Catalytic converter decontamination method

Abstract

A method for restoring exhaust purifying capability of a sulfur contaminated catalytic converter of an internal combustion engine. Catalytic converter efficiency is measured with a first exhaust gas oxygen sensor positioned upstream of the catalytic converter and a second exhaust gas oxygen sensor positioned downstream of the catalytic converter. When catalytic converter efficiency falls below a desired level, catalytic converter temperature is elevated and the engine is operated to produce a rich exhaust gas mixture to reduce the sulfur contamination. Then, to further reduce the sulfur contamination, the engine is operated to produce a lean exhaust mixture.

We claim:  
     
       1. A catalytic converter decontamination method for an internal combustion engine, the method comprising the steps of: 
       generating a catalytic converter contamination signal when catalytic converter efficiency falls below a desired level;  
       elevating a catalytic converter temperature in response to said catalytic converter contamination signal;  
       in response to said elevated temperature, initiating a decontamination period for removing sulfur, said decontamination period comprising:  
       a first interval where the engine operates in a rich condition; and  
       a second interval where the engine operates in a lean condition after said first interval; and  
       operating the engine rich during said first interval and operating the engine lean during said second interval to remove sulfur from said catalytic converter.  
     
     
       2. The method recited in  claim 1  wherein said generating step further comprises the steps of: 
       measuring a number of transitions from a first state to a second state of an exhaust gas oxygen sensor positioned upstream of the catalytic converter; and  
       indicating catalytic converter efficiency by calculating a ratio between said transitions in said upstream exhaust gas oxygen sensor to transitions in a downstream exhaust gas oxygen sensor position downstream of the catalytic converter.  
     
     
       3. The method recited in  claim 1  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by creating an exothermic reaction. 
     
     
       4. The method recited in  claim 1  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by adjusting engine operating parameters. 
     
     
       5. The method recited in  claim 4  wherein said increasing step further comprises the step of retarding an ignition timing. 
     
     
       6. The method recited in  claim 1  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by varying a length of an exhaust manifold. 
     
     
       7. The method recited in  claim 1  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by controlling an electric heater coupled to said catalytic converter. 
     
     
       8. A catalytic converter decontamination method for an internal combustion engine, the method comprising the steps of: 
       measuring catalytic converter efficiency;  
       generating a catalytic converter contamination signal when measured catalytic converter efficiency falls below a preselected value;  
       elevating the catalytic converter temperature to at least a predetermined temperature in response to a catalytic converter contamination signal;  
       in response to said elevated temperature, initiating a decontamination period for removing sulfur, said decontamination period comprising:  
       a first interval where the engine operates in a rich condition; and  
       a second interval where the engine operates in a lean condition after said first interval;  
       operating the engine rich during said first interval and operating the engine lean during said second interval while maintaining the catalytic converter temperature above said predetermined temperature to remove sulfur from said catalytic converter;  
       re-measuring catalytic converter efficiency; and  
       activating a malfunction indicator when the re-measured catalytic converter efficiency is below a desired value.  
     
     
       9. The method recited in  claim 8  wherein said predetermined temperature is 1250° F. 
     
     
       10. The method recited in  claim 8  wherein said measuring catalyst efficiency step further comprises the steps of: 
       measuring a number of transitions from a first state to a second state of an exhaust gas oxygen sensor positioned upstream of the catalytic converter; and  
       indicating catalytic converter efficiency by calculating a ratio between said transitions in said upstream exhaust gas oxygen sensor to transitions in a downstream exhaust gas oxygen sensor position downstream of the catalytic converter.  
     
     
       11. The method recited in  claim 8  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by creating an exothermic reaction. 
     
     
       12. The method recited in  claim 8  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by adjusting engine operating parameters. 
     
     
       13. The method recited in  claim 12  wherein said increasing step further comprises the step of adjusting ignition timing. 
     
     
       14. The method recited in  claim 8  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by varying a length of an exhaust manifold. 
     
     
       15. The method recited in  claim 8  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by controlling an electric heater coupled to said catalytic converter. 
     
     
       16. An engine control system for controlling engine air/fuel ratio and concurrently decontaminating an exhaust catalytic converter comprising: 
       an internal combustion engine capable of fuel combustion at lean air/fuel ratios and at rich air/fuel ratios;  
       an exhaust conduit connected to the engine;  
       a catalytic converter connected to the exhaust conduit susceptible to contamination by an exhaust gas containing sulfur;  
       a first exhaust gas oxygen sensor positioned upstream of said exhaust catalytic converter;  
       a second exhaust gas oxygen sensor positioned downstream of said exhaust catalytic converter;  
       an efficiency monitor for measuring catalytic converter efficiency by measuring a first number of transitions from a first state to a second state of said first exhaust gas oxygen sensor, measuring a second number of transitions from a first state to a second state of said second exhaust gas oxygen sensor, and calculating a ratio between said first and second number of transitions; and  
       a decontamination controller for elevating the catalytic converter temperature to at least a predetermined temperature in response to a catalytic converter efficiency signal;  
       in response to said elevated temperature, initiating a decontamination period for removing sulfur, said decontamination period comprising: a first interval where the engine operates in a rich condition; and a second interval where the engine operates in a lean condition after said first interval; operating the engine rich during said first interval and operating the engine lean during said second interval to remove sulfur from said catalytic converter; re-measuring catalytic converter efficiency; and activating a malfunction indicator in response to the re-measured catalytic converter efficiency.  
     
     
       17. The system recited in  claim 16  wherein said decontamination controller further elevates the catalytic converter temperature to at least a predetermined temperature by adjusting ignition timing. 
     
     
       18. A catalytic converter decontamination method for an internal combustion engine, the method comprising the steps of: 
       
         [a] determining when a catalytic converter performance falls below a desired level;  
       
       
         [b] elevating a catalytic converter temperature upon determining that said catalytic converter performance falls below said desired level;  
       
       
         [c] in response to said elevated temperature, initiating a decontamination period for removing sulfur, said decontamination period comprising:  
       
       
         [d] a first interval where the engine operates in a rich condition; and  
       
       
         [e] a second interval where the engine operates in a lean condition after said first interval; and  
       
       
         [f] operating the engine rich during said first interval and operating the engine lean during said second interval to remove sulfur from said catalytic converter. 
       
     
     
       19. The method recited in  claim 18  wherein said step of determining when a catalytic converter performance falls below a desired level comprises the step of generating a catalytic contamination signal. 
     
     
       20. The method recited in  claim 19  wherein said generating step further comprises the steps of: 
       
         [a] measuring a number of transitions from a first state to a second state of an exhaust gas oxygen sensor positioned upstream of the catalytic converter; and  
       
       
         [b] indicating catalytic converter performance by calculating a ratio between said transitions in said upstream exhaust gas oxygen sensor to transitions in a downstream exhaust gas oxygen sensor position downstream of the catalytic converter. 
       
     
     
       21. A catalytic converter decontamination method for an internal combustion engine, the method comprising the steps of: 
       
         [a] determining when a catalytic converter performance falls below a preselected level;  
       
       
         [b] in response to said determination elevating the catalytic converter temperature to at least a predetermined temperature;  
       
       
         [c] in response to said elevated temperature, initiating a decontamination period for removing sulfur, said decontamination period comprising:  
       
       
         [d] a first interval where the engine operates in a rich condition; and  
       
       
         [e] a second interval where the engine operates in a lean condition after said first interval;  
       
       
         [f] operating the engine rich during said first interval and operating the engine lean during said second interval while maintaining the catalytic converter temperature above said predetermined temperature to remove sulfur from said catalytic converter;  
       
       
         [g] redetermining catalytic converter performance; and  
       
       
         [h] activating a malfunction indicator when the redetermined catalytic converter performance is below said preselected value. 
       
     
     
       22. The method recited in  claim 21  wherein said predetermined temperature is  1250 ° F. 
     
     
       23. The method recited in  claim 21  wherein said step of determining when a catalytic converter performance falls below a preselected level further comprises the steps of: 
       
         [a] measuring a number of transitions from a first state to a second state of an exhaust gas oxygen sensor positioned upstream of the catalytic converter; and  
       
       
         [b] indicating catalytic converter performance by calculating a ratio between said transitions in said upstream exhaust gas oxygen sensor to transitions in a downstream exhaust gas oxygen sensor position downstream of the catalytic converter. 
       
     
     
       24. The method recited in  claim 21  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by creating an exothermic reaction. 
     
     
       25. The method recited in  claim 21  wherein said elevating step further comprises the step of increasing said catalytic converter temperature by adjusting engine operating parameters. 
     
     
       26. The method recited in  claim 25  wherein said increasing step further comprises the step of adjusting ignition timing. 
     
     
       27. A catalytic converter decontamination method for an internal combustion engine, the method comprising the steps of: 
       
         [a] operating an internal combustion engine in a lean condition;  
       
       
         [b] determining when a catalytic converter performance falls below a desired level during said lean operation;  
       
       
         [c] upon determining that said catalytic converter performance falls below said desired level elevating a catalytic converter temperature to at least a predetermined temperature during said lean operation;  
       
       
         [d] in response to said elevated temperature, initiating a decontamination period for removing sulfur, said decontamination period comprising:  
       
       
         [e] a first interval where the engine operates in a rich condition; and  
       
       
         [f] a second interval where the engine operates in a lean condition after said first interval; and  
       
       
         [g] operating the engine rich during said first interval and operating the engine lean during said second interval to remove sulfur from said catalytic converter. 
       
     
     
       28. The method recited in  claim 27  wherein said predetermined temperature is  1250 ° F. 
     
     
       29. The method recited in  claim 27  wherein said step of determining when a catalytic converter performance falls below a desired level comprises the step of generating a catalytic contamination signal. 
     
     
       30. The method recited in  claim 29  wherein said generating step further comprises the steps of: 
       
         [a] measuring a number of transitions from a first state to a second state of an exhaust gas oxygen sensor positioned upstream of the catalytic converter; and  
       
       
         [b] indicating catalytic converter performance by calculating a ratio between said transitions in said upstream exhaust gas oxygen sensor to transitions in a downstream exhaust gas oxygen sensor position downstream of the catalytic converter.