THERMAL MANAGEMENT OF AFTERTREATMENT DEVICES OF OPPOSED-PISTON ENGINES UNDER MOTORING CONDITIONS
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.
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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 FIELDThe 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.
BACKGROUNDA 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.
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.
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.
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.
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.
SUMMARYCertain 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.
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.
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.
With reference to
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.
With further reference to
As per
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
An air handling system 200 for a two-stroke cycle, opposed-piston engine 201 such as the engine illustrated by
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.
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.
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.
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.
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.
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.
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
Variations on the airflow control process of
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.
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.
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.
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.
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.
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.
Type: Application
Filed: Jan 6, 2020
Publication Date: Jun 4, 2020
Applicant: ACHATES POWER, INC. (San Diego, CA)
Inventors: FABIEN G. RENDON (San Diego, CA), ARUNANDAN SHARMA (San Diego, CA)
Application Number: 16/735,247