Method of Monitoring the Operation of a Catalytic Converter

1. Field of the Invention

The present invention relates to a method for analyzing a condition of at least a partial volume of a catalytic converter through which a gas mixture flows, in particular for monitoring an operation of a catalytic converter placed downstream of an electronically controlled internal combustion engine. The main fields of use for the invention are catalytic converters as well as so-called precatalysts disposed next to engines of passenger cars with Otto engines. In connection with increasingly more stringent world-wide laws for the reduction of noxious matter emissions from motor vehicles with internal combustion engines, it also becomes increasingly necessary to monitor the operation of a catalytic converter installed downstream of an internal combustion engine continuously or at intervals in order to obtain information regarding its condition, its effectiveness and, if possible, its remaining service life. Such monitoring is to be performed at opportune times in the course of operation and is therefore identified by the abbreviation OBD (on-board diagnosis).

Numerous methods for monitoring the operation of a catalytic converter which are known from the prior art, make use of various physical and chemical effects. First, it is possible to measure the oxygen content of the exhaust gas ahead of and behind the catalyst by means of so-called lambda probes. In the process it is possible to draw conclusions regarding the operation of the catalytic converter from a reduction in oxygen content between two probes. Another physical principle makes use of the fact that the processes occurring in the catalytic converter are exothermal reactions, which release heat energy. In the simplest case it is therefore possible to draw conclusions regarding the effectiveness of the catalytic converter from the temperature difference between temperature sensors between which at least a large portion of the catalytically active volume is located. Such a method and the associated device are described in Published International Application WO 91/14855, corresponding to U.S. Pat. Nos. 5,255,511 and 5,307,626, for example. Suitable sensors by means of which temperature measurements can be performed in a catalytic converter are described in that reference and also in Published International Application WO 93/05284, corresponding to U.S. Pat. No. 5,474,746. In principle it is necessary in connection with temperature measurements in the exhaust system of an internal combustion engine to distinguish between measurements of the gas temperature and measurements of the structural temperature of the catalytic converter. The structure of a catalytic converter supporting the catalytically active mass on its surface absorbs energy from an exothermal reaction on the catalytically active surface much faster than the exhaust gas flowing over it. The temperature measurement therefore takes place at the heat source, so to speak, and during transient processes reacts considerably faster and more accurately than the gas temperature in many cases. However, the gas temperature shows similar reactions, although delayed and/or weakened, so that measurements which can be evaluated are not only possible to be taken at the structure, but within limitations also inside the catalytic converter in the exhaust gas itself.

A measuring method is furthermore known from German Published, Non-Prosecuted Application DE 41 00 397 A1, corresponding to U.S. Pat. No. 5,133,184, wherein the condition of an internal combustion engine is briefly disrupted, particularly by turning off the ignition and injecting gasoline during operation under load, in the course of which the reaction of temperature sensors at various places in the exhaust system is observed. In this connection it is also suggested to differentiate the temperature signals and to store the differentiated signals or to compare those signals with already stored previous signals.

The following basic problems occur during temperature measurement in the exhaust system, in particular inside catalytic converters: On one hand, the occurring absolute temperatures are so high that it is impossible to measure the absolute temperatures with sufficient accuracy with conventional, economically usable temperature sensors in order to draw dependable conclusions therefrom. In particular, when forming the difference between several temperature sensors, the measuring errors are cumulative so that because of the measuring errors it is no longer possible to detect the changes, which are small per se, with certainty. A further problem lies in the fact that the values measured by a temperature sensor inside a catalytic converter depend to a large extent on the location where the sensor has been installed. If, for example, a temperature sensor is installed close to the beginning of an approximately 20 cm long catalytic converter, after a short time in operation this sensor can be located in a catalytically less active zone, so that the values measured there can provide practically no further information regarding the operational ability of the remaining catalyst volume. On the other hand, during transient processes, particularly during brief disruptions of the operational condition of the internal combustion engine with a catalyst which has only been briefly operational, a temperature sensor installed at the end of the catalytic converter would measure practically no change at all, since the entire exothermal reaction occurs in the front portion of the catalytic converter, so that brief changes cannot be detected at all or can only be detected belatedly and are greatly weakened at the end of the catalytic converter, because of the heat capacity of the portion located behind it. The situation becomes even more difficult in connection with the frequent cases wherein a catalytic converter is formed of several partial bodies disposed one behind the other. In this case the meaningfulness of a measured temperature value obtained at any arbitrary location is very small in relation to the total condition of the system.

It is accordingly an object of the invention to provide a method of monitoring the operation of a catalytic converter and more particularly a method for the analysis of the condition of a partial volume of a catalytic converter through which a mixture of gases flows, which overcomes the hereinafore-mentioned disadvantages of the heretofore-known methods of this general type and which, by itself or together with the analyses of the condition of further partial volumes, provides dependable information regarding the total condition of a catalytic converter. In this regard, the invention is based on the knowledge that the condition of a catalytic converter and its behavior under operational conditions can be very well described by means of simple models and that only a few physical values are required for the mathematical equations for describing such a model.

Some basic reflections can be found in the document SAE Technical Paper Series 930938, entitled "A Linear Catalyst Temperature Sensor for Exhaust Gas Ignition (EGI) and On Board Diagnostics of Misfire and Catalyst Efficiency" by Nick Collings et al., and from the document SAE Technical Paper Series 930624, entitled "Thermal Measurements Inside a Three-Way Catalytic Converter on Engine Bench" by Angelo Germidis et al.

The invention of the instant application therefore proceeds from the reflection that theoretically a catalyst volume can be divided into two or more successive partial volumes, and that these partial volumes must be considered separately or in correlation.

With the foregoing and other objects in view there is provided, in accordance with the invention, a method for analyzing a condition of at least one partial volume of a catalytic converter through which a gas mixture flows, which comprises measuring a temperature with a sensor at least at one location or in a region within a partial volume of a catalytic converter during a change of at least one of chemical and physical properties of a gas mixture flowing through the catalytic converter; selecting the location or the region and a configuration of the sensor for at least approximately representing a reaction of the temperature in the partial volume of the catalytic converter with a reaction of the measured temperature to a change of the properties of the gas mixture; determining set point values for the respective change in the properties of the gas mixture on the basis of a thermodynamic model while taking physical boundary conditions and properties of the partial volume into account; and determining and comparing the reaction of the measured temperature with the set point values.

In accordance with another mode of the invention, the derivative with respect to time of the measured temperature is observed as the reaction, wherein it is intended to be at least approximately representative of the chronological change of the temperature in the partial volume of the catalytic converter, and wherein furthermore the derivative with respect to time of the measured temperature is determined and compared with set point values for the respective change of the properties of the gas mixture. In particular, the height of the maximum of the derivative with respect to time of the measured temperature during a change in the exhaust gas composition in comparison to previously measured maxima with the same changes or in comparison to set point values, is very meaningful.

In accordance with a further mode of the invention, there is provided a method which comprises observing the integral of the temperature with respect to time over the period of the respective change of the exhaust gas composition. In the course of this observation it may be necessary to take into consideration a time delay of the reaction in the catalytic converter with respect to the exhaust gas composition. It is also, of course, necessary to subtract the quasi-constant temperature portion of the temperature measured before and after the change, from the integral. Figuratively speaking, the result then is the area below the temperature peak which is triggered by the change at the temperature sensor.

Since a motor vehicle is almost constantly subjected to transient operational conditions, it can be difficult to assign measured temperature changes to changes in the exhaust gas composition in order to draw conclusions regarding the condition of the catalytic converter.

For this reason, in accordance with an added mode of the invention, the two or more changes are imprinted on the exhaust gas in a typical, recognizable sequence, i.e. a change pattern.

In accordance with an additional mode of the invention, the imprinting of the change pattern takes place periodically, aperiodically or selectively and also with changes (amplitudes) of different strengths.

In accordance with yet another mode of the invention, the change pattern differs from all conceivable operationally caused changes, so that the temperature change at the sensor can be assuredly associated with the imprinted change pattern of the exhaust gas composition. Particular frequencies, which are so low that they can be barely detected by the sensors and lie below the typical, operationally connected change frequencies, are particularly suitable in connection with periodic change patterns. On the other hand, the frequencies must be sufficiently high to permit a sufficient number of changes within a short period of time at constant operational conditions (load, idle).

In accordance with yet a further mode of the invention, the change pattern has frequencies of 0.1 to 10 Hz, and in particular 0.5 to 2 Hz.

Further advantageous embodiments of the invention are described in the remaining dependent claims.

In general, when new, a catalytic converter is oversized for all operational states. This means that more than 90% of all noxious matter are already converted within the first few centimeters in the converter. In the course of the aging of the catalyst with increasing operating time, the efficiency in the front part of the catalytic converter decreases, for example by poisoning and/or thermal aging. Thus it is not possible to conclude from the fact that a temperature sensor disposed further back hardly shows a change in its measured values during a brief disruption that the catalytic converter does not fulfill its function. On the other hand, in the case of an aged catalytic converter wherein a temperature sensor disposed very near the front hardly shows a reaction to a disruption of the operational condition of the internal combustion engine, it can also not be concluded that in its remaining volume the catalytic converter does not completely do its job. Added to this is the fact that all sensors in a motor vehicle, those for engine control as well as those for monitoring the catalytic converter, make measurement errors because of technical production tolerances and aging, and that furthermore a catalytic converter can also have considerable tolerances in its production and installation, particularly with respect to the catalytically active layers. Thus, the evaluation of individual, measured temperature values, their differentiated or integrated signals or also differences between the values measured by temperature probes, contain such large errors that an exact evaluation is hardly possible. The definition of threshold values from which a faulty operation of the catalytic converter can be deduced when they are reached, in particular is very problematic.

The present invention solves this problem particularly advantageously by a theoretical division of the catalytic converter into two or more partial areas and the observation of the reaction of the temperatures in at least one of these partial areas during changes of the chemical and/or physical properties of the gas mixture flowing through the catalytic converter, i.e. the operational condition of the internal combustion engine. However, preferably the observed differentiated or integrated signals or their differences are not compared with fixed threshold values, but with theoretical set point value ranges or those determined by previous testing. In this case, for measurements in two or more partial volumes, in the course of the determination of the set point value ranges of the second partial volume and all subsequent partial volumes, the actually measured values in all preceding partial volumes are taken into consideration, since otherwise the image regarding the operational ability of the catalytic converter remains incomplete.

With catalytic converters of greater length in particular, it is especially advantageous if the temperature is measured, its derivative with respect to time is determined and the comparison with set point value ranges is performed, in at least three partial volumes. Since the present invention operates in a certain way in accordance with the theory of finite elements, the accuracy of the results is a function of the mesh width, i.e. the distance between the individual elements. The result of course becomes all the more accurate with an increase in the partial volumes which are considered and the temperatures which are measured.

In accordance with a concomitant mode of the invention, the set point value ranges are determined by means of a model function which discloses the functional connections of the temperatures in different partial volumes of the catalytic converter with each other and with the data of the electronic control of the internal combustion engine for the respective condition and/or the respective condition change of the internal combustion engine. Measured values, such as mass flow, exhaust gas temperature, air/fuel ratio, etc. are available from the internal combustion engine. It is then possible to draw conclusions regarding a temperature change (for a defined aging condition of the catalyst) to be expected in the first partial volume of the catalytic converter from these values and from the known value of a condition change. In order to compensate for measurement inaccuracies and production tolerances a test is then performed as to whether or not the measured temperature lies within a defined pre-calculated set point value range. This provides the first information regarding the condition of the catalytic converter. With the same information and additionally taking into consideration the measured temperature change in the first partial volume, it is possible to make a prediction of the temperature change to be expected in the second partial volume. In this case too, a check is performed as to whether or not the measured value of the temperature change lies within a tolerance range. This method is continued for all partial volumes. If all measured temperature values lie below the set point value range, the catalytic converter no longer performs its intended functions. The further downstream the measured temperature change value is located in the set point value range, the more the catalytic converter has aged. Assuming that no sudden destruction of the catalytic converter can take place between two measuring processes, it is sufficient to monitor only the reaction in a rear partial volume of the catalytic converter for a change in the condition of the internal combustion engine. If the catalyst is new, a condition change should have little effect there, while with a catalytic converter that has aged to a continuously greater degree, the temperature changes occurring there continue to become greater. However, with only this monitoring it would not be possible to detect a sudden destruction of the catalytic converter (occurring extremely rarely in actuality), rapid poisoning between two measuring processes and especially a worsening of the condition of the front area of the catalytic converter which, among others, is decisive for the cold-starting behavior. Therefore, preferably at least two, but particularly three or more measurements of the temperature changes in different partial volumes are useful for measuring the temperature changes.

If fuel is additionally mixed into the exhaust gas for disruption, care must be taken to ensure that the amount of the fuel as well as the ratio of fuel and air with respect to the entire exhaust gas mass flow are set to a maximum conversion capability in the volume of the catalytic converter during the duration of the disruption and in particular in such a way that the amount of fuel is completely converted over the time of the change and the length of the catalytic converter. In the process, the storage properties of the catalytic converter must be taken into consideration. Measuring signals which are easy to detect are attained in this way and without unburned hydrocarbons being emitted into the environment during the measurement.

Other features which are considered as characteristic for the invention are set forth in the appended claims.

Although the invention is illustrated and described herein as embodied in a method of monitoring the operation of a catalytic converter, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.

FIG. 1 is a schematic and block circuit diagram of an exemplary embodiment of a configuration suitable for executing the method of the invention;

FIG. 2 is a diagram with examples of curves of temperature changes occurring during changes in exhaust gas composition; and

FIG. 3 is a diagram illustrating a chronological temperature integral over the duration of a change.

Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen an exhaust system 3, 4 incorporating a catalytic converter K and being connected downstream of an internal combustion engine 1 with an electronic control 2. The volume of the catalytic converter K includes a plurality of (theoretical) partial volumes, which are four partial volumes K1, K2, K3, K4 in the instant example. A respective sensor S1, S2, S3, S4 which is disposed in each one of the partial volumes approximately representatively measures the temperature in the partial volume, which is preferably the temperature of the support structure. In the simplest case, such a sensor can be in the form of a sensor that measures in a punctiform manner and is located approximately at the center of the respective partial volume K1, K2, K3 or K4. However, it is more advantageous if linear or planar sensors are used, because the accuracy of measurement is increased by their use. It is particularly advantageous if measurements are taken not only representatively over a cross section, but also representatively over the axial length of the partial volume. The measurement is most sensitive if the temperature of the support structure to which the catalytically active mass has been applied is directly measured. This can be done, for example, by means of sensors that are on or integrated into the support structure, such as are known from the prior art. However, basically a measurement with sensors detecting the gas temperature is also possible, since there is always a heat transfer from the structure and the catalytically active surface to the gas flowing through.

By way of example, FIG. 2 shows a diagram wherein the first derivative of the temperature in accordance with the time d/dt T is entered on the vertical axis and wherein the horizontal axis represents the time t. The solid line represents the derivative of the temperature of the gas, the dotted line represents the theoretical temperature at a sensor in the catalytic converter without a change in the gas composition, i.e. without an increase, for example, in the hydrocarbon supply to the catalytic converter, and the dash-dotted line represents the derivative of the temperature at a sensor when supplying additional hydrocarbons to the exhaust gas. In the course of this measurement, the hydrocarbon portions in the exhaust gas are increased at a time t.sub.1 until a time t.sub.2 during a constant load phase of the internal combustion engine, which starts at a time t.sub.0. The reaction of the temperature can be clearly seen and the elevation of the maximum of the temperature increase can also be determined.

FIG. 3 shows, by way of example, the conditions or statuses when the integral below a temperature curve (solid line) is determined during a change. In this diagram the temperature T is entered on the vertical axis and the time t on the horizontal axis. The shaded area corresponds to the integral of the temperature over the entire time that the change has an effect, wherein a quasi-constant portion of the temperature, i.e. the area below the theoretically undisturbed temperature curve (dashed line), remains unconsidered.

In contrast to measuring and monitoring methods known from the prior art, the measuring method of the instant invention does not depend on the detection of absolute temperatures or temperature differences between two measuring points. Instead, the derivatives with respect to time of the temperatures measured by the sensors S1, S2, S3, S4, which occur during a change of the physical and/or chemical properties of the gas mixture reaching the catalytic converter K from the engine 1, are observed in one or several of the partial volumes K1, K2, K3, K4. Differentiating devices D1, D2, D3, D4, which are connected downstream of the sensors S1, S2, S3, S4 for this purpose, have output signals that are supplied to an electronic evaluation device 5. The electronic evaluation device 5 can be connected with the electronic engine control 2 through data lines 10, so that it is possible to transmit the data of the engine control 2 to the electronic evaluation device 5 and to transmit the condition values of the catalytic converter K to the electronic engine control 2. The electronic evaluation device 5 is connected to a first memory device 6 for set point value ranges, so that the measured derivatives with respect to time of the temperatures T1, T2, T3, T4 can be compared with set point value ranges. The results of this comparison can be stored in a second memory device 7 for subsequent diagnosis in a special technical location or shop and/or displayed by means of a display 8. It is also possible to employ integrating devices in place of or in addition to the differentiating devices, so that the areas below the temperature curves (without the quasi-constant portion) are also available for evaluation during a change.

A change of the chemical and/or physical properties of the exhaust gases leaving the engine 1 is needed to analyze the condition of the catalytic converter K. In order to perform a useful condition analysis, such a change must be defined with precise accuracy. In the course of this many condition changes occurring in daily operation must be considered, for example an acceleration phase following a phase of constant load, a load reduction following a phase of constant load, cold-starting after prolonged stopping, or the like. It is possible to check various aspects of the operation of the catalytic converter by means of an analysis of the reaction of the derivatives with respect to time of the temperatures T1, T2, T3, T4 to different condition changes. For example, during a cold-starting phase it is possible to determine the start of the catalytic reaction in the catalytic converter K as well as the partial volume in which the first conversion takes place. With other condition changes of the internal combustion engine wherein only the temperature of the exhaust gases, but not their chemical composition changes, for example, it is possible to check whether or not all probes still measure correctly, namely in this case with a time delay from the front to the back.

It is particularly advantageous if the operational condition of the internal combustion engine 1 is briefly disrupted, particularly with a defined change pattern, by means of the electronic control 2 which controls the engine through control lines 9. This can take place, for example, in a manner which is known per se by a brief injection of additional fuel with a simultaneous switching off of the ignition during a load phase. In this case the injection can also take place in accordance with a defined change pattern. The availability of additional chemical energy in the exhaust gas triggers a strong reaction of the temperature in the first still functioning partial volume of the catalytic converter K, having a derivative with respect to time or an integral which can be formed and analyzed by the electronic evaluation device 5.

In contrast to the methods known from the prior art, with the method in accordance with the invention it makes no difference which temperature distribution happens to prevail at the time of measurement. This in particular is a decisive advantage. Depending on the operational conditions through which a motor vehicle has gone prior to a measurement, it is possible for different temperature distributions to be possible in a catalytic converter. There are cases wherein the catalytic converter is considerably hotter in its front area than in its rear area, others with a more even temperature distribution, as well as cases wherein the catalytic converter is hotter in the rear than in the front. This fact adulterates all measuring methods known in the prior art which are based on measuring the thermal energy being released between two measuring areas. The manner of looking at things up to now was based on probes monitoring the volume located between them, while the invention of the instant application, in accordance with the method of finite elements, is based on the probes separately monitoring the partial volume surrounding them and the temperature changes occurring there.

It is, of course, not required for the number of sensors which are necessary therefor to correspond to that of the exemplary embodiment represented herein. Although the accuracy of measurement increases with an increasing number of sensors, to a certain extent the method of the invention is already capable of providing evidence, as mentioned above, if only a single sensor monitors only a single partial volume and compares the derivatives with respect to time and/or the integral of the temperature occurring there during operational changes with set point value ranges and/or previously measured values. The method is suitable for monolithic catalytic converters as well as catalytic converters being formed of several partial bodies and in the same way can include sensors in so-called pre-catalysts or start-up catalysts and/or electrically heatable catalytic converters. The sensors S1, S2, S3, S4 can of course also be utilized for measuring the absolute temperatures and/or the temperature profile in the catalytic converter, at least in a temperature range of, for example, below 500.degree. C. in which most temperature probes still can measure comparatively exactly. For example, such measurements provide information regarding the cold-starting behavior of the catalytic converter. In many cases it can be necessary to disconnect a lambda control during measuring, so that it does not again "level" a purposely applied disruption.

The invention is particularly suited for continuous operational monitoring of catalytic converters in motor vehicles for assuring that strict exhaust gas regulations are adhered to.