CATALYST MONITORING SYSTEMAND METHOD

BACKGROUND OF THE INVENTION

1. Field of the Invention [0001] The invention relates to a catalyst monitoring system and method.

More particularly, the invention relates to a catalyst monitoring system and method that monitors the deterioration state of an NOχ storage-reduction catalyst which is arranged in an exhaust passage of an internal combustion engine.

2. Description of the Related Art [0002] A three-way catalyst is widely used to purify exhaust gas of an internal combustion engine. The three-way catalyst is provided with oxygen storing material that stores oxygen. The three-way catalyst operates by storing and releasing oxygen to accurately maintain the stoichiometric air-fuel ratio within the catalyst, thus making it possible to purify the exhaust gas with high efficiency. [0003] However, unless the air-fuel ratio of the exhaust gas that flows into the three-way catalyst is near the stoichiometric air-fuel ratio, highly efficient purification cannot be achieved. Therefore, in an internal combustion engine that may operate with a leaner air-fuel ratio than the stoichiometric air-fuel ratio (i.e., a lean air-fuel ratio), an N0χ storage-reduction catalyst (hereinafter simply referred to as "NOχ catalyst") is provided in the exhaust passage of the internal combustion engine. The NOχ catalyst is provided with an N0χ storing material that stores NOχ.

[0004] By providing the NOχ catalyst, N0χ in the exhaust gas may be stored in the N0χ catalyst when the internal combustion engine is operating with the lean air-fuel ratio. Also, when purifying NOχ stored in the NOχ catalyst, control is performed that temporarily switches the air-fuel ratio from lean to rich or the stoichiometric air-fuel ratio (hereinafter, this control will simply be referred to as "rich spike"). Performing this rich spike introduces exhaust gas containing HC and CO and the like into the NOχ catalyst. This HC and CO and the like are used as reducing agents to reduce (i.e., purify) the stored N0χ to N ₂ , after which it is then released.

COMFfRMATJON COPY

[0005] Meanwhile, even an internal combustion engine in which lean . combustion is performed may operate with the stoichiometric air-fuel ratio depending on the operating region. While operating with the stoichiometric air-fuel ratio, the NOχ catalyst may be used as a three-way catalyst. Therefore, the N0χ catalyst is also provided with oxygen storing material in addition to the N0χ storing material. When the internal combustion engine is operating with the lean air-fuel ratio, the oxygen storing material in the N0χ catalyst becomes saturated with oxygen.

[0006] As this kind of N0χ catalyst deteriorates, the oxygen and NOχ storing capabilities decline. However, in this case, the manner in which the oxygen storage capability declines and the manner in which the N0χ storage capability declines are not the same. Therefore, it is preferable to be able to determine the oxygen storage capability and the N0χ storage capability separately in order to correctly diagnose the deterioration state of the N0χ catalyst.

[0007] Japanese Patent No. 2827954 describes a system that may determine the oxygen storage capability and the N0χ storage capability of an NOχ catalyst separately by executing the rich spike two times in succession. FIG. 12 is a view illustrating the operation of this comparative example.

[0008] With the system described in Japanese Patent No. 2827954, an air-fuel ratio sensor (hereinafter simply referred to as "A/F sensor") is provided upstream of the N0χ catalyst and an oxygen sensor (hereinafter simply referred to as "O ₂ sensor") is provided downstream of the N0χ catalyst. When the first rich spike is executed and reducing agents such as HC and CO flow into the N0χ catalyst, the oxygen and NOχ stored in the NOχ catalyst react with those reducing agents and are consumed in the process. Then, when all of the oxygen and N0χ that were stored in the N0χ catalyst have been consumed, the reducing agents pass through to the downstream side of the N0χ catalyst such that the output from the O ₂ sensor which is provided downstream of the N0χ catalyst changes from an output that indicates a lean air-fuel ratio to an output that indicates a rich air-fuel ratio. Accordingly, the amount of the reducing agents (i.e., "reducing agent amount I" in FIG. 12) that flow into the NO _x catalyst by the time the

output from the O ₂ sensor changes to the rich air-fuel ratio, corresponds to the sum of the amounts of oxygen and N0χ that have been stored in the N0χ catalyst. Accordingly, the sum of the oxygen stored amount and the N0χ stored amount in the N0χ catalyst (hereinafter referred to as the "total stored amount") may be calculated based on the reducing agent amount I that is calculated based on the output from the A/F sensor which is provided upstream of the N0χ catalyst.

[0009] When the first rich spike has ended, the air-fuel ratio returns to and is maintained at the lean air-fuel ratio until the oxygen storing material of the N0χ catalyst becomes saturated with oxygen. Then, the second rich spike is executed when the oxygen storing material of the N0χ catalyst becomes saturated with oxygen. In the second rich spike as well, the amount of reducing agents (i.e., "reducing agent amount II in FIG. 12) that flow into the N0χ catalyst by the time the output from the downstream O ₂ sensor changes to the rich air-fuel ratio, may be calculated based on the output from the upstream A/F sensor, just as described above. [0010] Here, the time that it takes for the oxygen storing material of the N0χ catalyst to become saturated with oxygen is extremely short (such as 1 to 2 seconds). That is, the time during for which the lean air-fuel ratio is maintained between the first rich spike and the second rich spike, is extremely short. Therefore, during this time, almost no N0χ is stored in the N0χ catalyst. That is, when the second rich spike starts, the oxygen storing material of the N0χ catalyst is already saturated with oxygen, but an N0χ amount that has been stored in N0χ storing material of the N0χ catalyst may be regarded as being zero. Therefore, the reducing agent amount II in the second rich spike corresponds to the oxygen stored amount in the N0χ catalyst. Accordingly, the oxygen stored amount may be calculated from the reducing agent amount II. Thus, subtraction of the oxygen amount that has been stored during the second rich spike from the total stored amount corresponds to the N0χ stored amount.

[0011] In this way, the system described in Japanese Patent No. 2827954 may separately detect the amount of stored oxygen, which is an indication of the oxygen storage capability, and the N0χ stored amount, which is an indication of the N0χ storage

capability, in the NOχ catalyst.

[0012] However, with the system described in Japanese Patent No. 2827954, the rich spike has to be executed at least two times in succession in order to separately calculate the oxygen stored amount and the N0χ stored amount. Therefore, the rich spike has to be performed more frequently.

[0013] While the rich spike is being executed, the air-fuel ratio is made rich so the fuel injection quantity has to be increased. As a result, as the frequency of the rich spike increases, the fuel efficiency decreases by a corresponding amount.

[0014] Furthermore, at the start and end of the rich spike, the value of the air-fuel ratio is greatly changed between the lean air-fuel ratio and the rich air-fuel ratio.

When the air-fuel ratio is changed, the emissions tend to deteriorate and torque shock tends to occur. Therefore, as the frequency of the rich spike increases, the deterioration of the emissions and the generation of torque shock tend to become significant.

SUMMARY OF THE INVENTION

[0015] The invention thus provides a catalyst monitoring system and method that may accurately monitor deterioration of an N0χ storage-reduction catalyst, thereby suppressing adverse effects such as a decrease in fuel efficiency, a deterioration of emissions, and the generation of torque shock. [0016] A first aspect of the invention thus relates to a catalyst monitoring system that includes a N0χ catalyst which is arranged in an exhaust passage of an internal combustion engine, and a first exhaust gas sensor which is arranged downstream of the NOχ catalyst and outputs a signal indicative of an air-fuel ratio of exhaust gas. More specifically, the first aspect relates to a catalyst monitoring system that further includes execution condition setting means for setting a plurality of different air-fuel ratio control execution conditions; air-fuel ratio controlling means for temporarily switching the air-fuel ratio of the exhaust gas of the internal combustion engine from the lean to the rich or stoichiometric air-fuel ratio when the plurality of different air-fuel ratio control execution conditions are satisfied; intake N0χ amount obtaining means for estimating or

detecting a total intake N0χ amount that flows into the N0χ catalyst between the time that air-fuel ratio control ends and the time that the air-fuel ratio control starts the next time; total stored amount calculating means for calculating a total stored amount based on the output from the first exhaust gas sensor during the air-fuel ratio control, the total stored amount corresponding to the sum of an stored amount of oxygen and an stored amount of N0χ that have been stored in the N0χ catalyst before the air-fuel ratio control started; and oxygen stored amount calculating means for calculating an oxygen stored amount of the total stored amount based on a relationship between the intake N0χ amount and the total stored amount, which is established beforehand by executing the air-fuel ratio control with at least two different air-fuel ratio control execution conditions.

[0017] Also, the catalyst monitoring system may further include oxygen storage capability monitoring means for determining an oxygen storage capability of the NOχ catalyst based on the calculated oxygen stored amount.

[0018] Further, the catalyst monitoring system may also include N0χ stored amount calculating means for calculating a N0χ stored amount by subtracting the oxygen stored amount from the total stored amount; and N0χ storage capability monitoring means for determining an N0χ storage capability of the NOχ catalyst based on the calculated N0χ stored amount.

[0019] Moreover, the plurality of different air-fuel ratio control execution conditions may include a condition that the intake NOχ amount reaches a predetermined value, and the execution condition setting means may set the predetermined value as at least two levels.

[0020] Also, the oxygen stored amount calculating means may calculate a value corresponding to the total stored amount at the time when the intake NOχ amount is zero by extrapolating the relationship between the intake N0χ amount and the total stored amount, and may set the calculated value as the oxygen stored amount.

[0021] Further, the catalyst monitoring system may also include an upstream catalyst which is arranged upstream of the NOχ catalyst; a second exhaust gas sensor which is arranged between the N0χ catalyst and the upstream catalyst, and which outputs

a signal according to the air-fuel ratio of the exhaust gas; and oxygen storage capacity calculating means for calculating an oxygen storage capacity of the upstream catalyst based on the output from the second exhaust gas sensor during the air-fuel ratio control. The total stored amount calculating means may calculate the total stored amount based on the outputs from the first and the second exhaust gas sensors during the air-fuel ratio control.

[0022] Also, the intake N0χ amount obtaining means may estimate the intake N0χ amount based on a relationship between i) a load and speed of the internal combustion engine and ii) an amount of N0χ generated per unit time. [0023] Moreover, the intake N0χ amount obtaining means may detect the intake N0χ amount based on an output from an N0χ sensor which is arranged upstream of the N0χ catalyst.

[0024] A second aspect of the invention relates to a catalyst monitoring method for a NOχ catalyst which is arranged in an exhaust passage of an internal combustion engine. More specifically, the second aspect relates to a catalyst monitoring method that includes; a) setting a plurality of different air-fuel ratio control execution conditions ; b) switching the air-fuel ratio of the exhaust gas of the internal combustion engine temporarily from the lean to the rich or stoichiometric air-fuel ratio when the plurality of different air-fuel ratio control execution conditions are satisfied; c) estimating or detecting a total intake NOχ amount that has flowed into the N0χ catalyst between the time that the air-fuel ratio control ends and the time that another air-fuel ratio control starts; d) calculating a total stored amount based on the signal from the first exhaust gas sensor that is output during the air-fuel ratio control, the total stored amount corresponding to the sum of the stored amount of oxygen and the stored amount of NOχ that have been stored in the NOχ catalyst before the air-fuel ratio control starts; and e) calculating a oxygen stored amount out of the total stored amount based on a relationship between the intake NOχ amount and the total stored amount. The relationship between the intake N0χ amount and the total stored amount is established beforehand by executing the air-fuel ratio control with at least two different air-fuel ratio control

execution conditions.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The foregoing and further objects, features and advantages of the invention will become apparent from the following description of example embodiments with reference to the accompanying drawings, wherein like numerals are used to represent like elements and wherein:

FIG. 1 is a schematic view of a system configuration according to a first example embodiment of the invention; FIGS. 2A to 2E are timing charts illustrating operation of the first example embodiment;

FIG. 3 is a expanded view illustrating a part of the timing chart of FIG. 2; FIG. 4 is a graph showing the relationship between an intake N0χ amount into the N0χ catalyst and the total stored amount; FIG. 5 is another graph showing the relationship between the intake N0χ amount into the N0χ catalyst and the total stored amount;

FIG. 6 is still another graph showing the relationship between the intake NOχ amount into the NOχ catalyst and the total stored amount;

FIG. 7 is yet another graph showing the relationship between the intake N0χ amount into the NOχ catalyst and the total stored amount;

FIG. 8 is a graph showing the relationship between the intake N0χ amount into the N0χ catalyst and a N0χ stored amount;

FIG. 9 is a flowchart of a routine executed in the first example embodiment of the invention; FIG. 10 is a schematic view of a system configuration according to a second example embodiment of the invention;

FIGS. HA to HC are timing charts illustrating operation of the second example embodiment; and

FIG. 12 is a view illustrating operation of a comparative system.

DETAILED DESCRIPTION OF EMBODIMENTS

[0026] FIG. 1 is a schematic view of a system configuration according to a first example embodiment of the invention. The system shown in FIG. 1 is provided with an internal combustion engine 10. The engine shown in the drawing is an inline four-cylinder internal combustion engine that has four cylinders "#1" to "#4". However, the number and arrangement of cylinders in the invention is not limited to the configuration shown in FIG. 1.

[0027] The internal combustion engine 10 is able to operate by burning fuel at an air-fuel ratio that is leaner than the stoichiometric air-fuel ratio (i.e., hereinafter, this air-fuel ratio will be referred to as "lean air-fuel ratio"). The internal combustion engine

10 may be any one of a port injection type internal combustion engine in which fuel is injected into an intake port, an in-cylinder direct injection type internal combustion engine in which fuel is injected directly into the cylinder, and a combination employing both port injection and in-cylinder direct injection.

[0028] Provided midway in an exhaust passage 12 of the internal combustion engine 10 are two start catalysts (S/C) 14 and 16, and one N0χ catalyst (NSR) 18. Exhaust gas from the #1 and #4 cylinders flows into the start catalyst 14 while exhaust gas from the #2 and #3 cylinders flows into the start catalyst 16. The exhaust gas that has passed through the start catalyst 14 merges with the exhaust gas that has passed through the start catalyst 16 and together they flow into the N0χ catalyst 18.

[0029] The start catalysts 14 and 16 function as three-way catalysts that may simultaneously purify HC, CO, and N0χ with the storage and release of oxygen when the air-fuel ratio of the inflowing exhaust gas is near the stoichiometric air-fuel ratio. It is to be understood that "storage" used herein means retention of a substance (solid, liquid, gas molecules) in the form of at least one of adsorption, adhesion, absorption, trapping, occlusion, and others.

[0030] Meanwhile, the NOχ catalyst 18 functions as an N0χ storage reduction catalyst, that is, stores N0χ when the air-fuel ratio of the inflowing exhaust gas is lean,

and purifies the stored N0χ by reducing the stored N0χ to N ₂ when the air-fuel ratio of the inflowing exhaust gas is rich or stoichiometric, thereby releasing N ₂ . Furthermore, this N0χ storage-reduction catalyst 18 is also able to store oxygen and functions as a three-way catalyst when the air-fuel ratio of the inflowing exhaust gas is near the stoichiometric air-fuel ratio.

[0031] In the exhaust passage 12, an A/F sensor 20 is arranged upstream of the start catalyst 14, an A/F sensor 22 is arranged upstream of the start catalyst 16, an A/F sensor 24 is arranged upstream of the N0χ catalyst 18, and an O ₂ sensor 26 is arranged downstream of the N0χ catalyst 18. [0032] The A/F sensors 20, 22, and 24 are air-fuel ratio sensors that produce linear outputs indicative of the air-fuel ratio of the exhaust gas. Also, the O ₂ sensor 26 is an oxygen sensor that produces an output that abruptly changes depending on whether the air-fuel ratio of the exhaust gas is richer or leaner than the stoichiometric air-fuel ratio. [0033] A temperature sensor 28 that detects a temperature (bed temperature)

TCAT of the NO _x catalyst 18 is arranged in the NO _x catalyst 18. Incidentally, the temperature TCAT of the N0χ catalyst 18 may be estimated from the exhaust gas temperature detected by an exhaust gas sensor provided upstream or downstream of the N0χ catalyst 18 instead of being directly detecting. Alternatively, the temperature TCAT of the N0χ catalyst 18 may be estimated based on the operating state of the internal combustion engine 10.

[0034] Also, an intake system, not shown, which draws in and distributes air to the cylinders is connected to the internal combustion engine 10.

[0035] The system according to the first example embodiment includes an ECU (Electronic Control Unit) 30. This ECU 30 is electrically connected to, in addition to the sensors described above, various sensors that detect the engine speed NE, the intake air pressure PM, the intake air amount GA, and the throttle opening amount TH, and the like. The ECU 30 is also electrically connected to various actuators of fuel injectors, spark plugs, and a throttle valve, and the like.

[0036] The internal combustion engine 10 operates by burning fuel at the lean air-fuel ratio in a predetermined operating region. While operating with the lean air-fuel ratio, N0χ is unable to be purified in the start catalysts 14 and 16 so N0χ is temporarily stored in the NO _x catalyst 18. When NO _x accumulates in the NO _x catalyst 18, the ECU 30 executes "rich spike" that temporarily swithes the combustion air-fuel ratio of the internal combustion engine 10 from lean to rich or the stoichiometric air-fuel ratio. Here, rich spike may be regarded as "air-fuel ratio control" of the invention.

[0037] FIGS. 2A to 2E are timing charts illustrating the operation of the first example embodiment. Hereinafter, the operation of the first example embodiment will be described with reference to FIG. 2A to 2E. The time along the horizontal axes in FIGS. 2A to 2E represents the time that has passed after rich spike has ended and the combustion air-fuel ratio of the internal combustion engine 10 has returned to the lean air-fuel ratio. Also in FIGS. 2A to 2E, the operation that includes the execution of another rich spike twice thereafter is shown. [0038] NO _x IN shown in FIG. 2 A represents an integrated amount of NO _x that flows into the NO _x catalyst 18. In this first example embodiment, a relationship between i) the load and speed of the internal combustion engine 10 and ii) the amount of NO _x generated per unit time is established through testing beforehand, and that relationship is then stored in advance in the ECU 30. Then based on that relationship, the ECU 30 calculates the amount of NO _x generated per unit time at the current load and speed of the internal combustion engine 10, and calculates an integrated amount of NO _x generated per unit time as NO _x IN. When the air-fuel ratio returns to the lean air-fuel ratio after the internal combustion engine 10 has been operated at the stoichiometric air-fuel ratio or an air-fuel ratio that is richer than the stoichiometric air-fuel ratio, the NO _x IN is reset. That is, NO _x IN represents the total amount (an estimated value thereof) OfNO _x that has flowed into the NO _x catalyst 18 after the rich spike has ended.

[0039] In this invention, the method for calculating NO _x IN is not limited to the method of estimating NO _x IN from the operating state of the internal combustion engine 10. That is, an NO _x sensor that detects the NO _x concentration may be arranged

upstream of the N0χ catalyst 18, and NO _x IN may be calculated based on an output from that N0χ sensor.

[0040] FIG. 2C is a graph illustrating an output from the O ₂ sensor 26 which is arranged downstream of the NOχ catalyst 18, and FIG. 2D is a graph illustrating an output from the A/F sensor 24 which is arranged upstream of the N0χ catalyst 18. When the internal combustion engine 10 is operated at the lean air-fuel ratio, exhaust gas of the lean air-fuel ratio flows through the exhaust passage 12. Therefore, when the internal combustion engine 10 is operated at the lean air-fuel ratio, the output from the O ₂ sensor 26 indicates the lean air-fuel ratio, and the output from the A/F sensor 24 indicates a lean target air-fuel ratio of the internal combustion engine 10.

[0041] As shown in FIG. 2A, when the internal combustion engine 10 is operated at the lean air-fuel ratio, N0χIN increases monotonically. When NO _x IN reaches a predetermined value A ₁ , the rich spike starts (time tl). FIG. 2B is a timing chart of an execution flag FR of the rich spike. This execution flag FR of the rich spike is "1" when the rich spike is being executed, and "0" when the rich spike is not being executed.

[0042] When the rich spike starts, the combustion air-fuel ratio of the internal combustion engine 10 changes from the lean to the rich air-fuel ratio. Therefore, exhaust gas of the rich air-fuel ratio that includes large quantities of reducing agents such as HC and CO flows into the start catalysts 14 and 16. Then when all of the oxygen that was stored in the start catalysts 14 and 16 is used up, exhaust gas of the rich air-fuel ratio starts to pass through to the downstream side of the start catalysts 14 and 16. As a result, the output from the A/F sensor 24 changes from the lean to the rich air-fuel ratio, as shown in FIG. 2D. [0043] When the internal combustion engine 10 is operated at the lean air-fuel ratio, oxygen storing material in the N0χ catalyst 18 soon becomes saturated with oxygen. Therefore, when the rich spike starts, oxygen to reach the maximum oxygen storage capacity OSC is already stored in the NO _x catalyst 18.

[0044] On the other hand, the value of NO _x IN which is a rich spike starting

condition (i.e., the predetermined value A ₁ described above) is set so that the rich spike starts before the NO _x stored amount in the NO _x catalyst 18 reaches the maximum NO _x storage capacity NSC (i.e., a predetermined value A ₂ which will be described later is also similar). Accordingly, when the rich spike starts, NO _x of an amount that is less than the maximum NO _x storage capacity NSC is stored in the NO _x catalyst 18.

[0045] When exhaust gas that contains reducing agents such as HC and CO flows into the NO _x catalyst 18, the oxygen and NO _x stored in the NO _x catalyst 18 are consumed in a reaction that takes place with those reducing agents. During this time, the output from the O ₂ sensor 26 is maintained at the lean air-fuel ratio. Also, when all of the oxygen and NO _x that was stored in the NO _x 18 is consumed, rich exhaust gas that contains reducing agents starts to pass through to the downstream side of the NO _x catalyst 18. As a result, the output from the O ₂ sensor 26 changes from the "lean air-fuel ratio" to the "rich air-fuel ratio" (time t2). At the time t2, this rich spike ends.

[0046] In this way, there is a correlation between the amount of reducing agents that has flowed into the NO _x catalyst 18 between the time the output from the O ₂ sensor 26 changed from the lean air-fuel ratio to the rich air-fuel ratio and both the amount of oxygen (hereinafter, referred to as the "oxygen stored amount OSA") and NO _x (hereinafter referred to as the "NO _x stored amount NSA") that have been stored in the NO _x catalyst 18 before the rich spike starts. In this first example embodiment, the value corresponding to the sum of the oxygen stored amount OSA and the NO _x stored amount NSA will be represented by a total stored amount TSA which will be described below.

[0047] The total stored amount TSA is the sum of the NO _x stored amount NSA that has been converted to oxygen, and the oxygen stored amount OSA. In the system in this first example embodiment, the total stored amount TSA may be obtained based on the amount of reducing agent that has flowed into the NO _x catalyst 18, as will be described later.

[0048] FIG. 3 is an expanded view of the portions in FIG. 2C and 2D at the time the rich spike is executed. The reducing agent that flows into the NO _x catalyst 18 is unburned fuel in the exhaust gas. Therefore, the amount of reducing agent that flows

W

13 into the N0χ catalyst 18 may be calculated based on the hatched portion in the graph of the A/F sensor output in FIG. 3. Accordingly, the total stored amount TSA may be calculated using Expression (1) below.

TSA = 10.23xGA/(A/F) x(A/F-14.6) | xCalculation routine cycle ...(1) where "0.23" is a conversion coefficient to O ₂ , "GA/(A/F)" is an amount of fuel flowing into the N0χ catalyst 18 per unit time, "A/F-14.6" is width of the hatched portion in FIG. 3, and " 10.23xGA/(A/F) x(A/F-14.6) | " is an amount of O ₂ consumed per unit time. In addition, "GA" is the intake air amount of the internal combustion engine 10, "A/F" is the air-fuel ratio of the exhaust gas that flows into the N0χ catalyst 18, and "14.6" is the stoichiometric air-fuel ratio. The intake air amount GA may be obtained based on an output from an airflow meter, for example. Also, the air-fuel ratio A/F may be obtained based on the output from the A/F sensor 24. Alternatively, the air-fuel ratio A/F may be obtained from the intake air amount GA and the fuel injection quantity.

[0049] The ECU 30 performs the calculation in Expression (1) above each time a predetermined calculation routine is executed. TSA calculated from Expression (1) above represents the amount of oxygen that corresponds to the amount of reducing agent that has flowed into the N0χ catalyst 18 during the execution cycle. The ECU 30 integrates TSA that is calculated from Expression (1) above after the output from the A/F sensor 24 has changed from a "lean air-fuel ratio" to a "rich air-fuel ratio". Thus, this integrated value of TSA represents the integrated amount of oxygen that corresponds to the integrated amount of reducing agent that has flowed into the N0χ catalyst 18 after the output from the A/F sensor 24 has changed from the lean air-fuel ratio to the rich air-fuel ratio. FIG. 2E shows the integrated value of TSA.

[0050] As described above, when the output from the O ₂ sensor 26 has changed from the lean air-fuel ratio to the rich air-fuel ratio (i.e., at time t2), it may be determined that the oxygen and N0χ that were stored in the N0χ catalyst 18 have all been consumed. Accordingly, the integrated value of TSA at the time t2 corresponds to the total stored amount TSA. That is, in the example shown in FIG. 2E, TSA ₁ at time t2 is the total stored amount TSA before the rich spike started. Incidentally, when the rich

spike ends, the integrated value of TSA is reset.

[0051] Thus far the first rich spike in FIG. 2 has been described. After time t2 when this rich spike ends, the combustion air-fuel ratio returns to the lean target air-fuel ratio and the internal combustion engine 10 operates at the lean air-fuel ratio. Then after a while, another rich spike is executed for the second time.

[0052] The first rich spike is executed (started) on the condition that NOχIN has reached the predetermined value A ₁ , as described above. In contrast, as shown in

FIG. 2A, the second rich spike is executed (started) (i.e., at time t3) on the condition that

NOχIN has reached the predetermined value A ₂ that is not equal to A ₁ (in the drawing, A ₁ is less than A ₂ ).

[0053] The operation during the second rich spike is similar to the operation during the first rich spike except that the execution condition of rich spike is different (i.e., A ₁ is not equal to A ₂ ), as described above. That is, the second rich spike ends when the output from the O ₂ sensor 26 changes from the lean air-fuel ratio to the rich air-fuel ratio (i.e., at time t4). TSA ₂ at the time t4 is the total stored amount TSA before the second rich spike started.

[0054] According to the control shown in FIG. 2 described above, it is possible to detect both the total stored amount TSA ₁ where N0χIN, i.e., the total amount of N0χ that has flowed into the NOχ catalyst 18 is A ₁ between the time that the first rich spike has ended and the time that the second rich spike starts (hereinafter this total amount of N0χ will be referred to as "intake N0χ amount") and the total stored amount TSA ₂ where the intake N0χ amount is A ₂ .

[0055] In this way, with the system according to the first example embodiment, the intake N0χ amount into the NOχ catalyst 18 is set to a plurality of different levels and the total stored amount TSA may be detected at each level. FIG. 4 is a graph in which test results each time the value of the intake N0χ amount was changed and the total stored amount TSA was detected, which was done a plurality of times, are plotted on a coordinate system in which the horizontal axis represents the intake N0χ amount and the vertical axis represents the total stored amount TSA. Incidentally, each rich spike

has been executed under substantially the same operating conditions. As shown in FIG. 4, each point indicating the intake NOχ amount and the total stored amount TSA each time the rich spike was performed lies on a generally straight line. Accordingly, the N0χ stored amount NSA in the total stored amount TSA may increase proportionately as the intake N0χ amount increases.

[0056] On the other hand, as described above, when the internal combustion engine 10 is operating at the lean air-fuel ratio, the N0χ catalyst 18 soon becomes saturated with oxygen. Therefore, when the rich spike starts, the NOχ catalyst 18 is already saturated with oxygen up to the oxygen storage capacity OSC. Accordingly, the oxygen stored amount OSA in the total stored amount TSA may be equal to the oxygen storage capacity OSC regardless of the intake N0χ amount.

[0057] If the intake N0χ amount is zero, the NOχ stored amount NSA is of course zero so the entire total stored amount TSA in this case corresponds to the oxygen stored amount OSA. As shown in FIG. 4, by extrapolating the straight line in FIG. 4 the value of the total stored amount TSA when the intake N0χ amount is zero may be obtained as an intercept of this straight line. This intercept value is equal to the oxygen stored amount OSA of the N0χ catalyst 18, and thus equal to the oxygen storage capacity OSC of the NO _x catalyst 18.

[0058] As described above, in the first example embodiment, the value of the oxygen stored amount OSA which is obtained based on the total stored amount TSA of the N0χ catalyst 18 is equal to the value of the oxygen storage capacity OSC of the N0χ catalyst 18. Thus, the value of the oxygen stored amount OSA will simply be referred to as the "oxygen storage capacity OSC" in the following description, for the sake of convenience. [0059] FIG. 5 is a graph in which the total stored amounts TSA ₁ and TSA ₂ and the intake oxygen amounts A ₁ and A ₂ during the second rich spike shown in FIG. 2 are plotted on the same coordinate system as that shown in FIG. 4. As shown in FIG. 5, in this invention, if the total stored amount TSA is detected at least once for each of at least two different levels of the intake N0χ amount, a straight line that represents the

relationship between the intake N0χ amount and the total stored amount TSA may be drawn so the oxygen storage capacity OSC may be estimated.

[0060] Accordingly, in the invention, the oxygen storage capacity OSC may also be estimated based on the total stored amount TSA detected at three or more different levels of the intake N0χ amount. Also, the rich spike is executed two or more times at each level of the intake NOχ amount and the oxygen storage capacity OSC may be estimated based on the total stored amounts TSA obtained from those executions. FIG. 6 is a graph in which a total of nine points are plotted on the same coordinate system as in FIG. 4 when the total stored amount TSA was detected after executing the rich spike three times at three different levels of the intake N0χ amount (i.e., A ₁ , A ₂ , A ₃ ).

[0061] As shown in FIG. 6, when there are at least two points, a straight line that represents relationship between the intake N0χ amount and the total stored amount TSA may be obtained by executing a linear approximation according to the least-square method, for example, with respect to those points. The oxygen storage capacity OSC may then be obtained by extrapolating the straight line. In such a case, the oxygen storage capacity OSC may be estimated with even greater accuracy.

[0062] In this way, according to this first example embodiment, the oxygen storage capacity OSC of the N0χ catalyst 18 may be accurately estimated without executing the rich spike two times in succession. The N0χ reduction performance when the N0χ catalyst 18 is used under the stoichiometric air-fuel ratio may be determined by the oxygen storage capability of the N0χ catalyst 18. As the N0χ catalyst 18 deteriorates, the oxygen storage capability of the N0χ catalyst 18 also declines. The oxygen storage capability may be detected by the value of the oxygen storage capacity OSC. [0063] Accordingly, it is possible to accurately determine whether the oxygen storage capability of the N0χ catalyst 18 is normal (i.e., is within an allowable range) by beforehand setting a predetermined determining value for determining the oxygen storage capability of the N0χ catalyst 18 and comparing the oxygen storage capacity OSC that was estimated in the manner described above with the determining value, for example.

[0064] Also, in FIGS. 4 to 6, a steeper slope of the straight line representing the relationship between the intake N0χ amount and the total stored amount TSA indicates that a greater percentage of inflowing N0χ is captured by the N0χ catalyst 18. That is, it could be said that the slope of this straight line indicates the N0χ storage capability of the N0χ catalyst 18 (i.e., the N0χ reducing performance when the N0χ catalyst 18 is used under the lean air-fuel ratio).

[0065] Accordingly, it is possible to accurately determine whether the N0χ storage capability of the N0χ catalyst 18 is normal (i.e., is within an allowable range) by beforehand setting a predetermined determining value for determining the N0χ storage capability of the N0χ catalyst 18 and comparing the slope of the straight line that represents the relationship between the intake N0χ amount and the total stored amount TSA with that predetermined determining value.

[0066] FIG. 7 is a graph on which are plotted the results of a similar test to FIG.

6. However, the test that showed the results in FIG. 7 was performed on an N0χ catalyst 18 in which deterioration has progressed more than the NOχ catalyst 18 for which the results are shown in FIG. 6. That is, the NOχ catalyst 18 corresponding to

FIG. 7 has a higher degree of deterioration than the N0χ catalyst 18 corresponding to FIG.

6. Accordingly, the straight line in FIG. 7 has a smaller a slope (i.e., less N0χ storage capability) and intercept (i.e., a smaller oxygen storage capacity OSC) than the straight line in FIG. 6.

[0067] FIG. 8 is a graph in which the N0χ stored amount NSA for the nine test results shown in FIG. 6 are plotted as black triangles and the N0χ stored amount NSA for the nine test results shown in FIG. 7 are plotted as white triangles on a coordinate system, where the horizontal axis represents the intake N0χ amount and the vertical axis represents the N0χ stored amount NSA.

[0068] Incidentally, the NOχ stored amount NSA may be calculated by the following expression based on the total stored amount TSA and the oxygen storage capacity OSC. NSA = (TSA - OSC) x 46 / 32 ...(2)

W

18 where "46 / 32" is a conversion coefficient from O ₂ to NO ₂ .

[0069] When a predetermined determining value is set like the sloped straight line in FIG. 8, the nine N0χ stored amounts NSA for the N0χ catalyst 18 in FIG. 6 which is not deteriorated are all above the sloped straight line. On the other hand, the nine N0χ stored amounts NSA for the N0χ catalyst 18 in FIG. 7 which is deteriorated are all below that straight line. In this way, it is apparent that there is an accurate correlation between the N0χ stored amount NSA and the degree of deterioration.

[0070] Accordingly, in this first example embodiment it is possible to accurately determine whether the N0χ storage capability of the N0χ catalyst 18 is normal (i.e., is within an allowable range) by beforehand setting a determining value such as the sloped straight line in FIG. 8 and comparing the detected intake N0χ amount and N0χ stored amount NSA with that determining value. That is, the N0χ storage capability may also be determined by using the determining value instead of using the slope of the straight line that represents the relationship between the intake NOχ amount and the total stored amount TSA.

[0071] FIG. 9 is a flowchart of a routine executed by the ECU 30 in order to determine (diagnose) deterioration of the N0χ catalyst 18 according to the method described above in the first example embodiment. This routine is repeatedly executed at predetermined intervals of time. [0072] In the routine shown in FIG. 9, first the value of NO _x IN that has added up the amount of N0χ that has flowed into the N0χ catalyst 18 is read (step 100). Next it is determined whether the NOχIN has reached a predetermined value A (step 102). This predetermined value A is a value that is set as the intake N0χ amount flowing into the N0χ catalyst 18 when rich spike starts. As described above, in this first example embodiment, the rich spike is executed at each of at least two different levels of the intake N0χ amount. When the rich spike is executed for two different levels of the intake N0χ amount, two values, i.e., A ₁ and A ₂ , are prepared as the predetermined value A. Also, when the rich spike is executed at three different levels of the intake N0χ amount, three values, i.e., A ₁ , A _2, and A ₃ , are prepared as the predetermined value A. In

step 102, one of these predetermined values A is selected and compared with N0χIN.

[0073] If it is determined in step 102 that NOχIN has not yet reached the predetermined value A, then it is determined that the execution condition of the rich spike is not satisfied. In this case, this cycle of the routine directly ends and the internal combustion engine continues to operate at the lean air-fuel ratio.

[0074] If, on the other hand, it is determined in step 102 that NO _x IN has reached the predetermined value A, then it is determined that the rich spike execution condition is satisfied. In this case, the rich spike is executed and the execution flag FR of the rich spike is set to "1" (step 104). While the rich spike is being executed, an integrated value of TSA as shown in FIG. 2E is calculated (step 106).

[0075] Next it is determined whether a condition that the integrated value of TSA calculated in step 106 should be stored as data of the total stored amount TSA used to determine deterioration of the N0χ catalyst 18 (hereinafter, this condition will simply be referred to as "data storing condition") is satisfied (step 108). The data storing conditions are: (a) the rich spike has ended; (b) the operating conditions (such as the engine speed NE, the throttle opening amount TH, and the intake air amount GA) when the rich spike is executed are within predetermined ranges; and (c) the temperature TCAT of the N0χ catalyst 18 when the rich spike is executed is within a predetermined range.

[0076] Condition (a) above is a necessary requirement because the integrated value of TSA at the time that the rich spike ends is a value that should be input as the total stored amount TSA, as described above. Condition (b) above is a condition provided so that only data obtained when the rich spike is executed under predetermined operating conditions such as no sudden acceleration or deceleration, is used as the basis for the catalyst deterioration determination in order to prevent an erroneous determination due to a calculation error of the NO _x IN or the like. Condition (c) above is a condition to prevent an erroneous determination due to the effect of the temperature of the NO _x catalyst 18. That is, the purifying capability of the N0χ catalyst 18 changes depending on its temperature. Therefore, condition (c) above is provided so that only data obtained when the rich spike is executed within a temperature range is used as the basis for the

catalyst deterioration determination because the purifying capability of the N0χ catalyst 18 may be regarded as being constant within the temperature range.

[0077] When it is determined in step 108 that all of the conditions (a) to (c) above are satisfied, the integrated value of TSA that was calculated in step 106 is linked to the predetermined value A (i.e., the intake N0χ amount) that was selected in step 102 as data of the total stored amount TSA used for the catalyst deterioration determination, and stored in the ECU 30 (step 110).

[0078] Incidentally, even if the rich spike is executed within a temperature range deviated from condition (c) above, the integrated value of TSA may also be converted to a value that may be obtained within the temperature range of condition (c) above by performing a correction such as multiplying the integrated value of TSA by a correction coefficient. Accordingly, when condition (c) above is not satisfied, the integrated value of TSA may be stored as data of the total stored amount TSA after the integrated value of TSA has been corrected in a predetermined manner. [0079] Once the data of the total stored amount TSA is stored, it is then determined whether a condition for executing the catalyst deterioration determination is satisfied (step 112). More specifically, it is determined whether the data of the total stored amount TSA for the rich spike that was executed with at least two levels of the intake N0χ amount is stored. That is, it is determined that the deterioration determination execution condition is satisfied when the data of at least two points, which is necessary to calculate the oxygen storage capacity OSC, is stored, as described with reference to FIG. 5. Also, when the oxygen storage capacity OSC is calculated based on predetermined data of three or more points, as shown in FIG. 6, it may be determined that the deterioration determination execution condition is satisfied when the predetermined data is assembled.

[0080] If it is determined in step 112 that the deterioration determination execution condition is not satisfied, this cycle of the routine directly ends. In this case, when the routine is executed the next time and thereafter, it is determined whether the rich spike execution condition is satisfied after the predetermined value A selected in step

102 has been changed as necessary.

[0081] If, on the other hand, it is determined in step 112 that the deterioration determination execution condition is satisfied, then the oxygen storage capacity OSC is calculated based on the stored data (step 114). That is, the oxygen storage capacity OSC is calculated according to the method described above with reference to FIG. 5 or FIG. 6.

Then the N0χ stored amount NSA is calculated based on Expression (2) above.

[0082] Next it is determined whether the oxygen storage capability of the N0χ catalyst 18 is normal based on the oxygen storage capacity OSC that was calculated in step 114 above (step 118). More specifically, the value of that oxygen storage capacity OSC is compared with a predetermined determining value and if the value of the oxygen storage capacity OSC is equal to or greater than that predetermined determining value, the oxygen storage capability is determined to be normal. In this case, a flag XOD is set to "0" (step 120) to indicate that the oxygen storage capability of the N0χ catalyst 18 is normal. If, on the other hand, the value of the oxygen storage capacity OSC is less than that predetermined determining value, it is determined that the oxygen storage capability is abnormal. In this case, the flag XOD is set to "1" (step 122) to indicate that the oxygen storage capability of the N0χ catalyst 18 is abnormal (i.e., to indicate that the allowable range of the N0χ catalyst 18 has been exceeded and the N0χ catalyst 18 is deteriorating). [0083] Continuing on, it is determined whether the N0χ storage capability of the N0χ catalyst 18 is normal based on the N0χ stored amount NSA that was calculated in step 116 (step 124). More specifically, the value of that N0χ stored amount NSA is compared with a predetermined determining value such as that shown in FIG. 8 and if the value of that N0χ stored amount NSA is equal to or greater than that predetermined determining value, the N0χ storage capability is determined to be normal. In this case, a flag XND is set to "0" (step 126) to indicate that the NO _x storage capability of the NO _x catalyst 18 is normal. If, on the other hand, the value of the N0χ stored amount NSA is less than that predetermined determining value, it is determined that the N0χ storage capability is abnormal. In this case, the flag XND is set to "1" (step 128) to indicate that

the NOχ storage capability of the N0χ catalyst 18 is abnormal (i.e., to indicate that the allowable range of the N0χ catalyst 18 has been exceeded and the N0χ catalyst 18 is deteriorating).

[0084] Incidentally, the N0χ storage capability in step S 124 may be determined based on the slope of a straight line representing the relationship between the intake N0χ amount and the total stored amount TSA, as described above.

[0085] As described above, according to the routine illustrated in FIG. 9, the total stored amount TSA of the N0χ catalyst 18 may be broken down. That is, the oxygen storage capacity OSC (oxygen stored amount OSA) and the N0χ stored amount NSA may each be calculated. Then using each of these values, the oxygen storage capability, which is the reference for the capability when the N0χ catalyst 18 is used under the stoichiometric air-fuel ratio, and the N0χ storage capability, which is the reference for the capability when the N0χ catalyst 18 is used under the lean air-fuel ratio, may be determined separately. Accordingly, the deterioration state of the N0χ catalyst 18 may be accurately diagnosed.

[0086] Also in this invention, it is not necessary to successively execute the rich spike at short intervals (i.e., intervals during which almost no N0χ is stored in the N0χ catalyst 18). That is, the foregoing effects may be obtained by executing the rich spike at intervals close to the intervals at which the rich spike is normally executed. Accordingly, it is possible to prevent the rich spike from being executed more frequently, which in turn makes it is possible to prevent adverse effects such as a deterioration of fuel efficiency and emissions, and an increased tendency for torque shock to be generated.

[0087] Also, in the first example embodiment described above, the N0χ catalyst 18 may be regarded as the "N0χ catalyst" of the invention, and the O ₂ sensor 26 may be regarded as the "first exhaust gas sensor" of the invention. Further, the ECU 30 may be regarded as the "execution condition setting means" of the invention by executing the process in step 102, as the "air-fuel ratio controlling means" of the invention by executing the process in step 104, as the "intake N0χ amount obtaining means" of the invention by executing the process in step 100, as the "total stored amount calculating

means" of the invention by executing the process in step 106, and as the "oxygen stored amount calculating means" of the invention by executing the process in step 114.

[0088] Also, the ECU 30 may be regarded as the "oxygen storage capability monitoring means" of the invention by executing the processes in steps 118 to 122, and as "NOχ storage capability monitoring means" of the invention by executing the processes in steps 124 to 128.

[0089] Next, a second example embodiment of the invention will be described with reference to FIGS. 10 and 11. However, the following description will focus on those points that differ from the first example embodiment described above. Descriptions similar to the first example embodiment will be simplified or omitted. FIG. 10 is a schematic view of a system configuration according to the second example embodiment of the invention. As shown in FIG. 10, in the system according to this second example embodiment, instead of the AfF sensor 24 in the first example embodiment, an O ₂ sensor 32 that produces an output which suddenly changes depending on whether the air-fuel ratio of the exhaust gas is richer or leaner than the stoichiometric air-fuel ratio, is arranged upstream of the N0χ catalyst 18. In all other regards, the system in the second example embodiment is similar to the system in the first example embodiment. Hereinafter, for the sake of simplifying the description, the O ₂ sensor 32 arranged upstream of the N0χ catalyst 18 will be referred to as the upstream O ₂ sensor 32 and the O ₂ sensor 26 arranged downstream of the N0χ catalyst 18 will be referred to as the downstream O ₂ sensor 26.

[0090] In the second example embodiment, as will be described later, when the rich spike is executed, the oxygen storage capacity OSC of the start catalysts 14 and 16, which are three-way catalysts, may be detected at the same time that the total stored amount TSA of the NO _x catalyst 18 is detected.

[0091] FIGS. HA to HC are timing charts illustrating a method for detecting the oxygen storage capacity OSC of the start catalysts 14 and 16 and the total stored amount TSA of the N0χ catalyst 18. FIG. HA shows an output from the downstream O ₂ sensor 26. FIG. HB shows an output from the upstream O ₂ sensor 32. FIG. HC

shows an output from either the A/F sensors 20 or 22 arranged upstream of the start catalysts 14 and 16, or an average output from both the A/F sensors 20 and 22 (hereinafter, this output referred to as "A/F sensor output").

[0092] As shown in FIGS. HA to HC, when the rich spike is started and exhaust gas of the rich air-fuel ratio starts to be discharged from the internal combustion engine 10, first the A/F sensor output changes from the lean to the rich air-fuel ratio (time tl). Then when all of the oxygen that was stored in the start catalysts 14 and 16 is used up due to the reducing agent that flows into the start catalysts 14 and 16, exhaust gas of the rich air-fuel ratio starts to pass through to the downstream side of the start catalysts 14 and 16. As a result, the output of the upstream O ₂ sensor changes from the lean to the rich air-fuel ratio (time t2). _{

[0093] In this way, the amount of reducing agent that has flowed into the start catalysts 14 and 16 between time tl and time t2 (i.e., the portion with cross-hatching in

FIG. HC) corresponds to the oxygen storage capacity OSC of the start catalysts 14 and 16. Accordingly, the oxygen storage capacity OSC of the start catalysts 14 and 16 may be obtained by integrating the results of Expression (1) above from time tl to time t2. .

[0094] From time t2, the reducing agent starts to flow into the N0χ catalyst 18.

Then when all of the oxygen and N0χ that were stored in the N0χ catalyst 18 are used up due to the reducing agent, exhaust gas of the rich air-fuel ratio starts to pass through to the downstream side of the N0χ catalyst 18. As a result, the output of the downstream

O ₂ sensor 26 changes from the lean to the rich air-fuel ratio (time t3).

[0095] In this way, the amount of reducing agent that has flowed into the N0χ catalyst 18 between time t2 and time t3 (i.e., the portion with hatching in FIG. HC) corresponds to the total stored amount TSA of the N0χ catalyst 18. Accordingly, the total stored amount TSA of the N0χ catalyst 18 may be obtained by integrating the results of Expression (1) above from time t2 to time t3.

[0096] In this second example embodiment, as described above, both the total stored amount TSA of the N0χ catalyst 18 and the oxygen storage capacity OSC of the start catalysts 14 and 16 may be detected. Therefore, deterioration of the start catalysts

14 and 16 may also be diagnosed at the same time.

[0097] When calculating the amount of inflowing reducing agent, the exhaust air-fuel ratio may be calculated from the fuel injection quantity and the intake air amount GA of the internal combustion engine 10 instead of being obtained from the A/F sensor output.

[0098] All other aspects of the second example embodiment are similar to those of the first example embodiment described above so further description thereof will be omitted.

[0099] Incidentally, in the second example embodiment described above, the start catalysts 14 and 15 may be each be regarded as the "upstream catalyst" of the invention, and the upstream O ₂ sensor 32 may be regarded as the "second exhaust gas sensor" of the invention. Also, the ECU 30 may be regarded as the "oxygen storage capacity calculating means" of the invention by calculating the oxygen storage capacity OSC of the start catalysts 14 and 16. [0100] While the invention has been described with reference to example embodiments thereof, it is to be understood that the invention is not limited to the described embodiments or constructions. To the contrary, the invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the example embodiments are shown in various combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention.