WO2012081464A1 - NOx浄化率低下原因診断装置 - Google Patents

NOx浄化率低下原因診断装置 Download PDF

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Publication number
WO2012081464A1
WO2012081464A1 PCT/JP2011/078284 JP2011078284W WO2012081464A1 WO 2012081464 A1 WO2012081464 A1 WO 2012081464A1 JP 2011078284 W JP2011078284 W JP 2011078284W WO 2012081464 A1 WO2012081464 A1 WO 2012081464A1
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Prior art keywords
nox purification
failure
exhaust pipe
nox
cause
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PCT/JP2011/078284
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English (en)
French (fr)
Inventor
長岡 大治
輝男 中田
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Isuzu Motors Ltd
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Isuzu Motors Ltd
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Priority to EP11848567.1A priority Critical patent/EP2653684B1/en
Priority to US13/994,493 priority patent/US8973431B2/en
Priority to AU2011342305A priority patent/AU2011342305B2/en
Priority to CN201180059961.4A priority patent/CN103261609B/zh
Publication of WO2012081464A1 publication Critical patent/WO2012081464A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N11/00—Monitoring or diagnostic devices for exhaust-gas treatment apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404—Removing only nitrogen compounds
    • B01D53/9409—Nitrogen oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
    • B01D53/9477—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on separate bricks, e.g. exhaust systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9495—Controlling the catalytic process
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series
    • F01N13/0097—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0842—Nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/105—General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
    • F01N3/106—Auxiliary oxidation catalysts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2550/00—Monitoring or diagnosing the deterioration of exhaust systems
    • F01N2550/02—Catalytic activity of catalytic converters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2550/00—Monitoring or diagnosing the deterioration of exhaust systems
    • F01N2550/03—Monitoring or diagnosing the deterioration of exhaust systems of sorbing activity of adsorbents or absorbents
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/03—Adding substances to exhaust gases the substance being hydrocarbons, e.g. engine fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2900/00—Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06—Parameters used for exhaust control or diagnosing
    • F01N2900/16—Parameters used for exhaust control or diagnosing said parameters being related to the exhaust apparatus, e.g. particulate filter or catalyst
    • F01N2900/1631—Heat amount provided to exhaust apparatus
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion
    • F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
    • F01N3/2066—Selective catalytic reduction [SCR]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/40—Engine management systems
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T137/00—Fluid handling
    • Y10T137/8158—With indicator, register, recorder, alarm or inspection means

Definitions

  • the present invention relates to a NOx purification rate lowering cause diagnosis device capable of performing self-diagnosis for specifying the cause of NOx purification rate lowering.
  • De-NOx nitrogen oxide reduction
  • HC-SCR hydrocarbon selective reduction catalyst device
  • LNT NOx occlusion device
  • NOx sensors are installed on the upstream and downstream sides of the NOx purification device, and the NOx purification rate is calculated from the ratio of the NOx concentrations detected by these NOx sensors. Can do.
  • the NOx purification rate may decrease even if these members break down.
  • the NOx purification rate also decreases due to failure of various members around the engine and failure of the reducing agent addition device (exhaust pipe fuel injection device). Therefore, even if the NOx purification rate decreases, it cannot be determined immediately that the NOx purification device is out of order. It is desirable to determine whether the cause of the decrease in the NOx purification rate is a failure of various members around the engine, a failure of the reducing agent addition device, or a failure of the NOx purification device.
  • an object of the present invention is to provide a NOx purification rate lowering cause diagnosis device capable of solving the above-described problems and performing a self-diagnosis that identifies the cause of the NOx purification rate lowering.
  • the present invention is a NOx purification rate reduction cause diagnosis device applied to an engine system having an exhaust pipe fuel injector, an oxidation catalyst device, and a NOx purification device, and when the NOx purification rate is reduced. If the error between the measured heat generation amount and the theoretical heat generation amount in the oxidation catalyst device during the exhaust pipe fuel injection is within a threshold when the exhaust pipe fuel injection is performed for diagnosis and the exhaust pipe fuel injection control unit for diagnosis, The cause of the decrease in the NOx purification rate is that the error between the NOx purification device failure identification unit that identifies a NOx purification device failure and the actual calorific value and the theoretical calorific value at the oxidation catalyst device when the exhaust pipe fuel injection is performed exceed a threshold value. In this case, the cause of the NOx purification rate reduction is provided with an oxidation catalyst device failure identification unit that identifies the oxidation catalyst device.
  • the present invention exhibits the following excellent effects.
  • FIG. 6 is a distribution diagram of heat generation along the exhaust pipe. It is a figure which shows the diagnostic matrix equivalent to the control procedure of FIG.
  • a NOx purification rate decrease cause diagnosis apparatus 1 includes a diagnostic exhaust pipe fuel injection control unit 2 that performs exhaust pipe fuel injection for diagnosis when the NOx purification rate decreases, and an exhaust gas If the error between the measured exhaust gas air-fuel ratio and the theoretical exhaust gas air-fuel ratio when the pipe fuel injection is not performed exceeds the threshold value, the cause of the NOx purification rate decrease is the engine-side failure specifying unit 3 that specifies the engine-side failure; If the error between the measured exhaust gas air-fuel ratio and the theoretical exhaust gas air-fuel ratio at the time of exhaust pipe fuel injection exceeds the threshold, the cause of the decrease in the NOx purification rate is determined as an exhaust pipe fuel injector failure.
  • the cause of the decrease in the NOx purification rate is identified as a NOx purification device failure.
  • the cause of the decrease in the NOx purification rate is the oxidation that identifies the oxidation catalyst device failure.
  • the specifying unit 6 and the combined fault specifying unit 7 are realized by software executed by an electronic control unit (Electronic Control Unit; hereinafter referred to as ECU). It is assumed that the ECU grasps all engine parameters (sensor detection values, calculation values, control values, etc.) necessary for controlling the engine system.
  • the engine system 201 to which the NOx purification rate reduction cause diagnosis device 1 of the present invention is applied includes an exhaust gas recirculation device (ExGRt Gas Recirculation; EGR) in the exhaust manifold 203 of the engine 202.
  • EGR exhaust gas recirculation
  • the EGR pipe 204 is connected, and the inlet of the exhaust turbine 206 of the turbocharger 205 is connected.
  • the downstream end of the EGR pipe 204 is connected to the intake manifold 207.
  • An exhaust pipe 208 is connected to the outlet of the exhaust turbine 206.
  • an exhaust pipe fuel injector 209 for injecting fuel into the exhaust pipe 208 in order from the upstream, an oxidation catalyst device (Diesel Oxidation Catalyst; hereinafter referred to as DOC) 210 for promoting the oxidation of the fuel and intermediate products, NOx purification device 211 such as HC-SCR, LNT, diesel particulate filter (DieselDPParticulate Filter; hereinafter referred to as DPF) 212 that collects particulate matter (Particulate Matter; PM) or catalyzed soot filter (Catalyzed Soot Filter) CSF) is installed.
  • Diesel Oxidation Catalyst Diesel Oxidation Catalyst
  • DPF diesel particulate filter
  • PM particulate Matter
  • Catalyzed Soot Filter catalyzed soot filter
  • the DOC 210, the NOx purification device 211, and the DPF 212 all use a catalyst.
  • the DOC 210, the NOx purification device 211, and the DPF 212 may be simply referred to as a catalyst.
  • the exhaust pipe fuel injector 209 is provided for injecting light oil as fuel into the exhaust pipe 208 when the particulate matter collected by the DPF 212 is removed by combustion (DPF regeneration, PM regeneration).
  • the injected fuel can be oxidized in the DOC 210, the NOx purifying device 211, the DPF 212, etc. by the intervention of the catalyst, and the exhaust gas temperature can be raised to the DPF regeneration temperature.
  • exhaust pipe fuel injection can be performed for the purpose of adding hydrocarbon as a reducing agent to HC-SCR and LNT. In the present invention, exhaust pipe fuel injection is performed for diagnosis of the cause of the NOx purification rate reduction.
  • the intake pipe 214 is connected to the air filter 213 that takes in air from the atmosphere, and the downstream end of the intake pipe 214 is connected to the inlet of the intake compressor 215 of the turbocharger 205.
  • a high-pressure side intake pipe 216 is connected to the outlet of the intake compressor 215, and a downstream end of the high-pressure side intake pipe 216 is connected to the intake manifold 207.
  • a first NOx sensor 221 that detects the engine outlet NOx concentration is installed upstream of the DOC 210 of the exhaust pipe 208, and a second NOx sensor 222 that detects the post-catalyst NOx concentration is installed downstream of the DPF 212.
  • An exhaust gas ⁇ sensor 223 that detects the air-fuel ratio of exhaust gas (actually measured exhaust gas air-fuel ratio) is installed downstream of the DPF 212.
  • the exhaust pipe 208 includes a first temperature sensor 224 that detects the temperature of the exhaust gas flowing into the DOC 210 upstream of the DOC 210 (DOC inlet temperature), a DOC outlet temperature (NOx purification device inlet temperature) between the DOC 210 and the NOx purification device 211.
  • the third temperature sensor 226 for detecting the NOx purification device outlet temperature (DPF inlet temperature) between the NOx purification device 211 and the DPF 212.
  • a four temperature sensor 227 is installed.
  • An air flow sensor (Mass Airflow ⁇ ⁇ ⁇ sensor; hereinafter referred to as MAF sensor) 228 for detecting the amount of intake air is installed in the intake pipe 214.
  • the first NOx sensor 221, the second NOx sensor 222, the exhaust gas ⁇ sensor 223, and the first to fourth temperature sensors 224 to 227 are separate from the self-diagnosis by the NOx purification rate decrease cause diagnosis device 1 of the present invention. It is assumed that each sensor is confirmed to be normal by the self-diagnosis of the sensor performed in the above.
  • the control procedure executed by the NOx purification rate decrease cause diagnosis device 1 is NOx purification rate decrease determination step S ⁇ b> 1 for determining whether or not the NOx purification rate is decreased, and whether or not the non-injection air-fuel ratio abnormality is determined.
  • Step S2 for identifying the cause of failure when exhaust pipe fuel injection is not performed ( ⁇ diagnosis A)
  • Step S3 for performing exhaust pipe fuel injection, and identifying the cause of failure when performing exhaust pipe fuel injection to determine whether the air-fuel ratio is abnormal when injection is present
  • the NOx purification rate lowering cause diagnosis apparatus 1 determines whether or not the NOx purification rate lowering occurs when a predetermined determination condition is satisfied in step S1 of the NOx purification rate lowering determination.
  • the determination conditions are that the exhaust gas temperature is stable and the vehicle travel is stable. If the vehicle travel is unstable, the engine state becomes a transitional state and the detection of the NOx concentration in the exhaust gas becomes unstable, so the determination of the NOx purification rate reduction is suspended.
  • the NOx purification rate is obtained from the post-catalyst NOx concentration and the pre-catalyst NOx concentration.
  • the engine outlet NOx concentration is used as the pre-catalyst NOx concentration
  • the detected value of the first NOx sensor 221 is the engine outlet.
  • NOx purification rate (1 ⁇ NOx concentration after catalyst / NOx concentration at engine outlet) ⁇ 100 (%) Is calculated by
  • the engine outlet NOx concentration may be estimated from a known theoretical formula or map using engine parameters without using the first NOx sensor 221.
  • the engine outlet NOx concentration and the post-catalyst NOx concentration are always detected at predetermined sampling intervals, and the NOx purification rate can be calculated in real time.
  • the NOx purification rate decrease cause diagnosis device 1 determines that the NOx purification rate has decreased when the state where the NOx purification rate has become equal to or lower than a preset threshold value continues for a predetermined time or more. By this determination, the NOx purification rate reduction cause diagnosis of the present invention is substantially started.
  • step S2 for specifying the cause of failure when the exhaust pipe fuel injection is not performed it is determined whether the air-fuel ratio is abnormal when there is no injection. That is, the engine-side failure specifying unit 3 calculates the theoretical exhaust gas air-fuel ratio at the installation position of the exhaust gas ⁇ sensor 223 by a known theoretical formula using the intake air amount and the fuel injection amount, and the exhaust gas ⁇ sensor 223 detects the theoretical exhaust gas air-fuel ratio. Compare with the measured exhaust gas air-fuel ratio. If the error between the actually measured exhaust gas air-fuel ratio and the theoretical exhaust gas air-fuel ratio exceeds a preset threshold value, it is abnormal. In this case, since the theoretical exhaust gas air-fuel ratio cannot be calculated correctly, the cause of the decrease in the NOx purification rate is specified as an engine-side failure.
  • the engine side failure means a failure of any of the members located upstream from the exhaust pipe 208.
  • the MAF sensor 228 fails, the intake air amount becomes inaccurate, so that the calculation of the theoretical exhaust gas air-fuel ratio becomes inaccurate.
  • the fuel injector in the engine 202 is clogged, an error in the fuel injection amount becomes large, and the calculation of the theoretical exhaust gas air-fuel ratio becomes inaccurate.
  • a diagnosis for further specifying the failure site may be performed.
  • known abnormality determination information for example, sensor output voltage abnormality relating to various members such as the EGR valve, the intake throttle, the turbocharger, and the MAF sensor 228 may be used.
  • step S2 If it is determined in step S2 that the error is equal to or less than the threshold value, it can be determined that the air-fuel ratio without injection is normal, and therefore there is no abnormality on the engine side, and the process proceeds to the next.
  • step S3 for exhaust pipe fuel injection the diagnostic exhaust pipe fuel injection control unit 2 performs exhaust pipe fuel injection.
  • Exhaust pipe fuel injection is performed with the same injection amount as during DPF regeneration.
  • the operator may be prompted to perform an operation during the control procedure, and the operator may perform the operation manually.
  • step S4 of specifying the cause of failure when performing exhaust pipe fuel injection it is determined whether or not the air-fuel ratio is abnormal with injection. That is, the exhaust pipe fuel injector failure identifying unit 4 uses the exhaust gas ⁇ sensor 223 according to a known theoretical formula using the exhaust gas weight exhausted from the engine 202 and the exhaust pipe fuel injection amount obtained from the intake air amount and the fuel injection amount. Is calculated and compared with the actually measured exhaust gas air-fuel ratio detected by the exhaust gas ⁇ sensor 223. If the error between the actually measured exhaust gas air-fuel ratio and the theoretical exhaust gas air-fuel ratio exceeds a preset threshold value, it is abnormal. In this case, since it has been confirmed that the theoretical exhaust gas air-fuel ratio can be calculated correctly, the cause of the decrease in the NOx purification rate is specified as an exhaust pipe fuel injector failure.
  • step S4 If it is determined in step S4 that the error is equal to or smaller than the threshold value, the air-fuel ratio with injection is normal, and therefore the exhaust pipe fuel injector 209 can be determined normal, and the process proceeds to the next.
  • step S5 of failure cause identification (catalyst temperature diagnosis) based on the catalyst heat generation pattern
  • the catalyst heat generation pattern is determined.
  • the catalyst heat generation pattern represents a distribution shape of heat generation based on actual measurement in a route passing through the DOC 210, the NOx purification device 211, and the DPF 212 along the exhaust pipe 208.
  • the temperature difference between the inlet and outlet of each catalyst is obtained based on the exhaust gas temperature at each catalyst inlet and outlet detected by the first to fourth temperature sensors 224 to 227, and from this temperature difference.
  • the integrated heat generation amount in each catalyst can be calculated. This is the measured calorific value.
  • the integrated heat generation amount that should be generated in each catalyst can be calculated by applying the exhaust pipe fuel injection amount, the heat generation coefficient of the fuel depending on each catalyst, the heat release amount, and the like to empirical formulas obtained in advance by experiments. This is the theoretical calorific value.
  • the actually measured calorific value and the theoretical calorific value are obtained as follows, for example.
  • the exhaust gas flow rate is calculated from each catalyst inlet temperature, intake air amount, and fuel injection amount during DPF regeneration.
  • the instantaneous catalyst heating value is calculated from the temperature difference between the inlet and outlet of the DOC 210, the exhaust gas flow rate, and the exhaust gas specific heat.
  • the integrated heat generation amount is calculated by integrating the catalyst heat generation amount.
  • Instantaneous catalyst heating value DOC inlet / outlet temperature difference ⁇ exhaust gas flow rate ⁇ exhaust gas specific heat, the instantaneous catalyst heating value is calculated.
  • the instantaneous theoretical calorific value is calculated from the lower calorific value (for example, 38.2 MJ / L) of the light oil as the fuel and the fuel consumption amount, and this is also integrated.
  • Instantaneous calorific value Lower heating value of diesel oil x Fuel consumption
  • the theoretical calorific value rises greatly in the vicinity of the inlet in the DOC 210 as shown by the broken line in the figure, and becomes constant thereafter.
  • the catalyst heat generation pattern # 1 indicated by the solid line almost coincides with the distribution based on the theoretical heat generation amount.
  • the catalyst heat generation pattern # 2 hardly rises in the DOC 210, rises greatly in the vicinity of the inlet in the NOx purification device 211, and becomes constant thereafter.
  • the catalyst heat generation pattern # 3 hardly rises in the DOC 210 or the NOx purification device 211, and rises greatly in the vicinity of the inlet of the DPF 212.
  • the measured heat generation amount and the theoretical heat generation amount in DOC 210 are in good agreement, and it can be determined that DOC 210 is functioning normally. Since the exhaust gas temperature has increased in the DOC 210, it cannot be determined from the catalyst heat generation pattern # 1 alone whether the NOx purification device 211 is functioning normally.
  • the actual heat generation amount and the theoretical heat generation amount are greatly different in the DOC 210, the actual heat generation amount is large in the NOx purification device 211, and the heat generation amount distribution after the NOx purification device 211 matches. ing. From this, it can be determined that the DOC 210 is abnormal. Further, it can be determined that the temperature raising function of the NOx purification device 211 is normal.
  • the measured heat generation amount and the theoretical heat generation amount are greatly different in the DOC 210 and the NOx purification device 211. Therefore, it can be determined that both the DOC 210 and the NOx purification device 211 are abnormal.
  • the failure site can be identified.
  • the error between the actual heat generation amount in the DOC 210 and the theoretical heat generation amount is within the threshold value. Can be determined to be normal. Since it has already been determined that there is no abnormality on the engine side and the exhaust pipe fuel injector 209 is also normal, only the NOx purification device 211 remains as a factor for reducing the NOx purification rate. Therefore, the NOx purification device failure identifying unit 5 identifies the cause of the decrease in the NOx purification rate as the NOx purification device failure.
  • the threshold value is set with the theoretical calorific value ⁇ 0.8 as a guide.
  • the catalyst heat generation pattern # 2 When the catalyst heat generation pattern # 2 is obtained, it is determined that the DOC 210 is abnormal. On the other hand, the error between the measured calorific value and the theoretical calorific value in the NOx purifying device 211 is within a threshold value (theoretical calorific value x 0.8 as a guideline), and although the temperature raising function of the NOx purifying device 211 is normal, the NOx purifying is performed. It cannot be uniquely determined that the cause of the rate decrease is an oxidation catalyst device failure. This is because, in the NOx purification device 211, the temperature raising function is normal, but the possibility that the NOx purification function is abnormal remains.
  • a threshold value theoretical calorific value x 0.8 as a guideline
  • the oxidation catalyst device failure identification unit 6 identifies the cause of the decrease in the NOx purification rate as an oxidation catalyst device failure.
  • the combined failure identification unit 7 identifies the cause of the decrease in the NOx purification rate as the oxidation catalyst device failure and the NOx purification device failure.
  • the diagnosis matrix of FIG. 5 can be defined equivalently to the control procedure of FIG. That is, as shown in FIG. 5, if the determination of ⁇ diagnosis A in step S2 is NG (abnormal), the cause of the decrease in the NOx purification rate is specified as an engine-side failure. If the determination of ⁇ diagnosis A in step S2 is OK (normal) and the determination of ⁇ diagnosis B in step S4 is NG, the cause of the decrease in the NOx purification rate is identified as an exhaust pipe fuel injector failure.
  • the catalyst temperature diagnosis in step S5 is not executed. However, if it is executed, for example, a catalyst heat generation pattern in which there is no temperature rise is obtained for all catalysts, and the determination in this case is NG.
  • both ⁇ diagnosis A and ⁇ diagnosis B are determined to be OK, it is as follows. If the determination of the catalyst temperature diagnosis is OK (the actual calorific value and the theoretical calorific value coincide, that is, the catalyst heat generation pattern # 1), it is specified that the NOx purification device has failed. If the determination of the catalyst temperature diagnosis is NG based on the catalyst heat generation pattern # 2, it is specified that the oxidation catalyst device has failed. If the determination of the catalyst temperature diagnosis is NG based on the catalyst heat generation pattern # 3, the oxidation catalyst device failure and the NOx purification device failure are identified.
  • exhaust pipe fuel injection is performed for diagnosis when the NOx purification rate is decreased, and the catalyst temperature diagnosis of the DOC 210 is performed.
  • a normal calorific value is obtained in the DOC 210, it can be identified as a NOx purification device failure, and if a normal calorific value is not obtained in the DOC 210, it can be identified as an oxidation catalyst device failure.
  • ⁇ diagnosis A and ⁇ diagnosis B are performed as in this embodiment, engine-side failures and exhaust pipe fuel injector failures can be specified, and the failure classification can be further subdivided.
  • the NOx purification rate lowering cause diagnosis apparatus 1 can be realized only by changing the software of the ECU without adding a new member to the engine system 201, so that the member cost does not increase.
  • the present invention is applied to the engine system 201 in which the exhaust pipe fuel injector 209, the DOC 210, the NOx purification device 211, and the DPF 212 are installed in order from the upstream side of the exhaust pipe 208, but there is no DOC 210.
  • the present invention can also be applied to an engine system in which the exhaust pipe fuel injector 209, the NOx purification device 211, and the DPF 212 are installed. Further, when the engine side failure, the exhaust pipe fuel injector failure, and the DPF failure are specified at the time of PM purification failure in the engine system in which the DOC 210 and the NOx purification device 211 are not provided and the exhaust pipe fuel injector 209 and the DPF 212 are installed.
  • the present invention can be applied.
  • the present invention can be applied to cause determination other than the urea water injector failure when the NOx purification rate is reduced.

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Abstract

 NOx浄化率低下の原因を特定する自己診断が可能なNOx浄化率低下原因診断装置を提供する。 NOx浄化率の低下時に診断用に排気管燃料噴射を実施させる診断用排気管燃料噴射制御部2と、排気管燃料噴射実施時に酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値以内であれば、NOx浄化率低下の原因はNOx浄化装置故障と特定するNOx浄化装置故障特定部5と、排気管燃料噴射実施時に酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値を超えていれば、NOx浄化率低下の原因は酸化触媒装置故障と特定する酸化触媒装置故障特定部6を備える。

Description

NOx浄化率低下原因診断装置
 本発明は、NOx浄化率低下の原因を特定する自己診断が可能なNOx浄化率低下原因診断装置に関する。
 エンジンの排気ガス流路に炭化水素選択還元触媒装置(Hydrocarbon Selective Catalytic Reduction;以下、HC-SCRという)、NOx吸蔵器(Lean NOx Trap;以下、LNT)等のDe-NOx(窒素酸化物低減)触媒付き後処理装置(以下、NOx浄化装置という)を備える車両では、NOx浄化装置の上下流にNOxセンサを設置し、これらのNOxセンサが検出するNOx濃度の比からNOx浄化率を算出することができる。
 このNOx浄化率の時間的変化を求め、NOx浄化率が閾値を超えて低下したときNOx浄化装置が故障であるという自己診断(On-board Diagnostics;OBD)ができるようになると好ましい。
特開2008-75610号公報 特開2010-196496号公報
 しかしながら、エンジンからNOx浄化装置の下流までには、排気ガス流路に沿って多様な部材が設置されており、これらの部材が故障した場合もNOx浄化率が低下することがある。例えば、エンジン周辺の諸部材の故障、還元剤添加装置(排気管燃料噴射装置)の故障によっても、NOx浄化率が低下する。したがって、NOx浄化率が低下しても直ちにNOx浄化装置が故障であるとは断定できない。NOx浄化率低下の原因がエンジン周辺の諸部材の故障であるのか、還元剤添加装置の故障であるのか、NOx浄化装置の故障であるのかを切り分けることが望まれる。
 そこで、本発明の目的は、上記課題を解決し、NOx浄化率低下の原因を特定する自己診断が可能なNOx浄化率低下原因診断装置を提供することにある。
 上記目的を達成するために本発明は、排気管燃料噴射器と酸化触媒装置とNOx浄化装置とを有するエンジンシステムに適用されるNOx浄化率低下原因診断装置であって、NOx浄化率の低下時に診断用に排気管燃料噴射を実施させる診断用排気管燃料噴射制御部と、前記排気管燃料噴射実施時に前記酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値以内であれば、NOx浄化率低下の原因はNOx浄化装置故障と特定するNOx浄化装置故障特定部と、前記排気管燃料噴射実施時に前記酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値を超えていれば、NOx浄化率低下の原因は酸化触媒装置と特定する酸化触媒装置故障特定部を備えたものである。
 本発明は次の如き優れた効果を発揮する。
 (1)NOx浄化率低下の原因を特定する自己診断が可能となる。
本発明の一実施形態を示すNOx浄化率低下原因診断装置の構成図である。 図1のNOx浄化率低下原因診断装置が適用されるエンジンシステムの構成図である。 図1のNOx浄化率低下原因診断装置が実行する制御手順を示すフローチャートである。 排気管に沿った発熱の分布図である。 図3の制御手順と等価的な診断マトリクスを示す図である。
 以下、本発明の一実施形態を添付図面に基づいて詳述する。
 図1に示されるように、本発明に係るNOx浄化率低下原因診断装置1は、NOx浄化率の低下時に診断用に排気管燃料噴射を実施させる診断用排気管燃料噴射制御部2と、排気管燃料噴射未実施時における実測排気ガス空燃比と理論排気ガス空燃比との誤差が閾値を超えていれば、NOx浄化率低下の原因はエンジン側故障と特定するエンジン側故障特定部3と、排気管燃料噴射実施時における実測排気ガス空燃比と理論排気ガス空燃比との誤差が閾値を超えていれば、NOx浄化率低下の原因は排気管燃料噴射器故障と特定する排気管燃料噴射器故障特定部4と、排気管燃料噴射実施時に酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値以内であれば、NOx浄化率低下の原因はNOx浄化装置故障と特定するNOx浄化装置故障特定部5と、排気管燃料噴射実施時に酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値を超えていれば、NOx浄化率低下の原因は酸化触媒装置故障と特定する酸化触媒装置故障特定部6と、排気管燃料噴射実施時に酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値を超えており、かつ、NOx浄化装置での実測発熱量と理論発熱量との誤差が閾値を超えていれば、酸化触媒装置故障及びNOx浄化装置故障と特定する複合故障特定部7とを備える。
 NOx浄化率低下原因診断装置1を構成する診断用排気管燃料噴射制御部2、エンジン側故障特定部3、排気管燃料噴射器故障特定部4、NOx浄化装置故障特定部5、酸化触媒装置故障特定部6、複合故障特定部7は、電子制御装置(Electronical Control Unit;以下、ECUという)が実行するソフトウェアで実現される。ECUは、エンジンシステムの制御に必要な全てのエンジンパラメータ(センサ検出値、演算値、制御値など)を把握しているものとする。
 図2に示されるように、本発明のNOx浄化率低下原因診断装置1が適用されるエンジンシステム201は、エンジン202の排気マニホールド203に、排気ガス再循環装置(Exhaust Gas Recirculation;EGR)を構成するEGR管204が接続されると共に、ターボチャージャ205の排気タービン206の入口が接続される。EGR管204の下流端は、吸気マニホールド207に接続される。排気タービン206の出口に排気管208が接続される。
 排気管208には上流から順に、排気管208内に燃料を噴射する排気管燃料噴射器209、燃料や中間生成物の酸化を促進する酸化触媒装置(Diesel Oxidation Catalyst;以下、DOCという)210、HC-SCR、LNTなどのNOx浄化装置211、粒子状物質(Particulate Matter;PM)を捕集するディーゼルパティキュレートフィルタ(Diesel Particulate Filter;以下、DPFという)212又はキャタライズドスートフィルタ(Catalyzed Soot Filter;CSF)が設置される。なお、DOC210、NOx浄化装置211、DPF212は、いずれも触媒を使用するものであり、以下では、DOC210、NOx浄化装置211、DPF212の意味で単に触媒と表記することがある。
 排気管燃料噴射器209は、DPF212に捕集された粒子状物質を燃焼除去(DPF再生、PM再生)するときに、排気管208内に燃料である軽油を噴射するために設けられる。噴射された燃料をDOC210、NOx浄化装置211、DPF212などにおいて触媒の介在により酸化させ、排気ガス温度をDPF再生温度まで上昇させることができる。また、HC-SCR、LNTに対して還元剤としての炭化水素を添加する目的で排気管燃料噴射を行うことができる。本発明では、NOx浄化率低下原因の診断用に排気管燃料噴射を実施することになる。
 大気からの空気が取り込まれるエアフィルタ213には吸気管214が接続され、吸気管214の下流端はターボチャージャ205の吸気コンプレッサ215の入口に接続される。吸気コンプレッサ215の出口には高圧側吸気管216が接続され、高圧側吸気管216の下流端は、吸気マニホールド207に接続される。
 排気管208のDOC210の上流には、エンジン出口NOx濃度を検出する第一NOxセンサ221が設置され、DPF212の下流には触媒後NOx濃度を検出する第二NOxセンサ222が設置される。DPF212の下流には排気ガスの空燃比(実測排気ガス空燃比)を検出する排気ガスλセンサ223が設置される。排気管208には、DOC210の上流にDOC210に流れ込む排気ガスの温度(DOC入口温度)を検出する第一温度センサ224、DOC210とNOx浄化装置211との間にDOC出口温度(NOx浄化装置入口温度)を検出する第二温度センサ225、NOx浄化装置211とDPF212との間にNOx浄化装置出口温度(DPF入口温度)を検出する第三温度センサ226、DPF212の下流にDPF出口温度を検出する第四温度センサ227が設置される。吸気管214には、吸入空気量を検出する空気流量センサ(Mass Airflow sensor;以下、MAFセンサという)228が設置される。
 なお、第一NOxセンサ221、第二NOxセンサ222、排気ガスλセンサ223、第一~第四温度センサ224~227については、本発明のNOx浄化率低下原因診断装置1による自己診断とは別途に行われるセンサの自己診断により、各センサが正常であることが確認されているものとする。
 図3に示されるように、NOx浄化率低下原因診断装置1が実行する制御手順は、NOx浄化率低下かどうかを判定するNOx浄化率低下判定のステップS1、噴射無し時空燃比異常かどうかを判定する排気管燃料噴射未実施時の故障原因特定(λ診断A)のステップS2、排気管燃料噴射実施のステップS3、噴射有り時空燃比異常かどうかを判定する排気管燃料噴射実施時の故障原因特定(λ診断B)のステップS4、触媒発熱パターンに基づく故障原因特定(触媒温度診断)のステップS5を有する。
 以下、各ステップにおける動作を詳しく説明する。
 NOx浄化率低下原因診断装置1は、NOx浄化率低下判定のステップS1にて、あらかじめ決められた判定条件が成立しているときに、NOx浄化率低下かどうかを判定する。判定条件は、排気ガス温度が安定しており、かつ、車両走行が安定していることである。車両走行が不安定であると、エンジン状態が過渡的状態となって排気ガスのNOx濃度検出が不安定になってしまうので、NOx浄化率低下の判定は保留する。
 NOx浄化率は、触媒後NOx濃度と触媒前NOx濃度とから求められるが、本実施形態では、触媒前NOx濃度としてエンジン出口NOx濃度が用いられ、第一NOxセンサ221の検出値であるエンジン出口NOx濃度と第二NOxセンサ222の検出値である触媒後NOx濃度とから次式、
  NOx浄化率=(1-触媒後NOx濃度/エンジン出口NOx濃度)
                      ×100 (%)
により演算される。エンジン出口NOx濃度は、第一NOxセンサ221を使用せずに、エンジンパラメータを用いた公知の理論式あるいはマップから推定してもよい。
 エンジン出口NOx濃度と触媒後NOx濃度は、常時、所定のサンプリングインターバルで検出されており、リアルタイムにNOx浄化率を演算することができる。
 NOx浄化率低下原因診断装置1は、NOx浄化率があらかじめ設定した閾値以下になった状態があらかじめ設定した所定時間以上継続した場合、NOx浄化率が低下したと判定する。この判定によって本発明のNOx浄化率低下原因診断が実質的に開始される。
 排気管燃料噴射未実施時の故障原因特定(λ診断A)のステップS2にて、噴射無し時空燃比異常かどうかを判定する。すなわち、エンジン側故障特定部3は、吸入空気量と燃料噴射量とを用いる公知の理論式により排気ガスλセンサ223の設置位置における理論排気ガス空燃比を演算し、排気ガスλセンサ223が検出する実測排気ガス空燃比と比較する。実測排気ガス空燃比と理論排気ガス空燃比との誤差があらかじめ設定された閾値を超えていれば、異常である。この場合、理論排気ガス空燃比が正しく演算できていないので、NOx浄化率低下の原因はエンジン側故障と特定する。
 エンジン側故障とは、排気管208よりも上流に位置する諸部材のいずれかの故障という意味である。例えば、MAFセンサ228が故障すると吸入空気量が不正確になるため、理論排気ガス空燃比の演算が不正確になることになる。あるいはエンジン202内の燃料噴射器に詰まりが発生すると、燃料噴射量の誤差が大きくなって、理論排気ガス空燃比の演算が不正確になることになる。このように、NOx浄化率低下の原因がエンジン側故障と特定された場合には、故障部位をさらに特定する診断を行うとよい。これには、EGR弁、吸気スロットル、ターボチャージャ、MAFセンサ228などの諸部材に関する公知の異常判定情報(例えば、センサ出力電圧異常)を援用するとよい。
 ステップS2の判定で誤差が閾値以下であれば、噴射無し時空燃比は正常、よってエンジン側には異常はないと判定できるから、次へ進む。
 排気管燃料噴射実施のステップS3にて、診断用排気管燃料噴射制御部2は、排気管燃料噴射を実施する。排気管燃料噴射は、DPF再生時と同様の噴射量で行う。手動DPF再生のための再生スイッチを装備した車両では、制御手順中にオペレータに操作を促し、オペレータが手動で実施するようにしてもよい。
 排気管燃料噴射実施時の故障原因特定(λ診断B)のステップS4にて、噴射有り時空燃比異常かどうかを判定する。すなわち、排気管燃料噴射器故障特定部4は、吸入空気量と燃料噴射量から求めたエンジン202が排出する排気ガス重量と排気管燃料噴射量とを用いる公知の理論式により排気ガスλセンサ223の設置位置における理論排気ガス空燃比を演算し、排気ガスλセンサ223が検出する実測排気ガス空燃比と比較する。実測排気ガス空燃比と理論排気ガス空燃比との誤差があらかじめ設定された閾値を超えていれば、異常である。この場合、理論排気ガス空燃比が正しく演算できることが確認されているので、NOx浄化率低下の原因は排気管燃料噴射器故障と特定する。
 ステップS4の判定で誤差が閾値以下であれば、噴射有り時空燃比は正常、よって排気管燃料噴射器209は正常と判定できるから、次へ進む。
 触媒発熱パターンに基づく故障原因特定(触媒温度診断)のステップS5にて、触媒発熱パターンを判定する。触媒発熱パターンとは、排気管208に沿ってDOC210、NOx浄化装置211、DPF212を通る経路における実測に基づく発熱の分布形状を表すものである。
 図4に示されるように、第一~第四温度センサ224~227で検出される各触媒入口及び出口の排気ガス温度に基づいて触媒ごとの入口出口間の温度差を求め、この温度差から各触媒における積算発熱量を演算することができる。これを実測発熱量とする。一方、排気管燃料噴射量、各触媒に依存する燃料の発熱係数、放熱量などをあらかじめ実験により得た経験式に適用して各触媒において生ずるべき積算発熱量を演算することができる。これを理論発熱量とする。
 実測発熱量と理論発熱量は、例えば、次のように求められる。DPF再生時に各触媒入口温度、吸入空気量、燃料噴射量から排気ガス流量を算出する。DOC210の入口出口間の温度差、排気ガス流量、排気ガス比熱から瞬時の触媒発熱量を算出する。この触媒発熱量を積算して積算発熱量を算出する。具体的には、
  瞬時の触媒発熱量=DOC出入口温度差×排気ガス流量×排気ガス比熱
により瞬時の触媒発熱量が演算される。一方、瞬時の理論発熱量は、燃料である軽油の低位発熱量(例えば、38.2MJ/L)と燃料消費量とから演算され、こちらも積算される。
  瞬時の理論発熱量=軽油の低位発熱量×燃料消費量
 理論発熱量は、図に破線で示されるように、DOC210内の入口近傍で大きく立ち上がり、それ以降は一定となる。実線で示される触媒発熱パターン#1は、理論発熱量に基づく分布とほぼ一致している。これに対し、触媒発熱パターン#2は、DOC210内ではほとんど立ち上がらず、NOx浄化装置211内の入口近傍で大きく立ち上がり、それ以降は一定となる。触媒発熱パターン#3は、DOC210内でもNOx浄化装置211内でもほとんど立ち上がらず、DPF212の入口近傍で大きく立ち上がる。
 触媒発熱パターン#1を考察すると、DOC210において実測発熱量と理論発熱量がよく一致しており、DOC210は正常に機能していると判定できる。DOC210において排気ガス温度が上昇しているため、NOx浄化装置211が正常に機能しているかどうかは、この触媒発熱パターン#1のみからは判定できない。
 触媒発熱パターン#2を考察すると、DOC210において実測発熱量と理論発熱量が大きく相違しており、かつ、NOx浄化装置211では実測発熱量が大きく、NOx浄化装置211以降の発熱量分布が一致している。これより、DOC210に異常があると判定できる。また、NOx浄化装置211の昇温機能は正常であると判定できる。
 触媒発熱パターン#3を考察すると、DOC210とNOx浄化装置211において実測発熱量と理論発熱量が大きく相違している。したがって、DOC210とNOx浄化装置211は、共に異常があると判定できる。
 以上のような触媒発熱パターンによる考察と、NOx浄化率低下が判定されているという事象とを組み合わせることで、故障部位が特定できる。
 第一~第四温度センサ224~227で検出される排気ガス温度から触媒発熱パターン#1が得られた場合、DOC210での実測発熱量と理論発熱量との誤差が閾値以内となるので、DOC210は正常と判定できる。既に、エンジン側に異常がなく、排気管燃料噴射器209も正常であることが判定されているので、NOx浄化率を低下させる要因としてはNOx浄化装置211しか残っていない。よって、NOx浄化装置故障特定部5は、NOx浄化率低下の原因はNOx浄化装置故障と特定する。閾値は、例えば、理論発熱量×0.8を目安に設定する。
 触媒発熱パターン#2が得られた場合、DOC210に異常があることは確定する。一方、NOx浄化装置211での実測発熱量と理論発熱量との誤差が閾値(理論発熱量×0.8を目安)以内となり、NOx浄化装置211の昇温機能は正常であるものの、NOx浄化率低下の原因が酸化触媒装置故障であるとは一意的に断定できない。なぜならば、NOx浄化装置211において、昇温機能は正常であるが、NOx浄化の機能が異常である可能性が残る。しかし、発明者らの知見によれば、触媒の昇温機能異常とNOx浄化機能異常は同時に発生するので、酸化触媒装置故障の可能性が高い。よって、酸化触媒装置故障特定部6は、NOx浄化率低下の原因は酸化触媒装置故障と特定する。
 触媒発熱パターン#3が得られた場合、DOC210とNOx浄化装置211に異常があることが確定する。よって、複合故障特定部7は、NOx浄化率低下の原因は酸化触媒装置故障及びNOx浄化装置故障と特定する。
 図3の制御手順と等価的に図5の診断マトリクスを定義することができる。すなわち、図5に示されるように、ステップS2のλ診断Aの判定がNG(異常)であるならば、NOx浄化率低下の原因はエンジン側故障と特定される。ステップS2のλ診断Aの判定がOK(正常)であってステップS4のλ診断Bの判定がNGであるならば、NOx浄化率低下の原因は排気管燃料噴射器故障と特定される。ここで、図3の手順ではステップS5の触媒温度診断は実行されないが、仮に実行すれば、例えば、全ての触媒で昇温がない触媒発熱パターンが得られ、この場合の判定はNGとなる。
 λ診断A、λ診断Bの判定が共にOKである場合は、次のようになる。触媒温度診断の判定がOK(実測発熱量と理論発熱量が一致、つまり触媒発熱パターン#1)であるならば、NOx浄化装置故障と特定される。触媒温度診断の判定が触媒発熱パターン#2によってNGであるならば、酸化触媒装置故障と特定される。触媒温度診断の判定が触媒発熱パターン#3によってNGであるならば、酸化触媒装置故障及びNOx浄化装置故障と特定される。
 以上説明したように、本発明に係るNOx浄化率低下原因診断装置1によれば、NOx浄化率の低下時に診断用に排気管燃料噴射を実施させ、DOC210の触媒温度診断を行うようにした。これにより、DOC210で正常な発熱量が得られていればNOx浄化装置故障と特定でき、DOC210で正常な発熱量が得られていなければ酸化触媒装置故障と特定できる。
 さらに、本実施形態のように、λ診断A及びλ診断Bを行うようにすると、エンジン側故障、排気管燃料噴射器故障が特定でき、故障の切り分けがいっそう細分化できる。
 本発明に係るNOx浄化率低下原因診断装置1は、エンジンシステム201に新規な部材を追加することなく、ECUのソフトウェアを変更するのみで実現できるので、部材コストが上昇することがない。
 本実施形態では、排気管208の上流から順に、排気管燃料噴射器209、DOC210、NOx浄化装置211、DPF212が設置されたエンジンシステム201に本発明を適用するものとしたが、DOC210がなく、排気管燃料噴射器209、NOx浄化装置211、DPF212が設置されたエンジンシステムにも本発明は適用できる。さらに、DOC210、NOx浄化装置211がなく、排気管燃料噴射器209、DPF212が設置されたエンジンシステムにおけるPM浄化の不具合時にエンジン側故障、排気管燃料噴射器故障、DPF故障を特定する場合にも本発明が応用できる。また、NOx浄化に尿素SCRを用いるエンジンシステムに対しては、NOx浄化率低下時に尿素水噴射器故障以外の原因特定に本発明を応用することができる。
 1 NOx浄化率低下原因診断装置
 2 診断用排気管燃料噴射制御部
 3 エンジン側故障特定部
 4 排気管燃料噴射器故障特定部
 5 NOx浄化装置故障特定部
 6 酸化触媒装置故障特定部
 7 複合故障特定部

Claims (2)

  1.  排気管燃料噴射器と酸化触媒装置とNOx浄化装置とを有するエンジンシステムに適用されるNOx浄化率低下原因診断装置であって、
     NOx浄化率の低下時に診断用に排気管燃料噴射を実施させる診断用排気管燃料噴射制御部と、
     前記排気管燃料噴射実施時に前記酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値以内であれば、NOx浄化率低下の原因はNOx浄化装置故障と特定するNOx浄化装置故障特定部と、
     前記排気管燃料噴射実施時に前記酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値を超えていれば、NOx浄化率低下の原因は酸化触媒装置と特定する酸化触媒装置故障特定部とを備えたことを特徴とするNOx浄化率低下原因診断装置。
  2.  排気管燃料噴射実施時に前記酸化触媒装置での実測発熱量と理論発熱量との誤差が閾値を超えており、かつ、前記NOx浄化装置での実測発熱量と理論発熱量との誤差が閾値を超えていれば、酸化触媒装置故障及びNOx浄化装置故障と特定する複合故障特定部をさらに備えた
     請求項1記載のNOx浄化率低下原因診断装置。
PCT/JP2011/078284 2010-12-16 2011-12-07 NOx浄化率低下原因診断装置 Ceased WO2012081464A1 (ja)

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