Boosted Engine Pre-Ignition Control via Dual Calibration
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Solution Overview
Problem
Newly manufactured vehicles experience engine degradation due to pre-ignition and spark plug fouling, particularly when filled with low octane fuels and subjected to aggressive driving conditions during production and initial dealership phases, leading to reduced performance and drivability.
Innovation Solution
Implementing a dual engine calibration approach, with a pre-delivery calibration that addresses pre-ignition by using a leaner air/fuel ratio and more conservative engine load settings to reduce fouling, and a post-delivery calibration that switches to a stoichiometric air/fuel ratio and relaxed engine load settings to enhance performance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a leaner air/fuel ratio is used in pre-delivery calibration to reduce spark plug fouling, then spark plug reliability is improved, but engine power and drivability deteriorate
Solution Approach 1:
The patent implements dynamic switching between pre-delivery and post-delivery calibrations based on vehicle operational phase. The ECU automatically transitions from pre-delivery calibration (with leaner air/fuel ratio for reliability) to post-delivery calibration (with richer air/fuel ratio for power) as the vehicle moves from production/transport to normal operation, resolving the contradiction by making the air/fuel ratio adaptive to operational context
Solution Approach 2:
The patent changes the air/fuel ratio parameter between two distinct calibration modes. Pre-delivery calibration uses a leaner air/fuel ratio to prevent spark plug fouling during production and transport, while post-delivery calibration uses a richer air/fuel ratio to restore engine power and drivability during normal operation, directly addressing the contradiction through parameter adjustment
2Reliability
If more conservative engine load settings are used in pre-delivery calibration to reduce pre-ignition, then engine reliability is improved, but productivity and drivability worsen
Solution Approach 1:
The patent dynamically adjusts engine load settings based on the vehicle's operational phase. During pre-delivery phase, conservative engine load limits prevent pre-ignition and improve reliability. After delivery, the system automatically transitions to post-delivery calibration with relaxed engine load settings, restoring drivability and productivity without causing pre-ignition issues
Solution Approach 2:
The patent applies preliminary protective measures during the pre-delivery phase by implementing conservative engine load settings before the vehicle is delivered. This preliminary action prevents pre-ignition and engine degradation during production and transport, then removes these restrictions after delivery when the vehicle enters normal service conditions
3Duration of action of stationary object
If pre-delivery calibration is used to reduce pre-ignition and fouling, then engine durability is improved, but fuel efficiency and performance deteriorate
Solution Approach 1:
The patent implements dynamic calibration switching that adapts engine parameters to the vehicle's operational phase. Pre-delivery calibration with protective settings improves engine durability during production and transport. After delivery, the system automatically switches to post-delivery calibration with optimized settings that restore fuel efficiency and performance, resolving the contradiction by making durability measures temporary and context-dependent
Data Source
AI summary
Various systems and methods are described for controlling pre-ignition in a boosted engine in a newly manufactured vehicle. One method comprises, during a pre-delivery phase of the vehicle, operating the boosted engine in a pre-delivery calibration with a first, higher enrichment, in response to a pre-ignition event. The pre-delivery calibration is deactivated during a post-delivery phase and the boosted engine is operated with a second, lower enrichment in response to a pre-ignition event.