Design and Optimization of In-Cycle Closed-Loop Combustion Control with Multiple Injections

With the increasing demand of transportation, biofuels play a fundamental role in the transition to sustainable powertrains. For the increased uncertainty of biofuel combustion properties, advanced combustion control systems have the potential to operate the engine with high flexibility while maintaining a high efficiency and robustness. For that purpose, this thesis investigates the analysis, design, implementation, and application of closed-loop Diesel combustion control algorithms. By fast in-cylinder pressure measurements, the combustion evolution can be monitored to adjust a multi-pulse fuel injection within the same cycle. This is referred to as in-cycle closed-loop combustion control.The design of the controller is based on the experimental characterization of the combustion dynamics by the heat release analysis, improved by the proposed cylinder volume deviation model. The pilot combustion, its robustness and dynamics, and its effects on the main injection were analyzed. The pilot burnt mass significantly affects the main combustion timing and heat release shape, which determines the engine efficiency and emissions. By the feedback of a pilot mass virtual sensor, these variations can be compensated by the closed-loop feedback control of the main injection. Predictive models are introduced to overcome the limitations imposed by the intrinsic delay between the control action (fuel injection) and output measurements (pressure increase). High prediction accuracy is possible by the on-line model adaptation, where a reduced multi-cylinder method is proposed to reduce their complexity. The predictive control strategy permits to reduce the stochastic cyclic variations of the controlled combustion metrics. In-cycle controllability of the combustion requires simultaneous observability of the pilot combustion and control authority of the main injection. The imposition of this restriction may decrease the indicated efficiency and increase the operational constraints violation compared to open-loop operation. This is especially significant for pilot misfire. For in-cycle detection of pilot misfire, stochastic and deterministic methods were investigated. The on-line pilot misfire diagnosis was feedback for its compensation by a second pilot injection. High flexibility on the combustion control strategy was achieved by a modular design of the controller. A finite-state machine was investigated for the synchronization of the feedback signals (measurements and model-based predictions), active controller and output action. The experimental results showed an increased tracking error performance and shorter transients, regardless of operating conditions and fuel used.To increase the indicated efficiency, direct and indirect optimization methods for the combustion control were investigated. An in-cycle controller to reach the maximum indicated efficiency increased it by +0.42%unit. The indirect method took advantage of the reduced cyclic variations to optimize the indicated efficiency under constraints on hardware and emission limits. By including the probability and in-cycle compensation of pilot misfire, the optimization of the set-point reference of CA50 increased the indicated efficiency by +0.6unit at mid loads, compared to open-loop operation.Tools to evaluate the total cost of the system were provided by the quantification of the hardware requirements for each of the controller modules

Effects of rail pressure control on fuel consumption, emissions and combustion parameters in a turbocharged diesel engine

The influence of rail pressure control on fuel consumption, emissions and combustion in an automotive downsized turbocharged diesel engine was investigated, considering different operating modes in three-part load working conditions. These modes were selected according to the results of a previous step of the study, where low NOX and fuel consumption levels were obtained managing a hybrid exhaust gas recirculation (EGR) system and the turbocharger variable nozzle turbine (VNT). Aiming at limiting observed soot penalties, increased values of rail pressure were applied, deepening the interactions with engine-controlled sub-assemblies and the related variations in operating, environmental, energy and combustion parameters. At low levels of engine speed and load, major reduction in NOX emissions and fuel consumption were observed, with acceptable soot and noise combustion increase, while turbocharger speed was also enhanced. No variations in fuel consumption were achieved at higher load and speed, while soot penalty remained significant. A simplified method to describe and model engine behaviour and combustion process was also developed, defining linear relationships between rail pressure and engine quantities, including a wide set of combustion parameters derived from in-cylinder pressure diagrams and heat release curves

Optimal air and fuel-path control of a diesel engine

The work reported in this thesis explores innovative control structures and controller design for a heavy duty Caterpillar C6.6 diesel engine. The aim of the work is not only to demonstrate the optimisation of engine performance in terms of fuel consumption, NOx and soot emissions, but also to explore ways to reduce lengthy calibration time and its associated high costs. The test engine is equipped with high pressure exhaust gas recirculation (EGR) and a variable geometry turbocharger (VGT). Consequently, there are two principal inputs in the air-path: EGR valve position and VGT vane position. The fuel injection system is common rail, with injectors electrically actuated and includes a multi-pulse injection mode. With two-pulse injection mode, there are as many as five control variables in the fuel-path needing to be adjusted for different engine operating conditions. [Continues.

Influence of Fuel Injection, Turbocharging and EGR Systems Control on Combustion Parameters in an Automotive Diesel Engine

Indicated pressure diagrams were measured during experimental campaigns on the control of fuel injection, turbocharging and hybrid exhaust gas recirculation systems in an automotive downsized diesel engine. Three part load operating conditions were selected for four test sets, where strategies aimed at the reduction of NOX emissions and fuel consumption, limiting penalties in soot emissions and combustion noise were applied to the selected systems. Processing of in-cylinder pressure signal, its first derivative and curves of rate of heat release allowed to evaluate seven parameters related to combustion centre and duration, maximum values of pressure, heat release and its first derivative, heat released in the premixed phase and a combustion noise indicator. Relationships between these quantities and engine operating, energy and environmental parameters were then obtained referring to the four test sets. In the paper, the most significant links are presented and discussed, aiming at a better understanding of the influence of control variables on combustion process and the effects on engine behavior. The proposed methodology proved to be a consistent tool for this analysis, useful for supporting the application of alternative fuels or advanced combustion modes

Diesel Engine

Diesel engines, also known as CI engines, possess a wide field of applications as energy converters because of their higher efficiency. However, diesel engines are a major source of NOX and particulate matter (PM) emissions. Because of its importance, five chapters in this book have been devoted to the formulation and control of these pollutants. The world is currently experiencing an oil crisis. Gaseous fuels like natural gas, pure hydrogen gas, biomass-based and coke-based syngas can be considered as alternative fuels for diesel engines. Their combustion and exhaust emissions characteristics are described in this book. Reliable early detection of malfunction and failure of any parts in diesel engines can save the engine from failing completely and save high repair cost. Tools are discussed in this book to detect common failure modes of diesel engine that can detect early signs of failure

Reduced Exhaust Emissions Through Blending n-Butanol with Ultra Low Sulfur Diesel and Synthetic Paraffinic Kerosene in Reactivity Controlled Compression Ignition Combustion

Increasing restrictions on the emitted exhaust emissions in diesel engines are becoming a more challenging task than in previous years. An electronic common rail fuel injection system and a port fuel injection (PFI) system were developed for an experimental engine to research dual fuel combustion. The experimental research was conducted at 1500 rpm and 4, 5, and 6 bar indicated mean effective pressure (IMEP). n-Butanol was port fuel injected at a 60% by mass fraction coupled with direct injection (DI) of three fuels, including ultra-low sulfur diesel (ULSD RCCI), a 50-50 wt-% blend of ULSD and butanol (ULSD-Bu RCCI), and a 50-50 wt-% blend of Fischer Tropsch synthetic paraffinic kerosene and butanol (S8-Bu RCCI). Split DI events of high reactivity fuels were used to maintain constant combustion phasing. The fuel blends increased pressure rise rates and ringing intensity drastically compared to conventional diesel combustion (CDC) and ULSD RCCI. Both butanol fuel bends had lower ignition quality than ULSD, increasing the mass fraction at the first DI event, increasing heat release rates up to 30%. ULSD-Bu RCCI had the shortest ignition delay and combustion duration due to the low cetane number. NOx and soot were simultaneously reduced up to 90% with RCCI compared to CDC. Unburned hydrocarbons were increased for RCCI fuel blends. S8-Bu RCCI resulted in reductions in hydrocarbon emissions compared to ULSD-Bu RCCI. Results display large emission reductions of harmful pollutants, such as NOx and soot, with RCCI combustion and the potential of alternative fuels in diesel combustion

Remote Combustion Sensing in Diesel Engine via Vibration Measurements

An efficient control of the combustion process is required in order to comply with regulations on pollutant emissions from internal combustion engines. Literature presents investigations devoted to explore the potentiality of externally mounted sensor (speed sensor, microphone, and accelerometer) for combustion diagnosis. A relationship exists between the combustion event measured via an in‐cylinder pressure transducer and engine block vibration measured via an accelerometer. Time and frequency domain processing of acquired signals highlighted the correlation between parameters able to characterize the combustion development and features derived from the engine block vibration data. A methodology was developed by the authors that demonstrated to be suitable for real‐time estimation of combustion progress based on engine vibration. A two‐cylinder common rail diesel engine of small displacement was tested; two configurations were investigated, naturally aspirated, and turbocharged. The in‐cylinder pressure and block vibration signals were acquired and processed in time and frequency domains. The vibrational components mainly related to the combustion process were extracted, and indicators of the combustion positioning were computed. The angular positions of start of combustion (SOC) and MFB50 computed via the heat release curve by means of the in‐cylinder pressure measurements were compared to those obtained by means of the accelerometer signal. High correlation coefficients were obtained for the data acquired during the testing of both naturally aspirated and turbocharged configurations in the complete engine operative field

The Study Of Ionization In A Military, Heavy-Duty, Diesel Engine

This thesis is an investigation of ionization in a military, heavy-duty, diesel engine. Ionization is a phenomenon which occurs in both spark-ignited and diesel engines. During the reactions of combustion, charged molecules and electrons are produced. The current produced, ion current, from these charges can be measured. The measurement of ion current can serve as an in-cylinder diagnostic for closed-loop engine control strategies. In this work, a literature review was performed to survey previous work as it pertains to ionization in diesel engines. In addition, a detailed description and comparison of the HEUI injection system was made to HPCR. This was done to give a fundamental understanding of the characteristics of the injection system which was employed in the research engine. Lastly, an analysis of experimental data provides insight as to the relationship between ion current and key combustion parameters

In-Cylinder Pressure-Based Control of Premixed Dual-Fuel Combustion

[ES] La actual crisis climática ha instado a la comunidad investigadora y a los fabricantes a brindar soluciones para hacer que el sector del transporte sea más sostenible. De entre las diversas tecnologías propuestas, la combustión a baja temperatura ha sido objeto de una extensa investigación. La combustión premezclada dual-fuel es uno de los conceptos que abordan el compromiso de NOx-hollín en motores de encendido por compresión manteniendo alta eficiencia térmica. Esta combustión hace uso de dos combustibles con diferentes reactividades para mejorar la controlabilidad de este modo de combustión en un amplio rango de funcionamiento. De manera similar a todos los modos de combustión premezclados, esta combustión es sensible a las condiciones de operación y suele estar sujeta a variabilidad cíclica con gradientes de presión significativos. En consecuencia, se requieren estrategias de control avanzadas para garantizar un funcionamiento seguro y preciso del motor. El control en bucle cerrado es una herramienta eficaz para abordar los desafíos que plantea la combustión premezclada dual-fuel. En este tipo de control, para mantener el funcionamiento deseado, las acciones de control se adaptan y corrigen a partir de una retroalimentación con las señales de salida del motor. Esta tesis presenta estrategias de control basadas en la medición de la señal de presión en el cilindro, aplicadas a motores de combustión premezclada dual-fuel. En ella se resuelven diversos aspectos del funcionamiento del motor mediante el diseño de controladores dedicados, haciéndose especial énfasis en analizar e implementar estas soluciones a los diferentes niveles de estratificación de mezcla considerados en estos motores (es decir, totalmente, altamente y parcialmente premezclada). Inicialmente, se diseñan estrategias de control basadas en el procesamiento de la señal de presión en el cilindro y se seleccionan acciones proporcionales-integrales para asegurar el rendimiento deseado del motor sin exceder las limitaciones mecánicas del motor. También se evalúa la técnica extremum seeking para realizar una supervisión de una combustión eficiente y la reducción de emisiones de NOx. Luego se analiza la resonancia de la presión en el cilindro y se implementa un controlador similar a aquel usado para el control de knock para garantizar el funcionamiento seguro del motor. Finalmente, se utilizan modelos matemáticos para diseñar un modelo orientado a control y un observador que tiene como objetivo combinar las señales medidas en el motor para mejorar las capacidades de predicción y diagnóstico en dicha configuración de motor. Los resultados de este trabajo destacan la importancia de considerar el control en bucle cerrado para abordar las limitaciones encontradas en los modos de combustión premezclada. En particular, el uso de la medición de presión en el cilindro muestra la relevancia y el potencial de esta señal para desarrollar estrategias de control complejas y precisas.[CA] L'actual crisi climàtica ha instat a la comunitat investigadora i als fabricants a brindar solucions per a fer que el sector del transport siga més sostenible. D'entre les diverses tecnologies proposades, la combustió a baixa temperatura ha sigut objecte d'una extensa investigació. La combustió premesclada dual-fuel és un dels conceptes que aborden el compromís de NOx-sutge en motors d'encesa per compressió mantenint alta eficiència tèrmica. Aquesta combustió fa ús de dos combustibles amb diferents reactivitats per a millorar la controlabilitat d'aquest tipus de combustió en un ampli rang de funcionament. De manera similar a tots els tipus de combustió premesclada, aquesta combustió és sensible a les condicions d'operació i sol estar subjecta a variabilitat cíclica amb gradients de pressió significatius. En conseqüència, es requereixen estratègies de control avançades per a garantir un funcionament segur i precís del motor. El control en bucle tancat és una eina eficaç per a abordar els desafiaments que planteja la combustió premesclada dual-fuel. En aquesta mena de control, per a mantindre el funcionament desitjat, les accions de control s'adapten i corregeixen a partir d'una retroalimentació amb els senyals d'eixida del motor. Aquesta tesi presenta estratègies de control basades en el mesurament del senyal de pressió en el cilindre, aplicades a motors de combustió premesclada dual-fuel. En ella es resolen diversos aspectes del funcionament del motor mitjançant el disseny de controladors dedicats, fent-se especial èmfasi a analitzar i implementar aquestes solucions als diferents nivells d'estratificació de mescla considerats en aquests motors (és a dir, totalment, altament i parcialment premesclada). Inicialment, es dissenyen estratègies de control basades en el processament del senyal de pressió en el cilindre i se seleccionen accions proporcionals-integrals per a assegurar el rendiment desitjat del motor sense excedir les limitacions mecàniques del motor. També s'avalua la tècnica extremum seeking per a realitzar una supervisió d'una combustió eficient i la reducció d'emissions de NOx. Després s'analitza la ressonància de la pressió en el cilindre i s'implementa un controlador similar a aquell usat per al control de knock per a garantir el funcionament segur del motor. Finalment, s'utilitzen models matemàtics per a dissenyar un model orientat a control i un observador que té com a objectiu combinar els senyals mesurats en el motor per a millorar les capacitats de predicció i diagnòstic en aquesta configuració de motor. Els resultats d'aquest treball destaquen la importància de considerar el control en bucle tancat per a abordar les limitacions trobades en la combustió premesclada. En particular, l'ús del mesurament de pressió en el cilindre mostra la rellevància i el potencial d'aquest senyal per a desenvolupar estratègies de control complexes i precises.[EN] The current climate crisis has urged the research community and manufacturers to provide solutions to make the transportation sector cleaner. Among the various technologies proposed, low temperature combustion has undergone extensive investigation. Premixed dual-fuel combustion is one of the concepts addressing the NOx-soot trade-off in compression ignited engines, while maintaining high thermal efficiency. This combustion makes use of two fuels with different reactivities in order to improve the controllability of this combustion mode over a wide range of operation. Similarly to all premixed combustion modes, this combustion is nevertheless sensitive to the operating conditions and traditionally exhibits cycle-to-cycle variability with significant pressure gradients. Consequently, advanced control strategies to ensure a safe and accurate operation of the engine are required. Feedback control is a powerful approach to address the challenges raised by the premixed dual-fuel combustion. By measuring the output signals from the engine, strategies can be developed to adapt and correct the control actions to maintain the desired operation. This thesis presents control strategies, based on the in-cylinder pressure signal measurement, applied to premixed dual-fuel combustion engines. Various objectives were addressed by designing dedicated controllers, where a special emphasis was made towards analyzing and implementing these solutions to the different levels of mixture stratification considered in these engines (i.e., fully, highly and partially premixed). At first, feedback control strategies based on the in-cylinder pressure signal processing were designed. Proportional-integral actions were selected to ensure the desired engine performance without exceeding the mechanical constraints of the engine. Extremum seeking was evaluated to track efficient combustion phasing and NOx emissions reduction. The in-cylinder pressure resonance was then analyzed and a knock-like controller was implemented to ensure safe operation of the engine. Finally, mathematical models were used to design a control-oriented model and a state observer that aimed to leverage the signals measured in the engine to improve the prediction and diagnostic capabilities in such engine configuration. The results from this work highlighted the importance of considering feedback control to address the limitations encountered in premixed combustion modes. Particularly, the use of the in-cylinder pressure measurement showed the relevance and potential of this signal to develop complex and accurate control strategies.This thesis was financially supported by the Programa Operativo del Fondo Social Europeo (FSE) de la Comunitat Valenciana 2014-2020 through grant ACIF/2018/141.Barbier, ARS. (2022). In-Cylinder Pressure-Based Control of Premixed Dual-Fuel Combustion [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/18327