,
are intended for purposes of illustration only and are not intended
to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Exemplary embodiments of the invention will become more
fully understood from the detailed description and the accompanying
drawings, wherein:
[0009] FIG. 1 is a schematic view of an exemplary embodiment of a
portion of an engine system including an engine and an engine
cooling subsystem;
[0010] FIG. 2 is a schematic view of another exemplary embodiment
of a portion of an engine system including an engine and an engine
cooling subsystem; and
[0011] FIG. 3 is a flowchart of an exemplary embodiment of a method
of diagnosing a cooling subsystem of an engine system in response
to dynamic hydraulic pressure sensed in the cooling subsystem.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0012] The following description of the exemplary embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0013] Exemplary operating environments are illustrated in FIGS. 1
and 2 and may be used to implement a presently disclosed method of
diagnosing a cooling subsystem of an engine system in response to
dynamic hydraulic pressure sensed in the subsystem. The method may
be carried out using any suitable system and, more specifically,
may be carried out in conjunction with an engine system such as
system 10 or 210 of FIG. 1 or 2. The following system descriptions
simply provide a brief overview of two exemplary engine systems,
but other systems and components not shown here could also support
the presently disclosed method.
[0014] In general, and referring to FIG. 1, the system 10 may
include an internal combustion engine 12 that may combust a mixture
of fuel and induction gases for conversion into mechanical
rotational energy and exhaust gases, an engine breathing system 14
that may deliver induction gases to the engine 12 and carry exhaust
gases away from the engine 12. The system 10 may also include a
fuel subsystem (not shown) to provide any suitable liquid and/or
gaseous fuel to the engine 12 for combustion therein with the
induction gases, a cooling subsystem 16 for cooling the engine 12
and/or the breathing system 14, and a control subsystem 18 to
control operation of at least a portion of the engine system
10.
[0015] The internal combustion engine 12 may be any suitable type
of engine, such as a spark-ignition engine like a gasoline engine,
an auto ignition or compression-ignition engine like a diesel
engine, or the like. The engine 12 may include a block 20 with
cylinders and pistons therein (not separately shown), which, along
with a cylinder head 22 may define combustion chambers for internal
combustion of a mixture of fuel and induction gases. The engine 12
may include any quantity of cylinders, and may be of any size and
may operate according to any suitable speeds and loads.
[0016] The engine breathing system 14 may include an induction
subsystem 24 that may compress and cool induction gases and convey
them to the engine 12 and an exhaust subsystem 26 that may extract
energy from exhaust gases and carry them away from the engine 12.
The engine breathing system 14 may also include an exhaust gas
recirculation (EGR) subsystem 28 in communication across the
exhaust and induction subsystems 24, 26 to recirculate exhaust
gases for mixture with fresh air to reduce emissions and pumping
losses from the engine system 10.
[0017] The engine breathing system 14 may further include a
turbocharger 30 of any type, located between the induction and
exhaust 24, 26 subsystems to compress inlet air and thereby improve
combustion to increase engine power output. As used herein, the
phrase induction gases may include fresh air, compressed air,
and/or recirculated exhaust gases. The turbocharging subsystem 30
may be a single stage system as shown, or may be a multi-stage or
sequential turbocharging subsystem. The turbocharging subsystem 30
may include a turbine 32 in the exhaust subsystem 26, and a
compressor 34 in the induction subsystem 24 mechanically coupled to
and driven by the turbine 32. In another embodiment, the compressor
34 may be any suitable mechanical or electromechanical compressor
driven in any suitable manner and need not be driven by the turbine
32. In other words, a stand-alone compressor may be used to
compress inlet air and thereby improve combustion to increase
engine power output.
[0018] The induction subsystem 24 may include, in addition to
suitable conduit and connectors, an inlet end 36 which may have an
air filter 38 to filter incoming air, and the turbocharger
compressor 34 downstream of the inlet end 36 to compress the inlet
air. The induction subsystem 24 may also include a charge air
cooler 40 downstream of the turbocharger compressor 34 to cool the
compressed air, and an intake throttle valve 42 downstream of the
charge air cooler 40 to throttle the flow of the cooled air to the
engine 12. The induction subsystem 24 also may include an intake
manifold 44 downstream of the throttle valve 42 and upstream of the
engine 12, to receive the throttled air and distribute it to the
engine combustion chambers. The induction subsystem 24 may also
include any other suitable devices of any kind.
[0019] The exhaust subsystem 26 may include, in addition to
suitable conduit and connectors, an exhaust manifold 46 to collect
exhaust gases from the combustion chambers of the engine 12 and
convey them downstream to the rest of the exhaust subsystem 26. The
exhaust subsystem 26 also may include the turbocharger turbine 32
in downstream communication with the exhaust manifold 46. The
exhaust subsystem 26 may also include any quantity of suitable
emissions devices 48 anywhere downstream of the exhaust manifold
46.
[0020] The EGR subsystem 28 may recirculate portions of the exhaust
gases from the exhaust subsystem 26 to the induction subsystem 24
for combustion in the engine 12, and may be a single path EGR
subsystem as shown, or may be a hybrid or dual path EGR subsystem.
As shown, the EGR subsystem 28 may include a high pressure (HP) EGR
path connected to the exhaust subsystem 26 upstream of the
turbocharger turbine 32 but connected to the induction subsystem 24
downstream of the turbocharger compressor 34. The EGR subsystem 28
may include, in addition to suitable conduit and connectors, an EGR
cooler 50 and an EGR valve 52, which may be located upstream or
downstream of the EGR cooler 50, to apportion EGR flow between the
exhaust and induction subsystems 26, 24.
[0021] The cooling subsystem 16 may include any suitable device(s)
in any quantities that may be connected by any appropriate conduit
that may include hoses, piping, tubing, passageways, or the like. A
heater core 54 may be used to absorb heat from hot coolant exiting
the engine 12, such as the cylinder head 22, and dissipate the
heat, for example, into a passenger compartment (not shown) of an
automobile carrying the engine 12. Also, any suitable heat
exchanging device, such as a radiator 56 with or without a fan 58,
may be used to exchange heat of the coolant with another medium
such as air. Further, a pump 60 may be used to draw coolant out of
one portion of the engine 12 such as the cylinder head 22 and
deliver it back to another portion of the engine 12 such as the
cylinder block 20. The pump 60 may be mechanically driven, for
example, by an engine crankshaft and belt as shown, or may be an
electric pump powered in any suitable manner. Additionally, a
thermostat valve 62 may be used to regulate flow of coolant through
the cooling subsystem 16. Moreover, the EGR cooler 50 may be used
to absorb heat from hot exhaust gases and dissipate the heat into
engine coolant received, for example, from the engine 12 such as
from the cylinder head 22 and delivered to another portion of the
engine 12 such as the cylinder block 20.
[0022] The cooling subsystem 16 also includes one or more devices
64 to sense hydraulic pressure at one or more locations of the
cooling subsystem 16. For example, the sensing devices 64 may
include one or more hydraulic pressure sensors in fluid
communication with the coolant and/or hydrophones in fluid
communication with the coolant or carried in any suitable location
on the conduit or other components or devices. The sensing devices
64 may sense the actual physical parameter of hydraulic pressure,
from which other pressure-related parameters and values may be
derived or otherwise extracted by the devices 64 or by downstream
signal processing devices such as in the control subsystem 18.
[0023] As used herein, the terminology hydraulic pressure includes
actual fluid pressure and/or sound pressure corresponding to actual
fluid pressure. Unlike static hydraulic pressure sensors that
simply provide a discrete or instantaneous pressure output signal,
dynamic hydraulic pressure sensors measure hydraulic pressure waves
over a period of time and provide corresponding dynamic output
signals. Further as used herein, the term dynamic pressure
measurements may include, as an example, those taken from 10 Hz up
to an exemplary high of 10 kHz, for example, to measure pump
cavitation.
[0024] Any suitable hydraulic pressure sensors may be used, for
example, piezoelectric sensors such as hydrophones or the like.
Hydrophones may measure sound pressure and sound pressure
variations in space and time. A hydrophone may include an
acousto-electrical transducer, which may convert alternating sound
pressure acting on the hydrophone into a proportional alternating
voltage. One type of hydrophone includes a needle-type hydrophone
that may be equipped with a transducer element composed of
piezo-ceramic or piezo-foil glued on a point of a needle. Another
type of hydrophone includes a membrane-type hydrophone, which may
include a piezo-foil carried on a frame.
[0025] The control subsystem 18 may include, for example, a vehicle
controller, engine system controller, cooling system controller,
and/or the sensing device(s) 64. The control subsystem 18 may
include any suitable hardware, software, and/or firmware to carry
out at least some portions of the methods disclosed herein below.
For example, the control subsystem 18 may include various engine
system actuators and sensors (not shown). The engine system sensors
are not individually shown in the drawings but may include any
suitable devices to monitor engine system parameters.
[0026] The control subsystem 18 may further include one or more
controllers 19 in communication with the actuators and sensors for
receiving and processing sensor input and transmitting actuator
output signals. The controller(s) 19 may include one or more
suitable processors 19a, memory 19b, and one or more interfaces 19c
coupling the controller(s) 19 to one or more other devices. The
processor(s) 19a may execute instructions that provide at least
some of the functionality for the system 10. As used herein, the
term instructions may include, for example, control logic, computer
software and/or firmware, programmable instructions, or other
suitable instructions. The processor may include, for example, one
or more microprocessors, microcontrollers, application specific
integrated circuits, and/or any other suitable type of processing
device. Also, the memory 19b may be configured to provide storage
for data received by or loaded to the system 10, and/or for
processor- executable instructions. The data and/or instructions
may be stored, for example, as look-up tables, formulas,
algorithms, maps, models, and/or any other suitable format. The
memory may include, for example, RAM, ROM, EPROM, and/or any other
suitable type of storage device. Finally, the interfaces 19c may
include, for example, analog/digital or digital/analog converters,
signal conditioners, amplifiers, filters, other electronic devices
or software modules, and/or any other suitable interfaces. The
interfaces may conform to, for example, RS-232, parallel, small
computer system interface, universal serial bus, CAN, MOST, LIN,
FlexRay, and/or any other suitable protocol(s). The interfaces may
include circuits, software, firmware, or any other device to assist
or enable the controller 19 in communicating with other
devices.
[0027] FIG. 2 illustrates another exemplary embodiment of an engine
system 210. This embodiment is similar in many respects to the
embodiment of FIG. 1 and like numerals between the embodiments
generally designate like or corresponding elements throughout the
several views of the drawing figures. Additionally, the
descriptions of the embodiments are incorporated by reference into
one another and the common subject matter generally may not be
repeated here.
[0028] The engine system 210 may include an internal combustion
engine 212, an engine breathing system 214, a high-temperature (HT)
cooling subsystem 216a, a low-temperature (LT) cooling subsystem
216b, and a control subsystem 218. As used herein, high-temperature
and low-temperature are relative terms and may include any suitable
temperature ranges for cooling subsystems known to those of
ordinary skill in the art.
[0029] The engine breathing system 214 may include an induction
subsystem 224 and an exhaust subsystem 226. The engine breathing
system 214 may also include a first or high-pressure (HP) exhaust
gas recirculation (EGR) subsystem 228 in communication across the
exhaust and induction subsystems 224, 226. The engine breathing
system 214 may further include a turbocharger 230 of any type
located between the induction and exhaust 224, 226 subsystems and
including a turbine 232 in the exhaust subsystem 226 and a
compressor 234 in the induction subsystem 224. The engine breathing
system 214 additionally may include a second or low-pressure (LP)
EGR subsystem 229 in communication across the exhaust subsystem 224
downstream of the turbine 232 and upstream of the compressor
234.
[0030] The induction subsystem 224 may include an inlet end 236,
the turbocharger compressor 234, a charge air cooler (CAC) 240
downstream of the compressor 234, an intake throttle valve 242, and
an intake manifold 244. The exhaust subsystem 226 may include an
exhaust manifold 246, the turbocharger turbine 232, and an
emissions device 248. The HP EGR subsystem 228 may include a first
or HT EGR cooler 250a, a second or LT EGR cooler 250b, and an EGR
valve 252. Similarly, the LP EGR subsystem 229 may include a first
or HT EGR cooler 251a, a second or LT EGR cooler 251b, and an EGR
valve 253.
[0031] The HT cooling subsystem 216a may include a radiator 256a
with or without a fan 258, a first or HT coolant pump 260a, a
thermostat valve 262, the first and second HT EGR coolers 250a,
251a, and a first or HT coolant valve 263a. The LT cooling
subsystem 216b may include a radiator 256b with or without the fan
258, a second or LT coolant pump 260b, the first and second LT EGR
coolers 250b, 251b, and a second or LT coolant valve 263b.
[0032] The HT and LT cooling subsystems 216a, 216b also include one
or more devices 264a-264i to sense hydraulic pressure at one or
more locations in the cooling subsystems 216a, 216b. Where multiple
sensing devices are used, they may sense hydraulic pressure in
different locations to output signals that may be evaluated to
determine a coolant pressure differential between the locations.
The sensing devices 264a-264i may be part of and/or coupled to the
control subsystem 218 (interconnections not shown).
[0033] In a first example and referring to the HT cooling subsystem
216a, a first sensing device 264a may be placed in any suitable
location downstream of the HT coolant pump 260a and upstream of the
engine 212. In a more particular instance of this example, the
device 264a may be placed just upstream, downstream, or at a
junction between the pump and the thermostat valve and including a
branch supplying coolant to the HT EGR coolers 250a, 251a. As used
herein, the terminology just upstream or just downstream includes
such proximity to some device or component sufficient to monitor
and/or diagnose that device or component. In this example, the
device 264a may be used to monitor and diagnose operation of the
pump 260a, the thermostat 262, and/or coolant flow to the HT EGR
coolers 250a, 251a.
[0034] In a second example, a second sensing device 264b may be
placed in any suitable location downstream of the engine 212 and
upstream of the HT radiator 256a. In a more particular instance of
this example, the device 264b may be placed just upstream,
downstream, or at the HT coolant valve 263a, to monitor and
diagnose operation of the HT coolant valve 263a.
[0035] In a third example, a third sensing device 264c may be
placed in any suitable location downstream of the engine 212 and
upstream of the HT pump 260a. In a more particular instance of this
example, the device 264c may be placed in a bypass branch in
parallel across the HT radiator 256a to monitor and diagnose
coolant flow through the bypass branch.
[0036] In a fourth example, a fourth sensing device 264d may be
placed in any suitable location downstream of the engine 212 and
upstream of the HT pump 260a. In a more particular instance of this
example, the device 264d may be placed just upstream of the HT pump
260a to monitor and diagnose operation of the pump 260a.
[0037] In a fifth example, a fifth sensing device 264e may be
placed in any suitable location downstream of the HT EGR cooler
250a and upstream of the HT pump 260a. In a more particular
instance of this example, the device 264e may be placed just
upstream, downstream, or at a junction of HP and LP HT coolant
branches to monitor and diagnose flow of coolant downstream of the
HT EGR coolers 250a, 251a.
[0038] Similarly, in a sixth example and referring to the LT
cooling subsystem 216b, a sixth sensing device 264f may be placed
in any suitable location downstream of the LT EGR cooler 250b and
upstream of the LT radiator 256b. In a more particular instance of
this example, the device 264f may be placed just upstream,
downstream, or at a junction of HP and LP LT coolant branches to
monitor and diagnose flow of coolant downstream of the LT EGR
coolers 250b, 251b.
[0039] In a seventh example, a seventh sensing device 264g may be
placed in any suitable location downstream of the LT radiator 256b
and upstream of the LT pump 260b. In a more particular instance of
this example, the device 264g may be placed just upstream of the LT
pump 260b to monitor and diagnose operation of the pump 260b.
[0040] In eighth example, an eighth sensing device 264h may be
placed in any suitable location downstream of the LT pump 260b and
upstream of the CAC 240. In a more particular instance of this
example, the device 264h may be placed just downstream of the LT
pump 260b to monitor and diagnose operation of the pump 260b.
[0041] In a ninth example, a ninth sensing device 264i may be
placed in any suitable location downstream of both the CAC 240 and
the LP HT EGR cooler 251b, and upstream of the LT radiator 256b. In
a more particular instance of this example, the device 264i may be
placed just upstream, downstream, or at the LT coolant valve 263b,
to monitor and diagnose operation of the LT coolant valve 263b.
[0042] One embodiment of the invention may include an exemplary
method of diagnosing a cooling subsystem of an engine system in
response to dynamic hydraulic pressure sensed in the cooling
subsystem. The method may be at least partially carried out as one
or more computer programs usable, for example, within the operating
environment of one or both of the exemplary engine systems 10, 210
described above. Those skilled in the art will also recognize that
a method according to any number of embodiments of the invention
may be carried out using other engine systems within other
operating environments. Referring now to FIG. 3, an exemplary
method 300 is illustrated in flow chart form. As the description of
the method 300 progresses, reference will be made to the engine
system 10, 210 of FIG. 1 or 2.
[0043] As shown at step 310, the method 300 may be initiated in any
suitable manner. For example, the method 300 may be initiated at
startup of the engine 12 of the engine system 10 of FIG. 1.
[0044] At step 320, one or more engine system parameters may be
monitored, and may be used as input that may be processed in
diagnosing a cooling subsystem. For example, engine speed may be
sensed by one or more shaft position sensors or speed sensors, or
coolant temperature may be sensed by one or more temperature or
thermostat sensors.
[0045] Other sensors and related parameters may be used, for
example, pressure sensors in communication with engine combustion
chambers may measure engine cylinder pressure, intake and exhaust
manifold pressure sensors may measure pressure of gases flowing
into and away from the combustion chambers, an inlet air mass flow
sensor may measure incoming airflow in the induction subsystem,
and/or an intake manifold mass flow sensor may measure flow of
induction gases to the engine. Still other sensors and related
parameters may include temperature sensors to measure the
temperature of induction gases flowing to the engine, a speed
sensor suitably coupled to the turbocharger to measure the
rotational speed thereof, a throttle position sensor, a variable
turbine geometry (VTG) position sensor, a tailpipe temperature
sensor, temperature or pressure sensors placed upstream and
downstream of emissions device(s), and/or oxygen (O2) sensors
placed in the exhaust and/or induction subsystems, position sensors
to measure positions of any valves.
[0046] In addition to the sensors discussed herein, any other
suitable sensors and their associated parameters may be encompassed
by the presently disclosed system and methods. For example, the
sensors may also include accelerator sensors, vehicle speed
sensors, powertrain speed sensors, filter sensors, other flow
sensors, vibration sensors, knock sensors, intake and exhaust
pressure sensors, and/or the like. In other words, any sensors may
be used to sense any suitable physical parameters including
electrical, mechanical, and chemical parameters. As used herein,
the term sensor may include any suitable hardware and/or software
used to sense any engine system parameter and/or various
combinations of such parameters.
[0047] At step 330, hydraulic pressure of a cooling subsystem of an
engine system may be sensed. For example, dynamic hydraulic
pressure may be sensed using any suitable sensing apparatus,
including the sensing device(s) 64, 264a-i, placed in any suitable
location(s) of the cooling subsystem 16. The sensing device(s) 64,
264a-i may sense coolant pressure in components or devices of the
cooling subsystem 16, 216a,b. The pressure readings may be
communicated from the sensing device(s) 64, 264a-i to the control
subsystem 18, 218 with or without preprocessing.
[0048] At step 340, at least one parameter may be extracted from
the sensed dynamic hydraulic pressure. As used herein, dynamic
hydraulic-pressure-related parameters may include, for example,
acceleration, period, amplitude, frequency, wavelength, intensity,
velocity, direction, and/or any other like parameters. The
parameter(s) may be extracted in any suitable manner by any
suitable device. For instance, the sensing devices 64, 264a-i may
include standalone sensors that merely provide hydraulic pressure
signals to the control subsystem 18, 218. Or, the sensing devices
64, 264a-i may include sensors with built-in pre-processing
electronics that provide pre- processed signals to the control
subsystem 18, 218, and/or sensors with built-in processing
electronics that may carry out portions of the presently disclosed
method and may output suitable warning signals to other vehicle
systems.
[0049] Any of several well known techniques for conditioning or
processing sensor readings and providing such conditioned or
pre-processed output for further processing may be used. For
example, the pressure signals may be filtered, amplified,
conditioned, or the like. Any suitable preprocessing software
and/or devices may be used to reduce signal size and extract signal
contents, and processing may include Fast-Fourier Transforms (FFT),
wavelet analysis, principle component analysis, or the like.
Dynamic pressure readings may be digital or analog and may include
discrete pressure readings sampled at a certain frequency over a
certain period. For example, a dynamic pressure reading may be
sampled at a rate of 1 kHz over a 1 second period to yield 1,000
discrete pressure measurements.
[0050] At step 350, at least one condition of a cooling subsystem
may be diagnosed to provide a cooling subsystem diagnosis. The
diagnosis may be carried out by any suitable analytical techniques.
For example, the control subsystem 18, 218 may diagnose a condition
by receiving parameter values extracted from the sensed pressure
signals, executing instructions in light of such parameter values,
and transmitting suitable output signals such as control signals,
warning signals, or the like. Empirical models may be developed
from suitable engine system testing or calibration and may include
any construct that represents something using variables, such as
lookup tables, maps, formulas, algorithms and/or the like that may
be processed with the extracted parameters with or without other
engine system parameter values to produce a diagnosis. Of course,
models may be application specific and particular to the exact
design and performance specifications of any given engine
system.
[0051] In another example, artificial intelligence or neural
networks may be used to evaluate results from the preprocessed
data. Neural networks may be used to detect system status to which
the networks have been previously trained. Neural networks may be
trained to derive one or more pressure-related parameters from the
sensed dynamic hydraulic pressure signals. More specifically, the
network may be trained to produce given outputs for given inputs,
and may include adaptive weighting of certain input based on
experience. The network may be trained based on empirical engine
system calibration of an engine in an instrumented vehicle on a
dynamometer, or the like. After the neural network is trained, it
may be implemented in the control subsystem 18, 218 to process
input received from the sensing devices 64, 264a-i and other input
devices and produce some desired output signals for example to
control system devices or to issue warnings or alarms.
[0052] Steps 351 through 359 provide several specific examples of
step 350 that may be used independently or in any combination with
one another.
[0053] At step 351, one or more parameters associated with failure
of a device in a cooling subsystem may be evaluated to diagnose or
predict actual failure in the cooling subsystem. For example, the
sensing device(s) 64, 264a-i may be located at or in sufficient
proximity to any devices in the cooling subsystem 16, 216a,b that
may be susceptible to failure to reliably detect certain signals or
parameters generated by device failure. For instance, the sensing
device(s) 64, 264a-i may be located near the pump 60, 260,
thermostat valve 62, 262, or any other devices. As one example, the
frequency domain of the pressure signal may be evaluated to
determine whether the pump 60, 260 has failed in some way. This
step may allow early detection of device failure, for example,
before coolant temperature rises significantly and before
conventional temperature sensors indicate a problem by way of a
significant increase in temperature reading.
[0054] At step 352, one or more parameters associated with speed of
a pump in a cooling subsystem may be evaluated to diagnose or
estimate actual pump speed. For example, the sensing device(s) 64,
264a-i may include one or more hydraulic pressure sensors located
at or in sufficient proximity to the pump 60, 260 to reliably
detect hydraulic pressure signals generated by the pump 60, 260. In
a particular example, the frequency domain of the pressure signals
may be correlated to pump speed, such as during testing and
calibration of the system 10, 210. This step may allow early
detection of changes in pump speed, for example, before coolant
temperature rises significantly and before conventional temperature
sensors indicate a problem by way of a significant increase in
temperature reading.
[0055] At step 353, one or more parameters associated with volume
flow may be monitored to diagnose or assess actual volume flow
through one or more portions of a cooling subsystem. For example,
the sensing devices(s) 64, 264a-i may include a hydraulic pressure
sensor placed in one or more locations of the cooling subsystem 16,
216a,b where it is desired to measure coolant volume flow, for
example, at or near a restriction to detect turbulence "noise." In
a particular example, certain noises corresponding to certain flow
parameters can be processed with a model or trained into a neural
network and, thereafter, noise can be monitored to estimate volume
flow. Because volume flow through the cooling subsystem 16, 216a,b
tends to exhibit repeatable noise characteristics, volume flow may
be reliably estimated.
[0056] At step 354, one or more parameters associated with volume
flow splits in a cooling subsystem may be evaluated to diagnose or
assess whether volume flow splits are actually being carried out as
intended. For example, two or more hydraulic pressure sensors may
be placed in proximity to one or more volume flow split locations
of the cooling subsystem 16, 216a,b where it is desired to assess
absence or presence, or quality, of coolant volume flow splits. For
instance, the sensing devices 264a, 264e, 264f of FIG. 2 may be
used in proximity to their respective branch flow splits. This step
may be similar to that described in step 353. Because normal volume
flow splits in the cooling subsystem 16, 216a,b tends to exhibit
repeatable noise characteristics, volume flow splits may be
reliably assessed.
[0057] At step 355, one or more parameters, for example coolant
wave speed, associated with coolant temperature may be evaluated to
diagnose or estimate actual coolant temperature in a cooling
subsystem. For example, the sensing devices(s) 64, 264a-i may
include one or more hydrophones and/or hydraulic pressure sensors
in any location of the cooling subsystem 16, 216a,b where it is
desired to estimate coolant temperature. In a particular example,
the device(s) 64, 264a-i may be located in a side branch tube or
Helmholtz resonator, wherein Eigenfrequency of such tube or
resonator varies with changes in the speed of sound, which may be
calibrated to temperature changes in the subsystem. Accordingly,
the sensing device(s) 64, 264a-i may supplement or replace
conventional coolant temperature sensors in cooling subsystems.
[0058] At step 356, one or more parameters associated with leakage
of a cooling subsystem may be monitored to diagnose or predict
actual leakage in the cooling subsystem. For example, the sensing
device(s) 64, 264a-i may include hydraulic pressure sensors located
at or in sufficient proximity to locations in the cooling subsystem
16, 216a,b that may be susceptible to leakage to reliably detect
acoustic signals generated by actual leakage. In a particular
example, piezoelectric sensors may be mounted to subsystem conduit
or components on waveguides to transform acoustic waves to
electronic voltage signals, which may be amplified, filtered, and
processed to determine energy content emanating from sites of fluid
leakage such as through orifices, cracks, and/or corrosion in a
pressurized cooling sub-system. This step may allow early detection
of leakage, for example, before coolant temperature rises
significantly and before conventional temperature sensors indicate
a problem by way of a significant increase in temperature
reading.
[0059] At step 357, one or more parameters associated with
localized boiling of coolant in a cooling subsystem may be
monitored to diagnose or predict actual boiling in the cooling
subsystem. For example, the sensing device(s) 64, 264a-i may
include one or more hydraulic pressure sensors located at or in
sufficient proximity to locations in the cooling subsystem 16,
216a,b that may be susceptible to localized boiling to reliably
detect pressure signals generated by actual boiling. In a
particular example, buildup and collapse of coolant bubbles cause
certain acoustic footprints that may be sensed by the device(s) 64,
264a-i and identified by the control subsystem 18, 218. This step
may allow early detection of localized boiling, for example, before
coolant temperature rises significantly and before conventional
temperature sensors indicate a problem by way of a significant
increase in temperature reading.
[0060] At step 358, one or more parameters associated with a
variably controlled valve of a cooling subsystem may be monitored
to diagnose or assess position, opening or closing percentage, or
the like of the valve. For example, the sensing device(s) 64,
264a-i may include one or more hydraulic pressure sensors located
in proximity to a valve, such as valves 263a, 263b of FIG. 2. This
step may be similar to step 353, wherein volume flow may be
analyzed to assess whether a valve has been opened or not, as just
one example.
[0061] At step 359, one or more parameters associated with
cavitation in a cooling subsystem may be monitored to diagnose or
predict actual cavitation in the cooling subsystem. For example,
the sensing device(s) 64, 264a-i may include one or more hydraulic
pressure sensors located at or in sufficient proximity to locations
in the cooling subsystem 16, 216a,b that may be susceptible to
cavitation to reliably detect pressure signals generated by actual
cavitation. This step may allow early detection of cavitation, for
example, before damage occurs and the coolant temperature rises
significantly and before conventional temperature sensors indicate
a problem by way of a significant increase in temperature
reading.
[0062] At step 360, the method 300 may be terminated in any
suitable manner. For example, the method 300 may be terminated at
shutdown of the engine 12, 212 of the engine system 10, 210 of FIG.
1 or 2.
[0063] The method 300 may be used as input to any suitable control
of a cooling subsystem or any other subsystem or portion of an
engine system. In one example, the method 300 may be used to
generate an input parameter for closed-loop control of variable
pump speed. In another example, the method may be used to control
flow of coolant through a controllable or active thermostat. Of
course, control of variable pump speed or thermostat flow-through
may also involve other parameters such as engine speed, load,
vehicle speed, intake manifold temperature, and/or any other
suitable parameters.
[0064] The method 300 or any portion thereof may be performed as
part of a product such as the systems 10, 210 or subsystems 16,
216a,b of FIG. 1 or 2, and/or as part of a computer program that
may be stored and/or executed by the control subsystems 18, 218.
The computer program may exist in a variety of forms both active
and inactive. For example, the computer program can exist as
software program(s) comprised of program instructions in source
code, object code, executable code or other formats; firmware
program(s); or hardware description language (HDL) files. Any of
the above may be embodied on a computer usable medium, which
include storage devices and signals, in compressed or uncompressed
form. Exemplary computer usable storage devices include
conventional computer system RAM (random access memory), ROM (read
only memory), EPROM (erasable, programmable ROM), EEPROM
(electrically erasable, programmable ROM), and magnetic or optical
disks or tapes.
[0065] At least portions of the presently disclosed method may be
enabled by one or more computer programs and various engine system
data or instructions stored in memory as look-up tables, formulas,
algorithms, maps, models, or the like. In any case, the control
subsystems 18, 218 may control engine system parameters by
receiving input signals from the sensors, executing instructions or
algorithms in light of sensor input signals, and transmitting
suitable output signals to the various actuators.
[0066] The above description of embodiments of the invention is
merely exemplary in nature and, thus, variations thereof are not to
be regarded as a departure from the spirit and scope of the
invention.
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