Automated model based engine calibration procedure using co-simulation

The final validation and sign-off of a production powertrain control module (PCM) calibration is a time-consuming and expensive task and requires a high degree of expertise. There are two main reasons for this; firstly, the validation test is an iterative process due to the fact that calibration changes may affect the true operating point of the engine at the desired test point. Secondly, modifications to the calibration require expert knowledge of the complete control strategy so as to improve the correlation to validation data without potentially negatively impacting the correlated mapping points. This paper describes the implementation of an optimisation routine on a virtual platform in order to both reduce the requirement for experimental testing during the validation procedure, and for development of the optimisation routine itself prior to execution on the engine dynamometer. It is shown that in simulation, the optimisation routine is capable of producing an acceptable calibration within just 5 iterations, reducing the 11-week process down to just a few days. It is also concluded that there are also a number of further improvements that could be made to further improve the efficiency of this process

An Optimal Energy Management Strategy for Hybrid Electric Vehicles

Hybrid Electric Vehicles (HEVs) are used to overcome the short-range and long charging time problems of purely electric vehicles. HEVs have at least two power sources. Therefore, the Energy Management (EM) strategy for dividing the driver requested power between the available power sources plays an important role in achieving good HEV performance. This work, proposes a novel real-time EM strategy for HEVs which is named ECMS-CESO. ECMS-CESO is based on the Equivalent Consumption Minimization Strategy (ECMS) and is designed to Catch Energy Saving Opportunities (CESO) while operating the vehicle. ECMS-CESO is an instantaneous optimal controller, i. e., it does not require prediction of the future demanded power by the driver. Therefore, ECMS-CESO is tractable for real-time operation. Under certain conditions ECMS achieves the maximum fuel economy. The main challenge in employing ECMS is the estimation of the optimal equivalence factor L*. Unfortunately, L* is drive-cycle dependent, i. e., it changes from driver to driver and/or route to route. The lack of knowledge about L* has been a motivation for studying a new class of EM strategies known as Adaptive ECMS (A-ECMS). A-ECMS yields a causal controller that calculates L(t) at each moment t as an estimate of L*. Existing A-ECMS algorithms estimate L*, by heuristic approaches. Here, instead of direct estimation of L*, analytic bounds on L* are determined which are independent of the drive-cycle. Knowledge about the range of L*, can be used to adaptively set L(t) as performed by the ECMS-CESO algorithm. ECMS-CESO also defines soft constraints on the battery state of charge (SOC) and a penalty for exceeding the soft constraints. ECMS-CESO is allowed to exceed a SOC soft constraint when an energy saving opportunity is available. ECMS-CESO is efficient since there is no need for prediction and the intensive calculations for finding the optimal control over the predicted horizon are not required. Simulation results for 3 different HEVs are used to confirm the expected performance of ECMS-CESO. This work also investigates the performance of the model predictive control with respect to the predicated horizon length

An innovative approach to recovery of fluctuating industrial exhaust heat sources using cascade Rankine cycle and two-stage accumulators

The fluctuating property of the heat source is a technical obstacle of waste heat recovery, which leads to part-load operation and reduced economics. This work presents a novel system to mitigate the fluctuations by using steam-organic Rankine cycles (RC-ORC) and two-stage steam accumulators. The system can switch between isothermal heat storage and discharge simply by the regulation of water mass flow (m ) from the low-temperature accumulator (LTA) to the high-temperature accumulator (HTA). In the heat charge mode, m rises when the inlet temperature or mass flow of the heat source increases. The water level of the HTA elevates. Analogously, in the heat discharge mode, m decreases and more water accumulates in the LTA. The RC-ORC operates under the rated condition consistently through the unique structural design. The fundamentals and features of the system are illustrated. Given two typical heat source conditions, the fluctuations in thermal efficiencies are minor (15.63–15.84% and 19.57–19.70%). Thermo-economic estimation of the tanks indicates that the steel cost is roughly 1306 $and 432$, respectively. Compared with the single-stage ORC using stream control, the normalized investment cost (NIC) is reduced by 888–925 $/kW. 2 2

Real-time fault identification for developmental turbine engine testing

Hundreds of individual sensors produce an enormous amount of data during developmental turbine engine testing. The challenge is to ensure the validity of the data and to identify data and engine anomalies in a timely manner. An automated data validation, engine condition monitoring, and fault identification process that emulates typical engineering techniques has been developed for developmental engine testing.An automated data validation and fault identification approach employing enginecycle-matching principles is described. Engine cycle-matching is automated by using an adaptive nonlinear component-level computer model capable of simulating both steady state and transient engine operation. Automated steady-state, transient, and real-time model calibration processes are also described. The model enables automation of traditional data validation, engine condition monitoring, and fault identification procedures. A distributed parallel computing approach enables the entire process to operate in real-time.The result is a capability to detect data and engine anomalies in real-time during developmental engine testing. The approach is shown to be successful in detecting and identifying sensor anomalies as they occur and distinguishing these anomalies from variations in component and overall engine aerothermodynamic performance. The component-level model-based engine performance and fault identification technique of the present research is capable of: identifying measurement errors on the order of 0.5 percent (e.g., sensor bias, drift,level shift, noise, or poor response) in facility fuel flow, airflow, and thrust measurements; identifying measurement errors in engine aerothermodynamic measurements (rotorspeeds, gas path pressures and temperatures); identifying measurement errors in engine control sensors (e.g., leaking/biased pressure sensor, slowly responding pressure measurement) and variable geometry rigging (e.g., misset guide vanes or nozzle area) that would invalidate a test or series of tests; identifying abrupt faults (e.g., faults due to domestic object damage, foreign object damage, and control anomalies); identifying slow faults (e.g., component or overall engine degradation, and sensor drift). Specifically, the technique is capable of identifying small changes in compressor (or fan) performance on the order of 0.5 percent; and being easily extended to diagnose secondary failure modes and to verify any modeling assumptions that may arise for developmental engine tests (e.g., increase in turbine flow capacity, inaccurate measurement of facility bleed flows, horsepower extraction, etc.).The component-level model-based engine performance and fault identification method developed in the present work brings together features which individually and collectively advance the state-of-the-art. These features are separated into three categories: advancements to effectively quantify off-nominal behavior, advancements to provide a fault detection capability that is practical from the viewpoint of the analysis,implementation, tuning, and design, and advancements to provide a real-time fault detection capability that is reliable and efficient

Measured and Modeled Performance of a Spring Dominant Free Piston Engine Generator

Free Piston Engine Generators (FPEG) directly convert the reciprocating piston motion into electricity by using a linear alternator. Unlike conventional engines with piston motion restricted by a crankshaft mechanism, the FPEG piston motion is constrained by the energy available in the system. When stiff springs are considered in the design, the FPEG system attains high frequency with high power and efficiency. The main objective of this research was to model stiff spring-assisted FPEG system dynamics and performance accurately, and to apply the modeling results to the development of a 1kW, spark ignited, natural gas fueled, FPEG experimental prototype. The experimental data was further utilized to refine and improve the existing model. First, a MATLAB®/Simulink based multi-cycle numerical model was developed for single and dual cylinder FPEG systems to study the effects of major design parameters on FPEG dynamics and performance. When stiff springs were added, the dynamics became more sinusoidal and symmetric with respect to the initial starting position. For a total displacement of 34 cc, trapped compression ratio of 8.25, and assumed combustion efficiency of 95%, the modeled frequency and electric power varied from 72.3 Hz to 80.8 Hz and 0.81 kW to 0.88 kW for a single cylinder FPEG as the spring stiffness changed from 372 kN/m to 744 kN/m. For a dual cylinder FPEG with the same conditions, these modeled values changed from 76.8 Hz to 84.1 Hz and 1.7 kW to 1.8 kW with increasing spring stiffness. The numerical model was then expanded for sensitivity studies of major design parameters. When FPEG operating conditions were considered, the effective stroke length was found to have a dominant effect on efficiency followed by compression ratio, cylinder bore, and spring stiffness respectively. The experimental FPEG prototype generating 550 W of electricity with indicated efficiencies exceeding 13.8% was used for model validation. Finally, the stable FPEG system requires a control strategy to match the power generated by the engine to the power demanded by the alternator. A model-based control strategy was developed in Stateflow® for alternator mode switching, calibration maps, energy management, ignition and fuel injection timings. With the proposed control strategy and stiff spring dominance, the modeled and experimental FPEG system maintained stable operation with cycle-to-cycle variations less than 5%

Development of an Ammonia Reduction After-Treatment Systems for Stoichiometric Natural Gas Engines

Three-way catalyst (TWC) equipped stoichiometric natural gas vehicles have proven to be an effective alternative fuel strategy that shows significant low NOx emissions characteristics. However, recent studies have shown the TWC activity to contribute to elevated levels of tailpipe ammonia (NH 3) emissions. Although a non-regulated pollutant, ammonia is a potent pre-cursor to ambient secondary PM formation. Ammonia is an inevitable byproduct of fuel rich operation that results in lowest NOx slip through the TWC after-treatment system.;The main objective of the study is to develop a passive Ammonia Reduction Catalyst (passive-ARC) based NH3 reduction strategy that results in an overall reduction of ammonia as well as NOx emissions. The study investigated the characteristics of Fe-based and Cu-based zeolites SCR catalysts in storage and desorption of ammonia at high exhaust temperature conditions, that are typical of stoichiometric natural gas engines. Continuous measurements of NOx and NH3 before and after the SCR systems were conducted using a Fourier Transform Infrared Spectrometry (FTIR) gas analyzer. Results of the investigation showed that both, the Fe- and Cu zeolite SCRs adsorbed above 90% of TWC generated NH3 emissions below 350--375 °C SCR temperatures. Desorption or slipping of NH3 was observed at exhaust gas temperatures exceeding 400 °C. In terms of NOx conversions, Fe-zeolite showed efficiency between 50--80% above temperatures of 300--350 °C while Cu-zeolite performed well at lower SCR temperature from 250 °C and above with a conversion efficiency of greater than 50%.;In order to efficiently reduce both NOx and NH3 simultaneously over longer durations it was found that an engine-based air fuel ratio operation strategy for the passive-ARC system must be developed. To this extent, the study extended its objectives to develop an engine-based control strategy that results in stoichiometric ammonia production operation followed by brief lean operation to regenerate the saturated ammonia reduction catalyst using high NOx slip through TWC. The study presents comprehensive results of ammonia storage characteristics of SCRs pertaining to stoichiometric natural gas engine exhaust as well as an advanced engine control strategy approach to simultaneously reduce both NOx and NH3 using an alternating air -fuel ratio approach

Real-time implementation of an ISM Fault Tolerant Control scheme for LPV plants

Copyright © 2014 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.This paper proposes a fault tolerant control scheme for linear parameter varying systems based on integral sliding modes and control allocation, and describes the implementation and evaluation of the controllers on a 6 degree-of-freedom research flight simulator called SIMONA. The fault tolerant control scheme is developed using a linear parameter varying approach to extend ideas previously developed for linear time invariant systems, in order to cover a wide range of operating conditions. The scheme benefits from the combination of the inherent robustness properties of integral sliding modes (to ensure sliding occurs throughout the simulation) and control allocation, which has the ability to redistribute control signals to all available actuators in the event of faults/failures

Adaptive Robust Guidance Scheme Based on the Sliding Mode Control in an Aircraft Pursuit-Evasion Problem

In this chapter, a robust guidance scheme utilizing a line-of-sight (LOS) observation is presented. Initial relative speed and distance, and error boundaries of them are estimated in accordance with the interceptor-target relative motion kinematics. A robust guidance scheme based on the sliding mode control (SMC) is developed, which requires the boundaries of the target maneuver, and inevitably has jitter phenomenon. For solving above-mentioned problems, an estimation to the target acceleration’s boundary is developed for enhancing robustness of the guidance scheme and the Lyapunov stabilization is analyzed. The proposed robust guidance scheme’s brief characteristic is to reduce the effect of relative speed and distance, to reduce the effect of target maneuverability on the guidance precision, and to strengthen the influence of line-of-sight angular velocity. The proposed scheme’s performances are validated by the simulations of different target maneuvers under two worst-case conditions

Integration of Active Systems for a Global Chassis Control Design

Vehicle chassis control active systems (braking, suspension, steering and driveline), from the first ABS/ESC control unit to the current advanced driver assistance systems (ADAS), are progressively revolutionizing the way of thinking and designing the vehicle, improving its interaction with the surrounding world (V2V and V2X) and have led to excellent results in terms of safety and performances (dynamic behavior and drivability). They are usually referred as intelligent vehicles due to a software/hardware architecture able to assist the driver for achieving specific safety margin and/or optimal vehicle dynamic behavior. Moreover, industrial and academic communities agree that these technologies will progress till the diffusion of the so called autonomous cars which are able to drive robustly in a wide range of traffic scenarios. Different autonomous vehicles are already available in Europe, Japan and United States and several solutions have been proposed for smart cities and/or small public area like university campus. In this context, the present research activity aims at improving safety, comfort and performances through the integration of global active chassis control: the purposes are to study, design and implement control strategies to support the driver for achieving one or more final target among safety, comfort and performance. Specifically, the vehicle subsystems that are involved in the present research for active systems development are the steering system, the propulsion system, the transmission and the braking system. The thesis is divided into three sections related to different applications of active systems that, starting from a robust theoretical design procedure, are strongly supported by objective experimental results obtained fromHardware In the Loop (HIL) test rigs and/or proving ground testing sessions. The first chapter is dedicated to one of the most discussed topic about autonomous driving due to its impact from the social point of view and in terms of human error mitigation when the driver is not prompt enough. In particular, it is here analyzed the automated steering control which is already implemented for automatic parking and that could represent also a key element for conventional passenger car in emergency situation where a braking intervention is not enough for avoiding an imminent collision. The activity is focused on different steering controllers design and their implementation for an autonomous vehicle; an obstacle collision avoidance adaptation is introduced for future implementations. Three different controllers, Proportional Derivative (PD), PD+Feedforward (FF) e PD+Integral Sliding Mode (ISM), are designed for tracking a reference trajectory that can be modified in real-time for obstacle avoidance purposes. Furthermore, PD+FF and PD+ISM logic are able to improve the tracking performances of automated steering during cornering maneuvers, relevant fromthe collision avoidance point of view. Path tracking control and its obstacle avoidance enhancement is also shown during experimental tests executed in a proving ground through its implementation for an autonomous vehicle demonstrator. Even if the activity is presented for an autonomous vehicle, the active control can be developed also for a conventional vehicle equipped with an Electronic Power Steering (EPS) or Steer-by-wire architectures. The second chapter describes a Torque Vectoring (TV) control strategy, applied to a Fully Electric Vehicle (FEV) with four independent electric motor (one for each wheel), that aims to optimize the lateral vehicle behavior by a proper electric motor torque regulation. A yaw rate controller is presented and designed in order to achieve a desired steady-state lateral behaviour of the car (handling task). Furthermore, a sideslip angle controller is also integrated to preserve vehicle stability during emergency situations (safety task). LQR, LQR+FF and ISM strategies are formulated and explained for yaw rate and concurrent yaw rate/sideslip angle control techniques also comparing their advantages and weakness points. The TV strategy is implemented and calibrated on a FEV demonstrator by executing experimental maneuvers (step steer, skid pad, lane change and sequence of step steers) thus proving the efficacy of the proposed controller and the safety contribution guaranteed by the sideslip control. The TV could be also applied for internal combustion engine driven vehicles by installing specific torque vectoring differentials, able to distribute the torque generated by the engine to each wheel independently. The TV strategy evaluated in the second chapter can be influenced by the presence of a transmission between themotor (or the engine) and wheels (where the torque control is supposed to be designed): in addition to the mechanical delay introduced by transmission components, the presence of gears backlashes can provoke undesired noises and vibrations in presence of torque sign inversion. The last chapter is thus related to a new method for noises and vibration attenuation for a Dual Clutch Transmission (DCT). This is achieved in a new way by integrating the powertrain control with the braking system control, which are historically and conventionally analyzed and designed separately. It is showed that a torsional preload effect can be obtained on transmission components by increasing the wheel torque and concurrently applying a braking wheel torque. For this reason, a pressure following controller is presented and validated through a Hardware In the Loop (HIL) test rig in order to track a reference value of braking torque thus ensuring the desired preload effect and noises reduction. Experimental results demonstrates the efficacy of the controller, also opening new scenario for global chassis control design. Finally, some general conclusions are drawn and possible future activities and recommendations are proposed for further investigations or improvements with respect to the results shown in the present work