U.S. patent application number 16/735247 was filed with the patent office on 2020-06-04 for thermal management of aftertreatment devices of opposed-piston engines under motoring conditions.
This patent application is currently assigned to ACHATES POWER, INC.. The applicant listed for this patent is ACHATES POWER, INC.. Invention is credited to FABIEN G. RENDON, ARUNANDAN SHARMA.
Application Number | 20200173387 16/735247 |
Document ID | / |
Family ID | 67953845 |
Filed Date | 2020-06-04 |
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United States Patent
Application |
20200173387 |
Kind Code |
A1 |
RENDON; FABIEN G. ; et
al. |
June 4, 2020 |
THERMAL MANAGEMENT OF AFTERTREATMENT DEVICES OF OPPOSED-PISTON
ENGINES UNDER MOTORING CONDITIONS
Abstract
A method of operating a two-stroke cycle, opposed-piston engine
comprising a pumping device coupled to pump air to cylinders of the
engine through a charge air cooler and an aftertreatment system of
thermally-activated devices coupled to receive exhaust from the
cylinders by which a thermal state of the exhaust sufficient to
sustain thermal activation of one or more of the aftertreatment
system devices may be maintained during a deceleration or motoring
condition of operation by reducing the mass airflow to the
engine.
Inventors: |
RENDON; FABIEN G.; (San
Diego, CA) ; SHARMA; ARUNANDAN; (San Diego,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ACHATES POWER, INC. |
San Diego |
CA |
US |
|
|
Assignee: |
ACHATES POWER, INC.
San Diego
CA
|
Family ID: |
67953845 |
Appl. No.: |
16/735247 |
Filed: |
January 6, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/US2019/047772 |
Aug 22, 2019 |
|
|
|
16735247 |
|
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62725199 |
Aug 30, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F01N 2900/1411 20130101;
F02B 25/08 20130101; F02B 29/04 20130101; F02B 39/10 20130101; F02D
2200/703 20130101; F01N 2900/1404 20130101; F02D 2200/0406
20130101; F02B 37/04 20130101; F02D 41/0007 20130101; F02D 41/123
20130101; F01N 9/00 20130101; F02D 41/0055 20130101; F02D 2200/0414
20130101; F02B 29/0412 20130101; F02D 2400/04 20130101; F02B 37/18
20130101; F02B 2075/025 20130101; F02D 23/00 20130101; F02D
2200/0802 20130101; F02B 75/28 20130101; F02D 43/00 20130101; F02D
41/0235 20130101; F02D 41/0005 20130101; F01B 7/14 20130101; F02B
75/282 20130101; F02D 2200/021 20130101 |
International
Class: |
F02D 41/02 20060101
F02D041/02; F02D 23/00 20060101 F02D023/00; F02D 41/00 20060101
F02D041/00; F02D 43/00 20060101 F02D043/00; F02B 75/28 20060101
F02B075/28; F02B 25/08 20060101 F02B025/08 |
Claims
1. A method of operating a two-stroke cycle, opposed-piston engine
comprising a device coupled to pump air to cylinders of the engine
through a charge air cooler and an aftertreatment system of
thermally-activated devices coupled to receive exhaust from the
cylinders, the method comprising: injecting fuel into the engine
while operating the engine in a two-stroke cycle mode; operating
the device to provide a mass airflow to an inlet of the engine;
transporting a mass exhaust flow from an outlet of the engine to an
inlet of the aftertreatment system; ceasing fuel injection into the
engine while decelerating the engine; maintaining a thermal state
of the mass exhaust flow sufficient to sustain thermal activation
of one or more of the aftertreatment system devices during
deceleration of the engine by reducing mass airflow to the inlet of
the engine.
2. The method of claim 1, further comprising reducing the mass
exhaust flow to the aftertreatment system during deceleration of
the engine.
3. The method of claim 2, wherein the mass airflow includes
recirculated exhaust flow, the method further comprising reducing
the recirculated exhaust flow during deceleration of the
engine.
4. The method of claim 1, wherein the device is a supercharger and
reducing mass airflow to the inlet of the engine comprises
recirculation of a portion of the mass airflow obtained downstream
of an outlet of the charge air cooler to an inlet of the
supercharger.
5. The method of claim 4, further comprising reducing the mass
exhaust flow to the aftertreatment system during deceleration of
the engine.
6. The method of claim 5, wherein the mass airflow includes
recirculated exhaust flow, the method further comprising reducing
the recirculated exhaust flow during deceleration of the
engine.
7. A method of operating a two-stroke cycle, opposed-piston engine
comprising a supercharger coupled to pump air to cylinders of the
engine through a charge air cooler and an aftertreatment system of
thermally-activated devices coupled to receive exhaust from the
cylinders, the method comprising: injecting fuel into the engine
while operating the engine in a two-stroke cycle mode; operating
the supercharger to provide a mass airflow into the engine;
transporting a mass exhaust flow from the engine to the
aftertreatment system; ceasing fuel injection into the engine while
motoring the engine; maintaining a thermal state of the mass
exhaust flow sufficient to sustain thermal activation of one or
more of the aftertreatment system devices during motoring of the
engine by recirculating a portion of the mass airflow to an inlet
of the supercharger.
8. The method of claim 7, wherein the portion of the mass airflow
recirculated to the inlet of the supercharger is obtained
downstream of an outlet of the charge air cooler.
9. The method of claim 8, further including reducing the mass
exhaust flow to the aftertreatment system during motoring of the
engine.
10. The method of claim 7, wherein the mass airflow includes
recirculated exhaust flow and wherein the portion of the mass
airflow recirculated to the supercharger is obtained downstream of
the charge air cooler.
11. The method of claim 10, further including reducing the mass
exhaust flow to the inlet of the aftertreatment system during
motoring of the engine.
12. The method of claim 11, further including reducing the
recirculated exhaust flow during motoring of the engine.
13. A method of operating a fuel-injected, opposed-piston engine
comprising a supercharger coupled to pump air to cylinders of the
engine through a charge air cooler and an aftertreatment system of
thermally-activated devices coupled to receive exhaust from the
cylinders, the method comprising: injecting fuel into the engine
while operating the engine in a two-stroke cycle mode; operating
the supercharger to provide a mass airflow to the engine;
transporting a mass exhaust flow from the engine to the
aftertreatment system; ceasing fuel injection into the engine while
decelerating or motoring the engine; maintaining a thermal state of
the mass exhaust flow sufficient to sustain thermal activation of
one or more of the aftertreatment system devices during
deceleration or motoring of the engine by reducing the mass airflow
to the engine.
14. The method of claim 13, wherein the mass airflow to the engine
is reduced by recirculating a portion of the mass airflow to an
inlet of the supercharger obtained downstream of an outlet of the
charge air cooler.
15. The method of claim 14, further including reducing the mass
exhaust flow to the aftertreatment system during deceleration or
motoring of the engine.
16. The method of claim 13, wherein the mass airflow includes
recirculated exhaust flow.
17. The method of claim 16, further including reducing the mass
exhaust flow to the aftertreatment system during deceleration or
motoring of the engine.
18. The method of claim 17, further including reducing the
recirculated exhaust flow during deceleration or motoring of the
engine.
19. A method of operating a fuel-injected, opposed-piston engine
comprising a supercharger coupled to pump air to cylinders of the
engine through a charge air cooler and an aftertreatment system of
thermally-activated devices coupled to receive exhaust from the
cylinders, the method comprising: injecting fuel into the engine
while operating the engine in a two-stroke cycle mode; operating
the supercharger to provide a mass airflow to the engine;
transporting a mass exhaust flow from the engine to an inlet of the
aftertreatment system; ceasing fuel injection into the engine while
operating the engine; maintaining a thermal state of the mass
exhaust flow sufficient to sustain thermal activation of one or
more of the aftertreatment system devices during cessation of fuel
injection by reducing the mass airflow to the engine.
20. The method of claim 19, wherein the mass airflow to the engine
is reduced by recirculating a portion of the mass airflow obtained
downstream of an outlet of the charge air cooler to an inlet of the
supercharger.
21. The method of claim 20, further including reducing the mass
exhaust flow to the aftertreatment system during cessation of fuel
injection.
22. The method of claim 19, wherein the mass airflow includes
recirculated exhaust flow.
23. The method of claim 22, further including reducing the mass
exhaust flow to the aftertreatment system during cessation of fuel
injection.
24. The method of claim 23, further including reducing the
recirculated exhaust flow during cessation of fuel injection.
25. A method of operating a two-stroke, opposed-piston engine
comprising a supercharger coupled to pump air to cylinders of the
engine through a charge air cooler and an aftertreatment system of
thermally-activated devices coupled to receive exhaust from the
cylinders, the method comprising: injecting fuel into the engine
while operating the engine in a two-stroke cycle mode; operating
the supercharger to provide a mass airflow to the engine;
transporting a mass exhaust flow from the engine to an inlet of the
aftertreatment system; detecting an exhaust flow reduction
condition of engine operation; ceasing fuel injection in response
to the exhaust flow reduction condition of engine operation;
maintaining a thermal state of the mass exhaust flow sufficient to
sustain thermal activation of one or more of the aftertreatment
system devices during the exhaust reduction condition of operation
by reducing the mass airflow to the inlet of the engine.
26. The method of claim 25, wherein the mass airflow to the inlet
of the engine is reduced by recirculating a portion of the mass
airflow to an inlet of the supercharger obtained downstream of an
outlet of the charge air cooler.
27. The method of claim 26, further including reducing the mass
exhaust flow to the aftertreatment system during the exhaust
reduction condition of operation.
28. The method of claim 25, wherein the mass airflow includes
recirculated exhaust flow.
29. The method of claim 28, further including reducing the mass
exhaust flow to the inlet of the aftertreatment system during the
exhaust reduction condition of operation.
30. The method of claim 29, further including reducing the
recirculated exhaust flow during the exhaust reduction condition of
operation.
Description
PRIORITY
[0001] This application claims priority as a continuation of PCT
application PCT/US2019/047772, filed Aug. 22, 2019, which claims
priority to US provisional application for patent 62/725,199, filed
Aug. 30, 2018.
TECHNICAL FIELD
[0002] The field is exhaust management strategies of two-stroke
cycle, opposed-piston engines which maintain exhaust temperatures
at levels suitable for effective operation of aftertreatment
devices.
BACKGROUND
[0003] A two-stroke cycle engine is an internal combustion engine
that completes a cycle of operation with a single complete rotation
of a crankshaft and two strokes of a piston connected to the
crankshaft. The strokes are typically denoted as compression and
power strokes. One example of a two-stroke cycle engine is an
opposed-piston engine in which two pistons are disposed in the bore
of a cylinder for reciprocating movement in opposing directions
along the central axis of the cylinder. Each piston moves between a
bottom center (BC) location where it is nearest one end of the
cylinder and a top center (TC) location within the cylinder where
it is furthest from the one end. The cylinder has ports formed in
the cylinder sidewall near respective BC piston locations. Each of
the opposed pistons controls one of the ports, opening the port as
it moves to its BC location, and closing the port as it moves from
BC toward its TC location. One of the ports serves to admit charge
air (sometimes called "scavenging air") into the bore, the other
provides passage for the products of combustion out of the bore;
these are respectively termed "intake" and "exhaust" ports (in some
descriptions, intake ports are referred to as "air" ports or
"scavenge" ports). In a uniflow-scavenged opposed-piston engine,
pressurized charge air enters a cylinder through its intake port as
exhaust gas flows out of its exhaust port, thus gas flows through
the cylinder in a single direction ("uniflow")--from intake port to
exhaust port.
[0004] The opposed-piston engine has an air handling system that
manages the transport of charge air provided to, and exhaust gas
produced by, the engine during operation of the engine. A
representative air handling system construction includes a charge
air subsystem and an exhaust subsystem. The charge air subsystem
receives and compresses air and includes a charge air channel that
delivers the compressed air to the intake port or ports of the
engine. The charge air subsystem may comprise one or both of a
turbine-driven compressor and a supercharger. The charge air
channel typically includes at least one air cooler that is coupled
to receive and cool the charge air (or a mixture of gasses
including charge air) before delivery to the intake ports of the
engine. The exhaust subsystem includes an exhaust channel that
transports exhaust gas from engine exhaust for delivery to other
exhaust subsystem components such as a turbine that drives the
compressor, an exhaust gas recirculation (EGR) loop, and one or
more aftertreatment devices.
[0005] As in conventional four-stroke engines the aftertreatment
devices of opposed-piston engines cleanse exhaust gas of
undesirable components as it is transported through the devices
before being emitted into the atmosphere. The aftertreatment
devices are constructed to convert components such as soot, NOx,
and unburned hydrocarbons in the exhaust gas into harmless
compounds by thermally-driven processes that may include one or
more of catalyzation, decomposition, and filtration. The heat that
causes the devices to operate is obtained from the exhaust gas
itself, and the devices operate most effectively when exhaust gas
temperatures are relatively high. One goal of an exhaust strategy
for internal combustion engines equipped with aftertreatment
devices is to maintain exhaust temperatures within a range of
temperatures where the devices work most effectively. Ramesh, A.
K., Gosala, D. B., Allen, C., Joshi, M., McCarthy Jr., J., Farrell,
L., Koeberlein, E. D., and Shaver, G., "Cylinder Deactivation for
Increased Engine Efficiency and Aftertreatment Thermal Management
in Diesel Engines," SAE Technical Paper 2018-01-384, 2018.
[0006] One engine operating condition which presents a challenge
for such a strategy is motoring. In this regard, presume that the
engine is installed in a vehicle, in which case motoring occurs
during deceleration of the vehicle when the provision of fuel to
the engine is interrupted and the engine continues to run in
response to the vehicle's inertia. Motoring occurs in a dynamometer
when the engine is run, without provision of fuel, by application
of power to the engine's power train by a separate motor. The
absence of combustion during motoring cools down exhaust flow which
reduces the temperature of the aftertreatment devices. When
deceleration is followed by acceleration and fueling, combustion
occurs and mass exhaust flow is heated, thereby again heating
exhaust flow. However, if the motoring period results in reduction
of aftertreatment temperatures to suboptimal or non-operating
levels, there may be an initial period of acceleration when
undesirable emissions increase before the aftertreatment devices
are once again heated to effective levels by the mass exhaust
flow.
[0007] The goal of exhaust temperature maintenance may be attained
by a management process that reduces the flow of air through the
engine, which may result in higher exhaust temperatures. Ramesh, et
al., op. cit. An opposed-piston engine operated in a two-stroke
cycle mode has no intake stroke with which to pump air through the
engine. Instead the air handling system comprises one or more
devices for this purpose. In many cases the preferred pumping
device is a supercharger. Manifestly, when the engine is motored in
a moving vehicle (or in a dynamometer) by cessation of fueling,
operation of the pumping device continues to push air through the
engine, often through a charge air cooler. The continued flow of
air unheated by combustion may cool aftertreatment devices and make
them ineffective--causing emission of undesirable exhaust
components for a period of time after resumption of combustion
while the devices are brought to their effective operating
temperatures.
SUMMARY
[0008] Certain embodiments of the invention include a method of
operating a fuel-injected, opposed-piston engine comprising a
pumping device coupled to pump air to cylinders of the engine and
an aftertreatment system of thermally-activated devices coupled to
receive exhaust from the cylinders by which a thermal state of the
mass exhaust flow sufficient to sustain thermal activation of one
or more of the aftertreatment system devices may be maintained
during a deceleration or motoring condition of operation by
reducing the mass airflow to the engine.
[0009] In some embodiments, a thermal state of the mass exhaust
flow sufficient to sustain thermal activation of one or more of the
aftertreatment system devices may be maintained during deceleration
of the engine by recirculating a portion of the mass airflow to an
inlet of the pumping device.
[0010] In some other embodiments, a thermal state of the mass
exhaust flow sufficient to sustain thermal activation of one or
more of the aftertreatment system devices may be maintained during
motoring of the engine by recirculating a portion of the mass
airflow to an inlet of the pumping device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic diagram of an opposed-piston engine
equipped with an air handling system with an EGR loop and is
properly labeled "Prior Art".
[0012] FIG. 2 is a schematic drawing illustrating a control
mechanization for control of an air handling system in an
opposed-piston engine.
[0013] FIG. 3 is a flow diagram showing a process for maintaining a
thermal state of mass exhaust flow sufficient to sustain thermal
activation of one or more aftertreatment system devices of the air
handling system of an opposed-piston engine during a deceleration
or motoring condition of engine operation.
DETAILED DESCRIPTION
[0014] With reference to FIG. 1, a two-stroke cycle internal
combustion engine is embodied in an opposed-piston engine 49 having
at least one ported cylinder 50. For example, the engine may have
one ported cylinder, two ported cylinders, three ported cylinders,
or four or more ported cylinders. Each ported cylinder 50 has a
bore 52 and exhaust and intake ports 54 and 56 formed or machined
in the vicinity of respective ends of a cylinder wall. Each of the
ports 54 and 56 includes one or more circumferential arrays of
openings in which adjacent openings are separated by a solid
bridge. In some descriptions, each opening is referred to as a
"port"; however, the construction of a circumferential array of
such "ports" is no different than the port constructions shown in
FIG. 1. Pistons 60 and 62 are slideably disposed in the bore 52 of
each cylinder with their end surfaces 61 and 63 opposing one
another. Movements of the pistons 60 control the operations of the
exhaust ports 54. Movements of the pistons 62 control the
operations of the intake ports 56. Thus, the ports 54 and 56 are
referred to as "piston controlled ports". Pistons 60 controlling
the exhaust ports ("exhaust pistons") are coupled to a crankshaft
71. Pistons 62 controlling the intake ports of the engine ("intake
ports") are coupled to a crankshaft 72.
[0015] As pistons 60 and 62 approach respective TC locations, a
combustion chamber is defined in the bore 52 between the end
surfaces 61 and 63. Fuel is injected directly into the combustion
chamber through at least one fuel injector nozzle 100 positioned in
an opening through the sidewall of a cylinder 50. The fuel mixes
with charge air admitted through the intake port 54. As the mixture
is compressed between the end surfaces it reaches a temperature
that causes the fuel to ignite; in some instances, ignition may be
assisted, as by spark or glow plugs. Combustion follows.
[0016] With further reference to FIG. 1, the engine 49 includes an
air handling system 51 that manages the transport of charge air
provided to, and exhaust gas produced by, the engine 49. A
representative air handling system construction includes a charge
air subsystem and an exhaust subsystem. In the air handling system
51, the charge air subsystem includes a charge air source that
receives intake air and processes it into charge air, a charge air
channel coupled to the charge air source through which charge air
is transported to the at least one intake port of the engine, and
at least one air cooler in the charge air channel that is coupled
to receive and cool the charge air before delivery to the intake
port or ports of the engine. Such a cooler can comprise an
air-to-liquid and/or an air-to-air device, or another cooling
device. Hereinafter, such a cooler is denoted as a "charge air
cooler". The charge air subsystem also includes a supercharger that
pumps charge air in the charge air channel to intake ports of the
engine. The exhaust subsystem includes an exhaust channel that
transports exhaust products from exhaust ports of the engine to an
exhaust outlet.
[0017] As per FIG. 1, the preferred charge air subsystem includes a
supercharger 110, which can be driven by an electrical motor, or by
a gear, chain, or belt apparatus coupled to a crankshaft. The
supercharger 110 can be a single-speed or multiple-speed device, or
a fully variable-speed device. In some aspects, the air management
system 51 includes a turbocharger 120 with a turbine 121 and a
compressor 122 that rotate on a common shaft 123. The turbine 121
is coupled to the exhaust subsystem and the compressor 122 is
coupled to the charge air subsystem. The turbine 121 can be a
fixed-geometry or a variable-geometry device. The turbocharger 120
extracts energy from exhaust gas that exits the exhaust ports 54
and flows into the exhaust channel 124 directly from the exhaust
ports 54, or from an exhaust manifold 125. In this regard, the
turbine 121 is rotated by exhaust gas passing through it. This
rotates the compressor 122, causing it to generate charge air by
compressing intake air. The charge air output by the compressor 122
flows through a conduit 126 to a charge air cooler 127, whence it
is pumped by the supercharger 110 to the intake ports. Air
compressed by the supercharger 110 is output from the supercharger
through a charge air cooler 129 to an intake manifold 130. The
intake ports 56 receive charge air pumped by the supercharger 110,
through the intake manifold 130. Preferably, but not necessarily,
in multi-cylinder opposed-piston engines, the intake manifold 130
is constituted of an intake plenum that communicates with the
intake ports 56 of all cylinders 50.
[0018] The air handling system 51 may be equipped to control
emissions of nitrous oxide (NOx) by recirculating exhaust gas
through the one or more cylinders of the opposed-piston engine. The
recirculated exhaust gas is mixed with charge air to lower peak
combustion temperatures, which lowers NOx emissions. This process
is referred to as exhaust gas recirculation ("EGR"). The
opposed-piston engine 49 seen in FIG. 1 may be equipped with an EGR
loop that channels exhaust gas from the exhaust subsystem into the
charge air subsystem. An example of a specific EGR loop
construction (which is not intended to be limiting) is a high
pressure configuration illustrated in FIG. 1. In this regard, a
high pressure EGR loop circulates exhaust gas obtained from a
source upstream of the turbine 121 to a mixing point downstream of
the compressor 122. In this EGR loop the conduit 131 and an EGR
valve 138 shunt a portion of the exhaust gas from the exhaust
manifold 125 to be mixed with charge air output by the compressor
122 into the conduit 126. If no exhaust/air mixing is required the
valve 138 is fully shut and charge air with no exhaust gas is
delivered to the cylinders. As the valve 138 is increasingly
opened, an increasing amount of exhaust gas is mixed into the
charge air.
[0019] An air handling system 200 for a two-stroke cycle,
opposed-piston engine 201 such as the engine illustrated by FIG. 1
is shown in the schematic diagram of FIG. 2. The air handling
system 200 includes a supercharger 210 which receives input rotary
power from a drive unit 212. The supercharger 210 includes an inlet
213 and an outlet 214. The air handling system 200 may also include
a turbocharger 220 with a turbine 221 and a compressor 222. The
turbine 221 is coupled to an exhaust channel 224 and the compressor
222 is coupled to a charge air channel 225. The turbine 221 is spun
by exhaust gas expelled from the exhaust ports 156 of the engine
201 and transported through the exhaust channel 224. This spins the
compressor 222, causing it to generate charge air by compressing
inlet air that flows into the charge air channel. Compressed charge
air output by the compressor 222 is transported through the charge
air channel 225 to a charge air cooler 227. In this configuration,
the supercharger 210 constitutes a second stage of compression in
the air handling system 200 (following the compressor 222). In any
case, the supercharger 210 compresses air in the charge air channel
and provides compressed charge air (also called "boost") to the
intake ports 154 of the opposed-piston engine. In some instances, a
charge air cooler 229 may be provided to cool the output of the
supercharger 210. Optionally, the air handling system may include
an EGR loop 230 to transport exhaust products from the exhaust
channel 224 to the charge air channel 225 via an EGR mixer 226.
[0020] The exhaust channel 224 includes an exhaust aftertreatment
system 228 downstream of the turbine 221. Exhaust gas flowing from
the outlet of the turbine 221 flows through devices of the
aftertreatment system 228 and, from there, out of a tailpipe. The
aftertreatment system 228 may be constituted of one or more
aftertreatment devices. For example, the aftertreatment system 228
may include one or more devices to convert components such as soot,
NOx, and unburned hydrocarbons in the exhaust gas into harmless
compounds by thermally-driven processes that may include one or
more of catalyzation, decomposition, and filtration. In this
regard, the aftertreatment system may include a diesel oxidation
catalyst (DOC) device, a diesel particulate filter (DPF) device, a
selective catalytic reduction (SCR), and/or an ammonia slip
catalyst (ASC) device. Such an aftertreatment system would be
comparable to a typical exhaust after-treatment system on a
commercial heavy duty diesel four-stroke engine. The heat that
causes aftertreatment devices of the aftertreatment system to
operate is obtained from the exhaust gas itself, and the devices
operate most effectively when exhaust gas temperatures are
relatively high.
[0021] Control of the gas transport configuration of the air
handling system is implemented by a mechanization that includes a
programmable ECU (engine control unit) 240, air handling processes
executed on the ECU, air handling valves and associated actuators,
the supercharger 210, and engine sensors. The ECU 240 is programmed
to execute fuel handling algorithms and air handling algorithms
under various engine operating conditions. Such algorithms are
embodied in control modules that are part of an engine systems
control program executed by the ECU 240 while the engine is
operating. For a common rail direct injection system with which the
engine may be equipped, the ECU 240 can control injection of fuel
into the engine's cylinders by issuing rail pressure commands and
injector commands.
[0022] Air handling system control is exercised by settings of
variable valves. In this regard, for example, a supercharger bypass
valve 231 (also referred to as a "recirculation" or "shunt" valve)
bleeds charge air produced by the supercharger 210 through a bypass
channel 232 so as to modulate charge air pressure, and dampen
surges, at the intake ports 154. An EGR valve 233 adjusts the
amount of exhaust gas that is transported through the EGR loop 230
to the charge air channel 225 for control of emissions. A wastegate
valve 235 shunts exhaust gas around the turbine 221 in order to
control the amount of exhaust gas flowing through the turbine 221,
thereby modifying the turbine work and the exhaust gas temperature
downstream of the turbine. A backpressure valve 237 regulates
exhaust pressure at the turbine outlet in order to increase the gas
pressure inside the engine and warm the engine quickly during
start-up. For fast, precise automatic operation, it is preferred
that these and other valves in the air handling system be
high-speed, computer-controlled devices, with continuously-variable
settings. The ECU 240 is in control communication with actuators
(not shown) that operate the valves in response to ECU-issued
valve-setting commands. In cases where the supercharger 210 is
operated by a variable drive, the ECU 240 also controls gas
transport by issuing drive commands to actuate the supercharger
drive 212. And, in those instances where the turbine 221 may be
configured as a variable geometry device, the ECU 240 also controls
the transport of gas by issuing VGT commands to set the aspect
ratio of the turbine.
[0023] The ECU 240 monitors air handling system operating
conditions by way of various air handling sensors. In this regard,
such sensors may include, without limitation, accelerator position,
engine speed, fuel rail pressure, mass airflow, mass EGR flow,
intake manifold, exhaust manifold, supercharger inlet, supercharger
outlet, coolant temperature, and so on. For purposes of this
specification these and other sensors may comprise physical
measurement instruments and/or virtual systems.
[0024] In most cases, to obtain the rotary power necessary to its
operation, the supercharger 210 is directly coupled to the
engine-usually via a crankshaft-driven drive apparatus. In these
cases the speed of the supercharger is dependent on the speed of
the engine. In some instances, the drive 212 may be equipped with a
transmission that enables the supercharger to be driven, under
command of the air handling control mechanization, at a
continuously-, or incrementally-, variable speed, independently of
a crankshaft. In some of these instances, the supercharger bypass
valve 231 may be redundant. That is to say, the greater the
variability in supercharger speed afforded by the variable-speed
drive, the less likely a bypass valve would be needed to modulate
boost pressure. However, there may be instances wherein a drive
unit is constructed to provide a limited number of speeds (two
speeds, for example) and flexibility in control of boost pressure
may require the operations of the supercharger bypass valve
231.
[0025] Under control of an air handling process executed by the ECU
240, exhaust temperature management is provided by reducing the
flow of air through the engine in order to maintain effective
operation of thermally activated devices of the aftertreatment
system of an opposed-piston engine. The desired result is obtained
by taking advantage of the fact that such an opposed-piston engine
has negligible internal pumping. Instead one or more external
devices are provided for this purpose. In many cases the preferred
pumping devices comprise the supercharger and the turbocharger.
When the engine is decelerated in a moving vehicle (or motored in a
dynamometer), only the supercharger continues to push (i.e., pump)
air through the engine, often through one or more charge air
coolers. With nothing more, one would expect the continued flow of
air unheated by combustion to cool thermally-actuated
aftertreatment devices and make them ineffective--causing emission
of undesirable exhaust components during subsequent acceleration
until the devices are brought to their effective operating
temperatures.
[0026] FIG. 2 shows how this undesirable effect may be reduced or
eliminated in an opposed-piston engine operated in a two-stroke
cycle mode. Inlet air flows form the compressor 222 into the
supercharger 210 through the charge air cooler 227. The
supercharger 210 may be driven using a 2-speed drive in order to
control the drive ratio between the engine crankshaft to which the
drive is coupled and the input shaft of the supercharger 210. The
supercharger 210 may also act as a pump to draw recirculated
exhaust through the EGR loop 230. Charge air (with or without
recirculated exhaust) flows through the supercharger 210 into the
engine intake manifold 130 through the charge air cooler 229. The
supercharger bypass valve 231 enables the ECU 240 to accurately
control the mass airflow going into the engine, and therethrough to
the exhaust subsystem. All of the pumping work required to move the
mass of air is provided by the turbocharger 222 and the
supercharger 210. Pistons do not contribute to pumping. During
deceleration or motoring when the exhaust enthalpy is negligible,
the supercharger 210 does virtually all of the pumping. As a
result, during deceleration or motoring, it is possible to
significantly reduce the cold air flow going into the exhaust
subsystem through the engine by controlling the position of the
supercharger bypass valve 231. During deceleration or motoring this
reduction can contribute to keeping the aftertreatment system 238
of the opposed-piston engine warm unlike four-stroke engines in
which piston motion continues to pump cold air through the
aftertreatment system 238. Although FIG. 2 shows the aftertreatment
system 228 located on the downstream side of the backpressure valve
237, this is not the only location where this desirable effect may
be produced. The benefits of reducing cold airflow during
deceleration or motoring may be realized when the components of the
aftertreatment system 238 are situated between the downstream side
of the wastegate valve 235 and the downstream side of the
backpressure valve.
[0027] FIG. 3 illustrates the above-described process as a method
of airflow control for thermal management of aftertreatment devices
of an opposed-piston engine, which may be executed by the ECU 240
during two-stroke operation of an opposed-piston engine equipped
with an air handling system such as that of FIG. 2. The airflow
control process 300 is initiated at 302 by operation of the engine
either in a vehicle or a dynamometer. Operation of the engine may
include injecting fuel into the engine while operating the engine
in a two-stroke cycle mode, operating the supercharger to provide a
mass airflow into the engine, and transporting a mass exhaust flow
from the engine to the aftertreatment system.
[0028] When the engine is decelerated or motored at 304, fueling of
the engine is shut at 306 by one or more fuel stop commands (best
seen in FIG. 2). At 308, exhaust flow out of the engine into the
exhaust subsystem is reduced by reducing mass airflow into the
engine, which may be accomplished by reduction of airflow out of
the supercharger 210. In the preferred embodiment, this reduction
is accomplished by opening the bypass valve 231, which causes
charge air to be circulated or shunted from the outlet 214 to the
inlet 213 of the supercharger. As per FIG. 2, when the recirculated
charge air is diverted into the bypass channel 232 downstream of
the charge air cooler 229 and returned to the supercharger 210 via
the inlet of the charge air cooler 227, the combined cooling effect
of the two coolers on the reduced air mass delivered to the
aftertreatment exhaust subsystem is minimized. In other
implementations, the bypass channel 232 can be modified to obtain
the output of the supercharger from a point between the
supercharger outlet 214 and the inlet of the charge air cooler 229.
Upon resumption of combustion by the engine at 310, the control
process returns to 302.
[0029] Variations on the airflow control process of FIG. 3 may be
implemented. For example, when the supercharger bypass valve 231 is
opened during deceleration or motoring the backpressure valve 237
may be partially or fully closed. Further, when the supercharger
bypass valve 231 is opened and the backpressure valve 237 is
closed, the EGR valve 233 may be opened. Opening the bypass channel
and the EGR loop may allow for lower restriction and even lower
supercharger loads. If the drive 212 is equipped with a clutch, the
drive may be de-clutched to reduce the supercharger rotation speed
to zero, which may eliminate all pumping from the engine and
essentially cut off exhaust flow. Alternatively, If the
supercharger drive is variable, a lower ratio can be selected.
[0030] A surprising result of these strategies may be that the
engine motoring torque or engine drag may be reduced enough to
allow the vehicle to roll without power for a longer distance and
thereby reduce fuel consumption. Further with the exhaust
backpressure valve remaining closed, the engine drag can be
modulated to provide a desired level of deceleration of the vehicle
or to compensate for other vehicle loads to meet vehicle
drivability requirements.
[0031] The desired exhaust management strategy can be triggered
based on a variety of parameters including reduction of the fuel
flow request to zero. This strategy can be enabled within a given
vehicle speed range, within a given engine speed range, within a
given coolant temperature range, within a given catalyst
temperature range, within a given ambient temperature range, and/or
within a given ambient pressure range.
[0032] In the case when there is a specific request for a different
engine drag torque, a model of the supercharger power consumption
based on supercharger inlet and outlet pressure and temperature may
be used to adjust the bypass valve and/or EGR valve to achieve the
requested drag torque.
[0033] In the foregoing specification, embodiments have been
described with reference to numerous specific details that can vary
from implementation to implementation. Certain adaptations and
modifications of the described embodiments can be made. Other
embodiments can be apparent to those skilled in the art from
consideration of the specification and practice of the invention
disclosed herein. It is intended that the specification and
examples be considered as exemplary only, with a true scope and
spirit of the invention being indicated by the following
claims.
[0034] It is also intended that the sequence of steps, acts, or
states shown in figures are only for illustrative purposes and are
not intended to be limited to any particular sequence of steps. As
such, those skilled in the art can appreciate that these steps,
acts, or states can be performed in a different order while
implementing the same method.
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