Engine thermal management with model predictive control

The global greenhouse gas CO2 emission from the transportation sector is very significant.To reduce this gas emission, EU has set an average target of not more than 95 CO2/km for new passenger cars by the year 2020. A great reduction is still required to achieve the CO2 emission target in 2020, and many different approaches are being considered. This thesis focuses on the thermal management of the engine as an area that promise significant improvement of fuel efficiency with relatively small changes. The review of the literature shows that thermal management can improve engine efficiency through the friction reduction, improved air-fuel mixing, reduced heat loss, increased engine volumetric efficiency, suppressed knock, reduce radiator fan speed and reduction of other toxic emissions such as CO, HC and NOx. Like heat loss and friction, most emissions can be reduced in high temperature condition, but this may lead to poor volumetric efficiency and make the engine more prone to knock. The temperature trade-off study is conducted in simulation using a GT-SUITE engine model coupled with the FE in-cylinder wall structure and cooling system. The result is a map of the best operating temperature over engine speed and load. To quantify the benefit of this map, eight driving styles from the legislative and research test cycles are being compared using an immediate application of the optimal temperature, and significant improvements are found for urban style driving, while operation at higher load (motorway style driving) shows only small efficiency gains. The fuel consumption saving predicted in the urban style of driving is more than 4%. This assess the chance of following the temperature set point over a cycle, the temperature reference is analysed for all eight types of drive cycles using autocorrelation, lag plot and power spectral density. The analysis consistently shows that the highest volatility is recorded in the Artemis Urban Drive Cycle: the autocorrelation disappears after only 5.4 seconds, while the power spectral density shows a drop off around 0.09Hz. This means fast control action is required to implement the optimal temperature before it changes again. Model Predictive Control (MPC) is an optimal controller with a receding horizon, and it is well known for its ability to handle multivariable control problems for linear systems with input and state limits. The MPC controller can anticipate future events and can take control actions accordingly, especially if disturbances are known in advance. The main difficulty when applying MPC to thermal management is the non-linearity caused by changes in flow rate. Manipulating both the water pump and valve improves the control authority, but it also amplifies the nonlinearity of the system. Common linearization approaches like Jacobian Linearization around one or several operating points are tested, by found to be only moderately successful. Instead, a novel approach is pursued using feedback linearization of the plant model. This uses an algebraic transformation of the plant inputs to turn the nonlinear systems dynamics into a fully or predominantly linear system. The MPC controller can work with the linear model, while the actual control inputs are found using an inverse transformation. The Feedback Linearization MPC of the cooling system model is implemented and testing using MathWork Simulink®. The process includes the model transformation approach, model fitting, the transformation of the constraints and the tuning of the MPC controller. The simulation shows good temperature tracking performance, and this demonstrates that a MPC controller with feedback linearization is a suitable approach to thermal management. The controller strategy is then validated in a test rig replicating an actual engine cooling system. The new MPC controller is again evaluated over the eight driving cycles. The average water pump speed is reduced by 9.1% compared to the conventional cooling system, while maintaining good temperature tracking. The controller performance further improves with future disturbance anticipation by 20.5% for the temperature tracking (calculated by RMSE), 6.8% reduction of the average water pump speed, 47.3% reduction of the average valve movement and 34.0% reduction of the average radiator fan speed

NASA Tech Briefs, January 2004

Topics covered include: Multisensor Instrument for Real-Time Biological Monitoring; Sensor for Monitoring Nanodevice-Fabrication Plasmas; Backed Bending Actuator; Compact Optoelectronic Compass; Micro Sun Sensor for Spacecraft; Passive IFF: Autonomous Nonintrusive Rapid Identification of Friendly Assets; Finned-Ladder Slow-Wave Circuit for a TWT; Directional Radio-Frequency Identification Tag Reader; Integrated Solar-Energy-Harvesting and -Storage Device; Event-Driven Random-Access-Windowing CCD Imaging System; Stroboscope Controller for Imaging Helicopter Rotors; Software for Checking State-charts; Program Predicts Broadband Noise from a Turbofan Engine; Protocol for a Delay-Tolerant Data-Communication Network; Software Implements a Space-Mission File-Transfer Protocol; Making Carbon-Nanotube Arrays Using Block Copolymers: Part 2; Modular Rake of Pitot Probes; Preloading To Accelerate Slow-Crack-Growth Testing; Miniature Blimps for Surveillance and Collection of Samples; Hybrid Automotive Engine Using Ethanol-Burning Miller Cycle; Fabricating Blazed Diffraction Gratings by X-Ray Lithography; Freeze-Tolerant Condensers; The StarLight Space Interferometer; Champagne Heat Pump; Controllable Sonar Lenses and Prisms Based on ERFs; Measuring Gravitation Using Polarization Spectroscopy; Serial-Turbo-Trellis-Coded Modulation with Rate-1 Inner Code; Enhanced Software for Scheduling Space-Shuttle Processing; Bayesian-Augmented Identification of Stars in a Narrow View; Spacecraft Orbits for Earth/Mars-Lander Radio Relay; and Self-Inflatable/Self-Rigidizable Reflectarray Antenna

Implementation of a fully variable valve actuation valvetrain

In January 2008 the Sasol (Pty) Ltd Advisory Board identified that the Sasol Advanced Fuels Laboratory's (SAFL) single cylinder research engine was not in line with the current engine technologies, in particular Fully Variable Valve Actuation (FVVA). This project represented the first stage of the engine upgrade, which was to modify the current single cylinder engine to interface with pneumatic valve actuators and a fully configurable Engine Control Unit (ECU)

Autonomous Pedestrian Detection in Transit Buses

This project created a proof of concept for an automated pedestrian detection and avoidance system designed for transit buses. The system detects objects up to 12 meters away, calculates the distance from the system using a solid-state LIDAR, and determines if that object is human by passive infrared. This triggers a visual and sound warning. A Xilinx Zynq-SoC utilizing programmable logic and an ARM-based processing system drive data fusion, and an external power unit makes it configurable for transit-buses

Prognostics and health management of light emitting diodes

Prognostics is an engineering process of diagnosing, predicting the remaining useful life and estimating the reliability of systems and products. Prognostics and Health Management (PHM) has emerged in the last decade as one of the most efficient approaches in failure prevention, reliability estimation and remaining useful life predictions of various engineering systems and products. Light Emitting Diodes (LEDs) are optoelectronic micro-devices that are now replacing traditional incandescent and fluorescent lighting, as they have many advantages including higher reliability, greater energy efficiency, long life time and faster switching speed. Even though LEDs have high reliability and long life time, manufacturers and lighting systems designers still need to assess the reliability of LED lighting systems and the failures in the LED. This research provides both experimental and theoretical results that demonstrate the use of prognostics and health monitoring techniques for high power LEDs subjected to harsh operating conditions. Data driven, model driven and fusion prognostics approaches are developed to monitor and identify LED failures, based on the requirement for the light output power. The approaches adopted in this work are validated and can be used to assess the life of an LED lighting system after their deployment based on the power of the light output emitted. The data driven techniques are only based on monitoring selected operational and performance indicators using sensors whereas the model driven technique is based on sensor data as well as on a developed empirical model. Fusion approach is also developed using the data driven and the model driven approaches to the LED. Real-time implementation of developed approaches are also investigated and discussed

Waste heat to power conversion by means of thermomagnetic hydrodynamic energy harvester

Energy harvesting from extremely low enthalpy sources can play an important role in increasing the sustainability of future energy applications: low temperature differences are common and offer an abundant source, available both in the natural environment and as the result of a many industrial process. This paper presents the first closed-loop thermomagnetic hydrodynamic energy harvester, based on thermomagnetic advection and exploiting a commercial ferrofluid. The lab-scale prototype has a toroidal geometry adopted from the well-known tokamak inertial machines. Peltier modules are used to control the thermal gradient that is harvested and converted directly to electric energy, while permanent magnets trigger the advection. Temperature sensors are installed along the toroidal walls (thermistors) and are placed in contact with the rotating fluid (thermocouples). To extract and ensure the electrical energy output, the structure is wrapped-up with induction coils. Two coil configurations (purely poloidal and mixed poloidal/toroidal windings) are tested, in a heterogeneous two-phase flow from the combination of water carrier and ferrofluid packets, reaching a maximum extracted electrical power per unit of temperature difference of 10.4 μW/K. This positions the device close to 20% of the ideal Carnot efficiency of a thermal machine working on the same temperature drop. Numerical analysis of the system has been performed developing a Fortran™ code in a Eulerian framework, using a mixed Fourier-Galerkin/finite difference spatial discretization. The harvester is suitable for producing electricity from running engines, appliances, warm gas exhausts, exothermic processes

Hardware Specific Integration Strategy for Impedance-Based Structural Health Monitoring of Aerospace Systems

The Integrated Vehicle Health Management (IVHM) Project, sponsored by NASA's Aeronautics Research Mission Directorate, is conducting research to advance the state of highly integrated and complex flight-critical health management technologies and systems. An effective IVHM system requires Structural Health Monitoring (SHM). The impedance method is one such SHM technique for detection and monitoring complex structures for damage. This position paper on the impedance method presents the current state of the art, future directions, applications and possible flight test demonstrations

Platform-based design, test and fast verification flow for mixed-signal systems on chip

This research is providing methodologies to enhance the design phase from architectural space exploration and system study to verification of the whole mixed-signal system. At the beginning of the work, some innovative digital IPs have been designed to develop efficient signal conditioning for sensor systems on-chip that has been included in commercial products. After this phase, the main focus has been addressed to the creation of a re-usable and versatile test of the device after the tape-out which is close to become one of the major cost factor for ICs companies, strongly linking it to model’s test-benches to avoid re-design phases and multi-environment scenarios, producing a very effective approach to a single, fast and reliable multi-level verification environment. All these works generated different publications in scientific literature. The compound scenario concerning the development of sensor systems is presented in Chapter 1, together with an overview of the related market with a particular focus on the latest MEMS and MOEMS technology devices, and their applications in various segments. Chapter 2 introduces the state of the art for sensor interfaces: the generic sensor interface concept (based on sharing the same electronics among similar applications achieving cost saving at the expense of area and performance loss) versus the Platform Based Design methodology, which overcomes the drawbacks of the classic solution by keeping the generality at the highest design layers and customizing the platform for a target sensor achieving optimized performances. An evolution of Platform Based Design achieved by implementation into silicon of the ISIF (Intelligent Sensor InterFace) platform is therefore presented. ISIF is a highly configurable mixed-signal chip which allows designers to perform an effective design space exploration and to evaluate directly on silicon the system performances avoiding the critical and time consuming analysis required by standard platform based approach. In chapter 3 we describe the design of a smart sensor interface for conditioning next generation MOEMS. The adoption of a new, high performance and high integrated technology allow us to integrate not only a versatile platform but also a powerful ARM processor and various IPs providing the possibility to use the platform not only as a conditioning platform but also as a processing unit for the application. In this chapter a description of the various blocks is given, with a particular emphasis on the IP developed in order to grant the highest grade of flexibility with the minimum area occupation. The architectural space evaluation and the application prototyping with ISIF has enabled an effective, rapid and low risk development of a new high performance platform achieving a flexible sensor system for MEMS and MOEMS monitoring and conditioning. The platform has been design to cover very challenging test-benches, like a laser-based projector device. In this way the platform will not only be able to effectively handle the sensor but also all the system that can be built around it, reducing the needed for further electronics and resulting in an efficient test bench for the algorithm developed to drive the system. The high costs in ASIC development are mainly related to re-design phases because of missing complete top-level tests. Analog and digital parts design flows are separately verified. Starting from these considerations, in the last chapter a complete test environment for complex mixed-signal chips is presented. A semi-automatic VHDL-AMS flow to provide totally matching top-level is described and then, an evolution for fast self-checking test development for both model and real chip verification is proposed. By the introduction of a Python interface, the designer can easily perform interactive tests to cover all the features verification (e.g. calibration and trimming) into the design phase and check them all with the same environment on the real chip after the tape-out. This strategy has been tested on a consumer 3D-gyro for consumer application, in collaboration with SensorDynamics AG

Radar Target Simulation for Vehicle-in-the-Loop Testing

Automotive radar sensors play a vital role in the current development of autonomous driving. Their ability to detect objects even under adverse conditions makes them indispensable for environment-sensing tasks in autonomous vehicles. As their functional operation must be validated in-place, a fully integrated test system is required. Radar Target Simulators (RTS) are capable of executing end-of-line, over-the-air validation tests by looping back a received and afterward modified radar signal and have been incorporated into existing Vehicle-in-the-Loop (ViL) test beds before. However, the currently available ViL test beds and the RTS systems that they consist of lack the ability to generate authentic radar echoes with respect to their complexity. The paper at hand reviews the current development stage of the research as well as commercial ViL and RTS systems. Furthermore, the concept and implementation of a new test setup for the rapid prototyping and validation of ADAS functions is presented. This represents the first-ever integrated radar validation test system to comprise multiple angle-resolved radar target channels, each capable of generating multiple radar echoes. A measurement campaign that supports this claim has been conducted

Exploration of Injection Strategy and Fuel Property Effects on Advanced Combustion

Over the past two decades increasingly strict emissions regulations have been implemented for on-road diesel engines. Additionally, reduced fuel consumption has recently become a priority for government regulatory agencies promising more stringent regulations on the horizon. This desire for less polluting, more efficient vehicles has fueled advanced engine research and development. Advanced combustion regimes such as homogeneous charge compression ignition (HCCI), premixed charge compression ignition (PCCI), and low temperature combustion (LTC) are topics at the forefront of this research. Each of these advanced combustion regimes essentially follow the same principle in which a homogeneous or near-homogeneous air and fuel mixture combusted at low temperatures can provide reductions in oxides of nitrogen (NOX), soot and fuel consumption while increasing brake-thermal efficiency.;Research performed at the Center for Alternative Fuels, Engines, and Emissions (CAFEE) at West Virginia University focused on achieving advanced combustion utilizing a European 1.9 Liter General Motors light-duty diesel engine. The engine was retrofit with a fully programmable electronic control unit (ECU) allowing for flexible control of fuel injection parameters, exhaust gas recirculation (EGR), boost pressure, and other independent control variables. Four different fuels with varying fuel properties, including but not limited to cetane number, aromatic content, 90 percent distillation temperature, and specific gravity, were tested during this research. Advanced injection strategies performed on each fuel were used to determine the effects of the fuel injection parameters, EGR, boost pressure, and fuel properties on advanced combustion.;Implementation of a single injection strategy with increased EGR levels and an advanced start of injection (SOI) timing resulted in significantly reduced NOX and soot emissions. Undesirable fuel consumption, extremely high carbon monoxide (CO) and hydrocarbon (HC) emissions, and in-cylinder pressure rise rates accompanying this strategy led to the development of a split injection strategy. Injection of 50 percent of the fuel at an early SOI timing, and the rest near top dead center reduced HC and CO emissions, improved fuel consumption from baseline tests, and retained NOX and soot emissions reductions. This split injection strategy also resulted in much safer in-cylinder pressure rise rates. Through testing of the different fuels it became apparent that cetane number was the dominant fuel property affecting gaseous emissions, soot, and in-cylinder pressure rise rates. Lower gaseous emissions were measured during the operation of high cetane number fuels. Fuels with lower cetane number resulted in less soot formation and lower in-cylinder pressure rise rates