Adaptive spark energy control

Abstract

Systems and methods for operating an ignition system. The ignition transformer has a primary winding and a secondary winding. The spark device is connected with the secondary winding of the ignition transformer. One or more characteristics of the spark generated by the spark device are provided. The electronic control unit is adapted to control the ignition transformer such that based on identification of the spark using the one or more characteristics and the spark reference data, the electronic control unit sends a control signal to the ignition transformer to modify the one or more characteristics of the spark. The modification of the one or more characteristics may occur within the same spark cycle as the measurement of the one or more characteristics.

Description

Technical Field

[0001] The present teachings relate generally to power electronics and, more particularly, to ignition systems that may be used in internal combustion engines. Background Art

[0002] Generally, as will be appreciated by those skilled in the art, an ignition system generates a high voltage that is sent to a spark plug to generate a spark. The spark in turn ignites the fuel-air mixture in the combustion chamber of the engine to drive the engine. An ignition coil (also known as an ignition transformer) typically generates a high voltage. U.S. Patent No. 7,401,603, entitled "High Voltage Capacitor Discharge Ignition with Enhanced Trigger Pulse," discloses an ignition system, and the entire contents of which are incorporated herein by reference.

[0003] Known ignition systems use open loop control, meaning they do not use feedback in spark control. Such systems may have undesirable drawbacks due to open loop decision making. For example, known systems may lag behind one or more engine rotations in their understanding of spark characteristics and therefore cannot make changes even for the next ignition event to optimize the spark for a particular application.

[0004] Closed loop control means that there is feedback information fed back to the controller of the system. As described below, observing the characteristics of the spark (e.g., within the same spark cycle) and adjusting the spark may be desirable to optimize the spark for a particular application.

[0005] Therefore, it would be beneficial to provide alternative systems and methods for adaptive spark energy control. Summary of the invention

[0006] The needs set forth herein, as well as further and other needs and advantages, are addressed by embodiments of the present invention, which embodiments illustrate the solutions and advantages described below.

[0007] One embodiment of a system according to the present teachings includes, but is not limited to, an ignition system. It includes an ignition assembly having: an ignition transformer having a primary winding and a secondary winding; and an electronic device including one or more characteristics of a spark generated by a spark device connected to the secondary winding (e.g., may have a sensor or may receive and store data from another source). The data storage has spark reference data. The control unit is adapted to send a control signal to the electronic device to modify one or more characteristics of the spark based on identification of the spark using the one or more characteristics and the spark reference data.

[0008] In one embodiment, the identification includes the location of the spark and the type of spark.

[0009] In one embodiment, the modification of the one or more characteristics occurs within the same spark cycle as the measurement of the one or more characteristics.

[0010] In one embodiment, the one or more characteristics include at least one of primary current, secondary current, secondary voltage, spark placement, and combustion.

[0011] In one embodiment, the control signal controls the spark current and / or the spark duration in a closed loop manner.

[0012] In one embodiment, the spark reference data comprises spark models, and a spark model is selected from the spark models based on one or more characteristics. The control unit uses the spark model to provide model-based control of the engine.

[0013] One embodiment of a system according to the present teachings includes, but is not limited to, an engine system comprising an engine having cylinders, an ignition system according to the present teachings, and a spark device adapted to generate sparks at the cylinders.

[0014] In one embodiment, the engine comprises a hydrogen fuel engine.

[0015] In one embodiment, the spark device comprises a spark plug.

[0016] In one embodiment, the one or more characteristics include secondary current and / or secondary voltage.

[0017] In one embodiment, the data storage is located in the ignition assembly.

[0018] One embodiment of a system according to the present teachings includes, but is not limited to, an ignition controller. A data store has spark reference data. A control unit is adapted to electronically communicate with an ignition assembly having an electronic device including one or more characteristics of a spark generated by a spark device. The control unit is adapted to send a control signal to the electronic device to modify the one or more characteristics of the spark based on identification of the spark using the one or more characteristics and the spark reference data.

[0019] In one embodiment, the identification includes the location of the spark and the type of spark.

[0020] In one embodiment, the modification of the one or more characteristics occurs within the same spark cycle as the measurement of the one or more characteristics.

[0021] In one embodiment, the one or more characteristics include secondary current and / or secondary voltage.The control signal controls spark current and / or spark duration.

[0022] In one embodiment, the system includes a plurality of sensors that measure a plurality of characteristics of the spark.

[0023] In one embodiment, the electronic control unit identifies characteristics of the spark for use in model-based control of the engine.

[0024] In one embodiment, the comparison of the spark reference data and the one or more characteristics is performed by a control unit.

[0025] An embodiment of a system according to the present teachings includes, but is not limited to, an engine ignition system, which includes an engine having (at least one) cylinder, and an ignition controller according to the present teachings.

[0026] In one embodiment, the control signal controls the spark current and / or the spark duration in a closed loop manner.

[0027] One embodiment of a method according to the present teachings includes, but is not limited to, a method for controlling a spark in an ignition system. An ignition transformer is provided for generating a spark. A control unit is provided for controlling the ignition transformer. One or more characteristics of the spark are compared to desired characteristics. Control of the ignition transformer is adjusted to change the spark to obtain the desired characteristics.

[0028] Other embodiments of the system and method are described in detail below and are also a part of the present teachings.

[0029] For a better understanding of the present embodiments, as well as other and further aspects of the present embodiments, reference should be made to the accompanying drawings and detailed description, and the scope thereof will be pointed out in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is an illustration of one embodiment of a system according to the present teachings.

[0031] Figure 2 is an illustration of one embodiment of a method according to the present teachings.

[0032] Figure 3 yes Figure 1 and Figure 2 An illustration of an embodiment of an engine control system. DETAILED DESCRIPTION

[0033] The present teaching will be described more fully below with reference to the accompanying drawings, in which the present embodiment is shown. The following description is for illustrative purposes only, and the present teaching should not be limited to these embodiments. Any computer configuration and architecture that meets the speed and interface requirements described herein may be suitable for implementing the system and method of the present embodiment.

[0034] In compliance with the statute, the present teachings describe structural and methodological features in more or less specific language. However, it should be understood that the present teachings are not limited to the specific features shown and described, since the systems and methods disclosed herein include preferred forms of putting the present teachings into practice.

[0035] For purposes of explanation rather than limitation, specific details are set forth, such as particular architectures, interfaces, techniques, etc., in order to provide a thorough understanding. In other instances, detailed descriptions of well-known devices, circuits, and methods are omitted so as not to obscure the description with unnecessary detail.

[0036] A "computing system" may provide functionality for the present teachings. A computing system may include software executed on a computer-readable medium that may be logically (but not necessarily physically) identified for a particular function (e.g., a functional module). A computing system may include any number of computers / processors that may communicate with each other over a network. A computing system may be in electronic communication with a data store (e.g., a database) that stores control and data information. The form of a computer-readable medium may include, but is not limited to, a disk, a hard drive, a random access memory, a programmable read-only memory, or any other medium that a computer can read.

[0037] Generally, unless otherwise expressly defined herein, all terms used in the claims should be interpreted according to their ordinary meaning in the technical field. Unless otherwise expressly stated, all references to elements, devices, parts, devices, steps, etc. should be publicly interpreted as referring to at least one instance of elements, devices, parts, steps, etc. Unless expressly stated, the steps of any method disclosed herein do not have to be performed in the exact order disclosed. The use of "first", "second", etc. for different features / components of the present disclosure is intended only to distinguish these features / components from other similar features / components, rather than to give these features / components any order or ranking.

[0038] To assist the Patent Office and any reader of patents issued based on this application in understanding the appended claims, it is noted that unless the words "means for..." or "step for..." are expressly used in a particular claim, no claim or claim element is intended to invoke 35 U.S.C. § 112(f).

[0039] The numerical range represented by the endpoint includes all numbers within the range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.). When the value range of a particular value is "greater than", "less than", etc., the value is included in the range. Any direction mentioned herein, such as "top", "bottom", "left", "right", "upper", "lower", "above", "below" and other directions and orientations, are described here with reference to the accompanying drawings for clarity and do not limit the actual device or system or the use of the device or system. Many devices, articles or systems described herein can be used in multiple directions and orientations.

[0040] Any citation to references in this disclosure or during its review is made with due care. Any citation (whether in an information disclosure statement or otherwise) should not be construed as an admission that the cited reference constitutes prior art or is from a field similar to or directly applicable to the present teachings.

[0041] The present teachings include adaptive measurements and changes in spark characteristics within a spark cycle. In one embodiment, the characteristics of the spark are observed from the device that creates the spark (e.g., a spark plug). Then, it is determined where the spark is formed and what type of spark is formed. In this way, during the same spark event, the characteristics of the spark can be changed, including but not limited to manipulating any characteristics of energy content.

[0042] The identification of the spark, such as its type, location, etc., can be determined based on characteristics of the spark, such as spark voltage and current, but is not limited thereto. As will be appreciated by those skilled in the art, there are many spark characteristics and applications of the present teachings for determining information about the spark using mathematical functions of feedback (e.g., spark characteristics) and cylinder characteristics. As an example, a calculus function of the electrical characteristics of the spark can be used to determine whether the spark is at the beginning or end of the gap.

[0043] As a non-limiting example of the type of calculations that may be performed in accordance with the present teachings, the integral of the KV signal may be analyzed (e.g., by an algorithm) to see changes in slope. This may be used to differentiate slopes and determine whether the spark starts at the beginning or end of the spark plug electrode, how fast it is moving, etc. A larger integral may indicate that the spark starts at the end of the electrode, and a smaller integral may indicate that the spark starts at the beginning of the electrode. This in turn indicates whether the spark requires more or less energy. Applying too much energy when it is not needed may cause hot spots in the spark plug and pre-ignite the volatile mixture. Insufficient energy when the electrode absorbs energy (heat from the spark) means that the mixture may not burn. Therefore, the integral and slope may be used to reduce spark plug wear and provide other benefits. Those skilled in the art understand the various calculations that may be performed in accordance with the present teachings.

[0044] Known systems may simply attempt to control the spark (using current) based on a set point. However, such systems lack intelligence on what the energy content actually does. For example, setting a set point of X current and then maintaining that set point may result in too much or too little energy, based on the type of spark being formed. Such systems that rely on current control can only keep the arc of the spark going, but have no idea whether any arc formed is too much or too little to meet the requirements for combustion.

[0045] According to the present teachings, the spark can be controlled more accurately and provide higher efficiency. This is because, for example, the type of spark can be identified. With this information, the control of the spark can be modified (e.g., changing the current set point, etc.) to maintain the energy of the cylinder. As an example, if the spark is located toward the tip of the electrode, less energy is required to burn the air / gas mixture than if it starts at the beginning of the electrode. Identifying the spark, such as its location and type, can better control the spark.

[0046] There are many reasons why this teaching has not been adopted before. For example, combustion using traditional fuel sources (e.g., natural gas, gasoline) has a higher tolerance to knock (abnormal combustion) and a slower and less volatile flame speed. However, new fuel sources (e.g., hydrogen, etc.) have problems, so changes as close to 0 degrees as possible are desired. In addition, induction ignition systems, which are mainly used in automotive applications, have been too slow to deploy this technology. In addition, based on the diode-like behavior of the arc, it may not be intuitive to understand the actual characteristics of the spark and what is happening. More current can be added and the voltage drop can generally remain unchanged. Similarly, if the KV increases, the external current may not decrease at the same rate. Therefore, this can be a difficult task, and there is no motivation to solve this problem in known systems.

[0047] According to the present teachings, it may be desirable to vary the delivery of the spark in a closed loop manner so that the exact spark meets the needs of the system. In this way, it can provide neither more nor less of the desired characteristics, but rather be optimized for a specific application. As will be appreciated by those skilled in the art, this can have direct effects on any spark generation system, including such things as electrode wear, heat release, spark temperature, ionization breakdown, etc.

[0048] In one embodiment, a system according to the present teachings is implemented using a computing system (e.g., a processor) and / or hardware (e.g., simulation). It may be desirable to use analog hardware to increase speed so that complex mathematical functions and measurements (e.g., nonlinearities) can be calculated and converted into digital outputs readable by the system. Once the physical hardware provides the mathematical functions to the computing system (e.g., a microcontroller), the computing system can process these functions so that the type of spark can be identified. Thereafter, a unique method can be used to form the spark pulse in a closed loop manner to provide precise spark characteristics, such as energy, but not limited to this. There can be a measurement time for the first portion of the spark, and there can be a characteristic adjustment period after the measurement.

[0049] The advantages of such a system include a direct impact on several items related to the spark generation system. For example, these items may include electrode wear, heat release, spark temperature, ionization breakdown, etc. It improves the function and effectiveness of engines and other equipment that use spark generation devices and any type of fuel combustion. For example, but not limited to, improvements can be seen in normal natural gas operation as well as new fuel operation such as hydrogen.

[0050] Reference now Figure 1 , which shows a diagram of one embodiment of a system 100 according to the present teachings. As will be appreciated by those skilled in the art, an ignition assembly 102 (e.g., an ignition coil / transformer, data storage, electronics, etc.) can provide energy to a spark generating mechanism 110 (e.g., a spark plug) so that a spark can be generated for the ignition system. This can be accomplished via a secondary coil path 114.

[0051] The ignition assembly 102 may include electronics (eg, a processor, one or more characteristics of the spark, one or more sensors, stored reference data, etc.) for identifying high voltage, low voltage, and voltage manipulation, but is not limited thereto. This may specifically include a voltage sensor.

[0052] The control logic 104 (e.g., a central control unit, a control circuit, etc.) can send electronic signals to drive the primary winding of the ignition transformer in the ignition assembly 102. As will be appreciated by those skilled in the art, various wires 112 can be used to exchange data signals between the control logic 104 and the ignition assembly 102. The control logic 104 (e.g., an electronic device driver) can include functionality for sensing current and voltage and for performing mathematical functions, but is not limited thereto.

[0053] The control logic 104 may send control signals that are approximately synchronized with the combustion event (or some angle before or after cylinder top dead center). The electrical characteristic (e.g., current / voltage / etc.) may be sensed anywhere at the load point, meaning that the electrical characteristic may be sensed locally in a circuit with sufficient integrity and minimal degradation losses. One skilled in the art understands where and how to sense electrical characteristics of the primary and / or secondary, including voltage and current.

[0054] The desired spark generation system inputs 106 may include, but are not limited to, desired primary current, secondary current, spark placement, secondary voltage, combustion, and any combination thereof. One skilled in the art understands the different characteristics that may be used in accordance with the present teachings. The inputs 106 may include data corresponding to or convertible to a feedback type. This may come from modeling, testing, experimentation, etc., to obtain desired engine results, but is not limited to this.

[0055] Depending on the application, the primary and secondary electronics 108 may be connected together or kept isolated. For example, but not limited to, signal integrity may be desired.

[0056] As will be appreciated by those skilled in the art, the system may include a data store (e.g., a database) that may store data such as a spark reference model (e.g., signature), spark reference characteristics, desired characteristic ranges, and the like. For example, measured spark characteristics may be compared to reference data in the data store to identify a spark, but is not limited thereto. The data store (and other functions) may be in electronic communication with a network (e.g., the Internet) so that the reference data may be updated (wired or wirelessly), but is not limited thereto. As will be appreciated and understood by those skilled in the art, the reference data may be stored in a table, database, or other form. This may allow for further validation of the system, as well as allowing artificial intelligence (AI) to teach and transform the operation of the system with greater predictability.

[0057] In one exemplary use according to the present teachings, electrical characteristics of the arc of the spark may be measured. This may include, but is not limited to, the spark current (e.g., secondary current) and the spark voltage. Various properties of these signals may be measured, such as peak value, average value, derivative, integral, etc. As will be appreciated by those skilled in the art, there are many different ways to perform these measurements in electronics.

[0058] These measurements can provide a “signature” of the spark between the spark plug electrodes. This signature directly provides insight into things like flow rate between the electrode gap, and can be used in conjunction with model-based control to predict various operating scenarios for the engine. In this way, the ignition system can be tailored to specific engines and specific operating conditions to improve efficiency.

[0059] Based on this prediction, the spark current or spark duration may be adjusted, but is not limited thereto. As an example, adjusting spark characteristics based on measured conditions allows for better control of engine combustion phasing.

[0060] Reference now Figure 2 , which shows a diagram of one embodiment of a method 200 according to the present teachings. One or more characteristics of the spark may be sensed 202. The sensed characteristics may be compared 204 to desired characteristics (e.g., to identify the spark, to identify the most preferred spark, etc.). Control of the ignition transformer may be adjusted 206 to change the spark to obtain the desired characteristics.

[0061] Reference now Figure 3 , which shows Figure 1 and Figure 2 An embodiment of the present invention is illustrated in an engine control system. As shown, the control unit 300 can be in electronic communication with one or more ignition control components 304, 306. Each component may include electronic equipment 304 (e.g., spark characteristics, sensors, data storage, etc.) and an ignition coil 306. Communication between the central control unit 301 and the electronic equipment 304, 304', 304" can be performed through one or more communication links 302, 302', 302". Each component can send energy to the spark plug 308, 308', 308". As understood by those skilled in the art, the spark plug can in turn drive the crankshaft in the engine 310 (e.g., one or more spark plugs in each engine cylinder).

[0062] Although the present teachings have been described above in terms of specific embodiments, it should be understood that they are not limited to these disclosed embodiments. Those skilled in the art will recognize many modifications and other embodiments, which are intended to be and are covered by the present disclosure. As those skilled in the art will understand from the disclosures in this specification and the accompanying drawings, the scope of the present teachings should be intended to be determined by appropriate interpretation and construction of its legal equivalents.

Claims

1. An ignition system, comprising: An ignition assembly having: an ignition transformer having a primary winding and a secondary winding; electronic device including one or more characteristics of a spark produced by a spark device connected to said secondary winding; data storage, which has spark reference data; A control unit is adapted to send a control signal to the electronic device to modify the one or more characteristics of the spark based on the identification of the spark using the one or more characteristics and the spark reference data.

2. The system according to claim 1, wherein: The identification includes the location of the spark and the type of the spark.

3. The system according to claim 1, wherein: The modification of the one or more characteristics occurs within the same spark cycle as the measurement of the one or more characteristics.

4. The system according to claim 1, wherein: The one or more characteristics include at least one of primary current, secondary current, secondary voltage, spark placement, and combustion.

5. The system according to claim 1, wherein: The control signal controls the spark current and / or the spark duration in a closed loop manner.

6. The system of claim 1, wherein: The spark reference data includes spark models, and selecting a spark model from the spark models based on the one or more characteristics; The control unit provides model-based control of the engine using the spark model.

7. The system of claim 1 further comprising a plurality of sensors that measure a plurality of characteristics of the spark.

8. An engine system, comprising: an engine having cylinders; The ignition system according to claim 1; A spark device is adapted to generate a spark at the cylinder.

9. The system according to claim 8, wherein: The engine comprises a hydrogen fuel engine.

10. The system according to claim 8, wherein: The spark device includes a spark plug.

11. The system according to claim 8, wherein: The one or more characteristics include a secondary current and / or a secondary voltage.

12. The system of claim 1, wherein: The data storage is located in the ignition assembly.

13. An ignition controller, comprising: data storage, which has spark reference data; a control unit adapted to electronically communicate with an ignition assembly having electronics including one or more characteristics of a spark generated by the spark device; The control unit is adapted to send a control signal to the electronic device to modify the one or more characteristics of the spark based on the identification of the spark using the one or more characteristics and the spark reference data.

14. The controller according to claim 13, wherein: The identification includes the location of the spark and the type of the spark.

15. The controller according to claim 13, wherein: The modification of the one or more characteristics occurs within the same spark cycle as the measurement of the one or more characteristics.

16. The controller of claim 13, wherein: The one or more characteristics include a secondary current and / or a secondary voltage; The control signal controls the spark current and / or the spark duration.

17. The controller according to claim 13, wherein: An electronic control unit identifies characteristics of the spark for model-based control of the engine.

18. The controller according to claim 13, wherein: The comparison of the spark reference data and the one or more characteristics is performed by the control unit.

19. An engine ignition system, comprising: an engine having cylinders; An ignition controller according to claim 13.

20. The system of claim 19, wherein: The control signal controls the spark current and / or spark duration in a closed loop manner.

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