Background of the Invention
1. Field of the Invention
The present invention relates generally to a plasma ignition system for an internal combustion engine having a plurality of engine cylinders and particularly to a plasma ignition system having (1) a power supply for supplying electric power to start a spark discharge in each plasma ignition plug and (2) a switching circuit for operatively connecting the power supply to each plasma ignition plug wherein the supply and circuit are separate from another power supply for supplying a large amount of electric power to continue an arc discharge subsequent to the spark discharge in each plasma ignition plug in order to provide high-temperature plasma gas combustion of a compressed air-fuel mixture in the corresponding engine cylinder and another switching circuit for operatively connecting the latter power supply to each plasma ignition plug, the number of the latter power supply being half that of the engine cylinders.
Summary of the Invention
It is an object of the present invention to provide a plasma ignition system for an internal combustion engine having a plurality of engine cylinders in each of which a plasma ignition plug is mounted.
Another object of the present invention is to separately control the application of high DC voltages derived from individual power supply units to both the spark discharge and arc discharge (which results in generation of high-temperature plasma gas) of plasma ignition plugs of the plasma ignition system.
It is a further object of the present invention to separately control the application of high DC voltages derived from individual power supply units to both the spark discharge and arc discharge of plasma ignition plugs of a plasma ignition system in an automotive vehicle in response to a vehicle operating condition, such as vehicle or engine speed.
A first power supply unit supplies sufficient electric power to generate a spark discharge in each plasma ignition plug. Switching circuitry operatively connects the first power supply unit to the corresponding plasma ignition plug according to a predetermined ignition order. A second power supply unit supplies sufficient electric power to generate an arc discharge subsequent to the spark discharge. The arc discharge results in a high-temperature plasma gas being injected to achieve complete combustion of the air-fuel mixture. Additional switching circuitry operatively connects the power supply unit to the plasma ignition plug. The number of switching circuit units of the additional switching circuitry is half that of the engine cylinders so that ignition for the compressed air-fuel mixture can be achieved at all engine operating conditions, and a small-sized and inexpensive ignition system can also be achieved.
Brief Description of the Drawings
The features and advantages of the present invention will be fully understood from the foregoing description and the attached drawings in which like reference numerals designate corresponding elements and in which:
FIG. 1 includes cross section and top views of a typical plasma ignition plug used for a plasma ignition system according to the present invention;
FIG. 2 shows a first preferred embodiment of a four-cylinder engine plasma ignition system according to the present invention;
FIG. 3 is a circuit diagram of a DC-DC converter used in a second preferred embodiment of the plasma ignition system according to the present invention;
FIG. 4 is a block diagram of a third preferred embodiment of the four-cylinder engine plasma ignition system according to the present invention;
FIG. 5 is a block diagram of a fourth preferred embodiment of the four-cylinder plasma ignition system according to the present invention; and
FIG. 6 is a signal waveform timing chart for each circuit shown in the first preferred embodiment of FIG. 2
Detailed Description of the Preferred Embodiments
Reference is hereinafter made to the attached drawings and first to FIG. 1, longitudinally sectioned and bottom views (X and Y) of a plasma ignition plug to be mounted in an engine cylinder.
In FIG. 1, are illustrated a central electrode 1 and a grounded side electrode 2. An insulating member 3, e.g., a ceramic is provided between the central and side electrodes 1 and 2. Furthermore, a discharge gap 4 of small volume is formed at lower ends of both the insulating member 3 and central electrode 1 so that the central electrode 1 faces the side electrode 2 and a jet hole 5 is also provided below the discharge gap 4 through the bottom center of the side electrode 2. Hole 5 injects a high-temperature plasma gas, generated at the discharge gap 4, into a combustion chamber in which the plasma ignition plug shown in FIG. 1 is mounted. The high temperature plasma ignites an air-fuel mixture in the chamber.
FIG. 2 is an overall circuit diagram of a first preferred embodiment of a plasma ignition system according to the present invention, representatively applied to a four-cylinder engine.
It should be noted that the plasma ignition system according to the present invention can be applied equally well to any number of engine cylinders.
In FIG. 2, a first DC--DC converter Da inverts a low DC voltage (e.g., 12 V) from a DC voltage supply, such as a vehicle battery B, into a corresponding AC voltage by an oscillatory action and converts the AC voltage into a relatively high DC voltage (e.g., 300 V). An output terminal of the first DC--DC converter Da is connected to a plurality of first capacitors C.sub.11 via first diodes D.sub.11, the number of which corresponds to that of the first capacitors C.sub.11. The capacitance of each first capacitor C.sub.11 is about 0.2 microfarads. Each first capacitor C.sub.11 is connected to a primary winding Lp of a corresponding transformer T. The number of transformers T is equal to that of the first capacitors C.sub.11, i.e., that of plasma ignition plugs P.sub.1 through P.sub.4. The sequencial number of the plasma ignition plugs P.sub.1 through P.sub.4 corresponds to that of the engine cylinders. The ignition order of the plugs P.sub.1 through P.sub.4 is determined previously as P.sub.1 , P.sub.3, P.sub.4, and P.sub.2. Each first capacitor C.sub.11 is connected to a second diode D.sub.12. One of thyristors SCR11 through SCR14 is respectively connected between a corresponding first capacitor C.sub.11 and ground. Each thyristors SCR11 through SCR14 serves as a first switching circuit. One end of each primary winding Lp of a transformer T and side electrode 2 of the plasma ignition plug P.sub.1 through P.sub.4 are grounded. A crank angle sensor 6 detects half a rotation of a crankshaft of the engine, i.e., 180.degree. rotation of the crankshaft, and produces a first pulse signal having a period corresponding to 180.degree. rotation of the crankshaft, i.e., engine. Sensor 6 also produces a second pulse signal having a period corresponds to 720.degree. rotation (two rotations) of the crankshaft, i.e., engine. The rotation through 720.degree. of the engine is one engine cycle of any number of cylinders. In the case of a six-cylinder engine, the period of the first pulse signal corresponds to a 120.degree. rotation of the engine and in the case of a eight-cylinder engine, the period thereof corresponds to a 90.degree. rotation of the engine. A four-bit ring counter 7, connected to the crank angle sensor 6, receives the first pulse signal derived from the crank angle sensor 6. Counter 7 sequentially supplies a third pulse signal to each of monostable multivibrators 8a through 8d, and is reset in response to derivation of the second pulse signal from the crank angle sensor 6. In the case of the six-cylinder engine, the counter is a six-bit ring counter.
The output terminals of first, second, third and fourth monostable multivibrators 8a through 8d are connected to the respective gate terminals of the thyristors SCR11 through SCR14. The output terminals of the first and third monostable multivibrators 8a and 8c are connected to a first OR gate circuit 9a and the output terminals of the second and fourth monostable multivibrators 8b and 8d are connected to a second OR gate circuit 9b. The output terminal of the first and second OR gate circuit 9a and 9b are respectively connected to first and second delay circuits 10a and 10b. Ignition pulse signals a-d (FIG. 6), respectively derived from monostable multivibrators 8a-8d, are supplied to the corresponding gate terminals of the thyristors SCR11-SCR14 with a predetermined ignition timing so as to turn on the corresponding thyristors SCR11-SCR14. The pulse width of each of ignition pulse signals a-d is approximately 100 microseconds. When each of thyristors SCR11-SCR14 turns on, the corresponding diode D.sub.12 is in a floating state with respect to the ground.
Next, a second DC--DC converter Db inverts the low DC voltage from the battery B into a corresponding AC voltage and converts the AC voltage into a relatively high DC voltage, e.g., about 1000 volts. The output terminal of the second DC--DC converter Db is connected to two second capacitors C.sub.12 via the respective diodes D.sub.13. It should be noted that the number (two) of the second capacitors C.sub.12 is one-half the number of engine cylinders. Each second capacitor C.sub.12 is also connected between a corresponding fourth diode D.sub.14, the second capacitors are respectively also connected to corresponding second thyristors SCR15 and SCR16, each of which functions as a second switching circuit. Furthermore, each second capacitor C.sub.12 is connected via a separate secondary winding Ls of the corresponding transformer T to the central electrode of a separate corresponding plasma ignition plug P.sub.1 -P.sub.4. Each of transformers T has an iron core. Gate terminals e and f of thyristors SCR15 and SCR16 are respectively connected to the first and second delay circuits 10a and 10b.
Second capacitor C.sub.12, connected to the thyrister SCR16, is also connected to the respective plasma ignition plugs in the third and second cylinders, while the other second capacitor C.sub.12, connected to thyristor SCR15, is also connected to the respective plasma ignition plugs in the first and fourth cylinders.
The first cylinder is at the start of an ignition cycle when the fourth cylinder is almost at the end of an engine exhaust stroke and vice versa; the second cylinder is at the start of an ignition cycle when the third cylinder is almost at the end of the engine exhaust stroke and vice versa.
The gate terminal of thyristor SCR15 receives a first trigger pulse signal e from the first delay circuit 10a. The width of the first trigger pulse signal e is about 100 microseconds, the same as the widths of the output pulse signals a and c of the first and third monostable multivibrators 8a and 8c. The timing of pulse signal e is such that pulse e occurs 100 microseconds later than the respective ignition start timings of the first and fourth cylinders through the use of the first delay circuit 10a.
In the same way, the gate terminal of thyristor SCR16 receives a second trigger pulse signal f from the second delay circuit 10b. The width of the second trigger pulse signal f is about 100 microseconds, the same as the respective output pulse signals b and d of the second and fourth monostable multivibrators 8b and 8d; the timing of signal f is such that the pulse occurs 100 microseconds later than the respective ignition start timings of the second and third cylinders through the use of the second delay circuit 10b.
On the other hand, a fifth monostable multivibrator 11 is connected between the crank angle sensor 6 and the first and second DC--DC converts Da and Db. The fifth monostable multivibrator 11 derives a plulse signal having a constant width (1 millisecond) whenever the first pulse signal (180.degree. signal) is supplied by the crank angle sensor 6 to the first and second DC--DC converters Da and Db so that each oscillatory action for inverting the low DC voltage into the corresponding AC voltage is halted after a time interval (1 millisecond) equal to the width of the output pulse signal from the fifth monostable multivibrator 11, at the start of each plasma ignition. Consequently, the power consumption from the battery B is relatively low.
The timing of the leading and trailing edges of each pulse signal described supra is described with reference to FIG. 6.
The high voltage DC output from the first and second DC--DC converters Da and Db completely charge the first and second capacitors C.sub.11 and C.sub.12 via the first and third diodes D.sub.11 and D.sub.13, respectively.
For example, the thyristor SCR11 turns on in response to the first ignition pulse signal a being supplied to the gate thereof by the first monostable multivibrator 8a. An electric charge on the corresponding first capacitor C.sub.11 is discharged through the thyristor SCR11 to the primary winding Lp of the transformer T. Hence, the DC voltage applied across the primary winding Lp is boosted by the transformer so the voltage at the secondary winding Ls is relatively high, e.g., -15 kV with respect to ground; the secondary winding voltage is determined by the turns ratio of the windings. Consequently, the first plasma ignition plug P.sub.1 generates spark discharge at the discharge gap 4 and a consequent electric breakdown occurs due to the application of minus 15 kilovolts across the side and central electrodes 2 and 1. The resistance between the central and side electrodes 1 and 2 is, therefore, greatly reduced to substantially zero. 100-microseconds later, upon the occurrence of the spark discharge, the first trigger pulse signal e from the first delay circuit 10a is applied to the gate terminal of the thyristor SCR15 to turn on the thyristor. When the thyristor SCR15 turns on, electric charge on the second capacitor C.sub.12, connected to thyristor SCR15 and storing a large amount of energy (about 0.5 Joules), is fed to the first plasma ignition plug P.sub.1 in which the spark discharge has already occurred. Therefore, the first plasma ignition plug P.sub.1 generates an arc discharge that injects, into the first cylinder, a high temperature plasma gas generated within the discharge gap 4. Consequently, the compressed air-fuel mixture is ignited completely without failure (misfire). In this case, the electric charge on the second capacitor C.sub.12 connected to thyristor SCR15 is also fed to the fourth ignition plug P.sub.4 through the corresponding secondary winding Ls of the transformer T. However, the fourth cylinder is almost at the start of a suction stroke so that the fourth plasma ignition plug P.sub.4 cannot instigate a plasma discharge since the corresponding thyristor SCR13 is not turned on. The resulting high impedance in the primary winding circuit including thyristor SCR13 prevents discharge of capacitor C11 connected to thyristor SCR13 so the fourth plasma ignition plug P.sub.4 can not generate a spark discharge.
Since the oscillation action of the first DC--DC converter Da is halted temporarily, when the thyristor SCR11 is turned on, due to the output pulse signal of the fifth multivibrator 11 as described above, the thyristor SCR11 returns to an original turn off state upon the completion of the discharge operation from the corresponding first capacitor 11 due to the damped oscillation between the corresponding first capacitor C.sub.11 and primary winding Lp of the corresponding transformer T.
Thyristor SCR15 also returns to an original turn off state upon the completion of the discharge operation of the corresponding second capacitor C.sub.12.
In this way, a plasma ignition sequence is carried out in the remaining cylinders as described for the first cylinder. The plasma ignition sequence is in a predetermined order, so the spark discharge occurs due to the discharge from the corresponding first capacitors C.sub.11 through each of thyristors SCR12, SCR13, and SCR14 and the high energy is subsequently coupled to the plugs due to the discharges from the corresponding second capacitors C.sub.12 through each of thyristors SCR15 and SCR16.
In the first preferred embodiment shown in FIG. 2, the plasma ignition system uses two separate DC--DC converters Da and Db and two separate groups of the capacitors C.sub.11 and C.sub.12 for charging the relatively high DC voltage (300 volts) from the first DC--DC converter Da and for charging the still higher DC voltage (1000 volts) from the second DC--DC converter Db. Such an arrangement enables at least the first DC--DC converter Da to completely provide the high DC voltage for each first capacitor C.sub.11. In turn, each of capacitors C.sub.11 completely charges the high DC voltage from the first capacitor C.sub.11 even when the engine rotates at a high speed. Therefore, ignition of an air-fuel mixture supplied to the plugs is achieved, as is stable combustion under every engine operating condition. In addition, since the number of thyristors SCR15 and SCR16 and second capacitors C.sub.12, each having a high-voltage withstanding characteristic, is half that of the engine cylinders, the plasma ignition system has a small size and is relatively inexpensive.
FIG. 3 is an internal circuit block diagram of a DC--DC converter D used in a second preferred embodiment of the plasma ignition system.
In FIG. 3, the DC--DC converter D comprises: (a) oscillation circuit which inverts the low DC voltage (12 volts) from the battery B into a corresponding AC voltage; (b) a transformer T.sub.D which boosts the AC voltage to pair of higher-amplitude AC voltages at the secondary windings thereof; (c) a first (full-wave) rectifying circuit F.sub.1 which rectifies the high AC voltage across one of the secondary windings of transformer T.sub.D into the corresponding DC voltage (300 volts) at the output terminal d.sub.1 thereof; (d) a second (full-wave) rectifying circuit F.sub.2 which rectifies the high AC voltage across the other secondary winding of transformer T.sub.D into the corresponding high DC voltage (1000 volts) at the output terminal d.sub.2 thereof. The output terminal of the first rectifying circuit F.sub.1 is connected via the respective first diodes D.sub.11 to the first capacitors C.sub.11 as shown in FIG. 2. The output terminal of the second rectifying circuit F.sub.2 is, on the other hand, connected via the respective third diodes D.sub.13 to the second capacitors C.sub.12 as shown in FIG. 2. The oscillation circuit is also connected to respond to a halt terminal of the fifth monostable multivibrator 11 shown in FIG. 2. The operation is the same as described hereinabove with reference to FIG. 2.
In the second preferred embodiment, since the DC--DC converter D serves as the first and second DC--DC converters Da and Db, the size of the plasma ignition system becomes smaller.
FIG. 4 is a block diagram of a third preferred embodiment of the plasma ignition system.
In FIG. 4, the first pulse signal (180.degree. signal) from the crank angle sensor 6 is supplied to a frequency-to-voltage converter 12 (hereinafter simply referred to as F/V converter), which derives a voltage level corresponding to the frequency of the first pulse signal. The voltage level corresponding to the engine speed is compared with a reference voltage corresponding to a predetermined engine speed (e.g., 3000 r.p.m.) by comparator 13, connected to respond to the output of F/V converter 12. The comparator 13 derives a high-level voltage signal corresponding to a positive logic level "1" whenever the voltage signal from the F/V converter 12 exceeds the refrence voltage. The output terminal of the comparator 13 is connected to a third OR gate circuit 9c, also responsive to the fifth monostable multivibrator 11. The output terminal of the third OR gate circuit 9c is connected to the oscillation halt terminal of the second DC--DC converter Da as shown in FIG. 2. Therefore, when the high voltage signal corresponding to the positive logic "1" is coupled from the comparator 13 through the third OR gate 9c, the oscillation action of the second DC--DC converter Db halts and the converter does not supply the high DC voltage (1000 volts) to each of second capacitors C.sub.12. Consequently, the plasma ignition plugs P.sub.1 through P.sub.4 do not receive the high energy to be discharged from the respective second capacitors C.sub.12 when the engine speed exceeds a predetermined value (300 rpm) corresponding to the reference voltage of the comparator 13. However, in such a high speed region, when the predetermined value of engine speed, is exceeded the plasma ignition plugs can fire the compressed air-fuel mixture supplied to the respective engine cylinders. In such a region a small amount of energy (about 0.1 joule) sufficient to generate only the spark, is fed from the respective first capacitors C.sub.11.
Therefore, the power consumption of the battery B is considerably reduced, as is the fuel consumption. The construction of the plasma ignition system of FIG. 4, other than the additional circuits described above, is the same as described hereinbefore with reference to FIG. 2.
FIG. 5 is a block diagram of fourth preferred embodiment of the plasma ignition system wherein the output trigger signals from the first, second, third, and fourth monostable multivibrators 8a through 8d, also shown in FIG. 2, are disabled by a low level signal corresponding to a positive logic "0" from the comparator 13'.
The comparator 13' derives the low level signal whenever the engine speed exceeds a predetemined value (3000 rpm), i.e., the output voltage signal from the F/V converter 12 exceeds the reference voltage, which differs from the third preferred embodiment shown in FIG. 4.
Therefore, first and second AND gate circuits 14a and 14b are electrically connected between the first and second OR gate circuits 9a and 9b and first and second delay circuits 10a and 10b, respectively. If the comparator 13 operates as described hereinabove with reference to FIG. 4, it is necessary to connect an inverter between the output terminal of the comparator 13 and first and second AND gate circuits AND1 and AND2. The operation of other circuits is the same as described hereinbefore with reference to FIG. 2.
As described hereinbefore, a plasma ignition system according to the present invention having a plasma ignition plug located within each engine cylinder, comprises a plurality of transformers (T), each havng a primary winding (LP) one terminal of which is grounded to a side electrode of the plasma ignition plug and another terminal connected to one end of a first capacitor and to an anode of a second diode having a grounded cathode. Each transformer has a secondary winding (LS), one terminal of which is connected to a central electrode of the transformer and another terminal of which is connected to one of plural second capacitors. The number of the second capacitors is half that of the engine cylinders. A plurality of switching circuits (SCR11 through SCR14), each of which selectively grounds the other end of the corresponding first capacitor, feeds spark discharging energy stored on the first capacitor to the plasma ignition plug in response to a trigger signal applied to it. The system includes a plurality of further switching circuits (SCR15 and SCR16), the number of which is half that of the engine cylinders. Each of the further switching circuits selectively grounds the other end of the corresponding second capacitor so as to feed arc discharging energy stored on the second capacitor to the plasma ignition plug during a predetermined interval of time after the spark discharge occurs in the plug. The further switching circuits respond to another trigger signal that is delayed by the predetermined interval of time with respect to the former trigger signal. Therefore, the charging operation of the first capacitors can be achieved even when the engine rotates at a higher speed becuse a smaller amount of energy is stored by the first capacitors and the plasma ignition plug can generate at least a spark discharge even in such a region as described above. That ignition for an air-fuel mixture is carried out in each engine cylinder without failure of fuel combustion for every region of the engine speed and engine characteristics become more stable. In addition, since the numbers of the second capacitors and latter switching circuits (thyristors) are reduced to half the number of engine cylinders, the entire system is smaller in size and inexpensive in assembly cost in view of the high voltage withstanding characteristics required for the second capacitors and switching circuits (thyrisors).
The engine performance is increased since a preferable ignition characteristic is met with the individual characteristics of the plasma ignition plugs and engine since the spark discharge and arc discharge operations are carried out with two separate switching circuits.
It will be fully appreciated that the foregoing relates to only preferred embodiments of the present invention herein chosen for the purpose of the disclosure, which do not constitute departures from the spirit and scope of the present invention. The scope of the present invention, therefore, is to be determined by the following claims.