Online Control of Automotive systems for improved Real-World Performance

[ES] La necesidad de mejorar el consumo de combustible y las emisiones de los sistemas propulsivos de automoción en condiciones reales de conducción es la base de esta tesis. Para ello, se exploran dos ejes: En primer lugar, el control de los sistemas de propulsión. El estado del arte de control en los sistemas propulsivos de automoción se basa en gran medida en el uso de técnicas de optimización que buscan las leyes de control que minimizan una función de coste en un conjunto de condiciones de operación denidas a priori. Estas leyes se almacenan en las ECUs de producción en forma de mapas de calibración de los diferentes actuadores del motor. Las incertidumbres asociadas al conjunto limitado de condiciones en el proceso de calibración dan lugar a un funcionamiento subóptimo del sistema de propulsión en condiciones de conducción real. Por lo tanto, en este trabajo se proponen métodos de control adaptativo que optimicen la gestión de la planta propulsiva a las condiciones esperadas de funcionamiento para un usuario y un caso determinado en lugar de a un conjunto genérico de condiciones. El segundo eje se reere a optimizar, en lugar de los parámetros de control del sistema propulsivo, la demanda de potencia de este, introduciendo al propio conductor en el bucle de control, sugiriéndole las acciones a tomar. En particular, este segundo eje se reere al control de la velocidad del vehículo (conocido popularmente como Eco-Driving en la literatura) en condiciones reales de conducción. Se proponen sistemas de aviso en tiempo real al conductor acerca de la velocidad óptima para minimizar el consumo del vehículo. Los métodos de control desarrollados para cada aplicación se describen en detalle en la tesis y se muestran ensayos experimentales de validación en los casos de estudio diseñados. Ambos ejes representan un problema de control óptimo, denido por un sistema dinámico, unas restricciones a cumplir y un coste a minimizar, en este sentido las herramientas desarrolladas en la tesis son comunes a los dos ejes: Un modelo de vehículo, una herramienta de predicción del ciclo de conducción y métodos de control óptimo (Programación Dinámica, Principio Mínimo de Pontryagin y Estrategia de Consumo Equivalente Mínimo). Dependiendo de la aplicación, los métodos desarrollados se implementaron en varios entornos experimentales: un motor térmico en sala de ensayos simulando el resto del vehículo, incluyendo el resto del sistema de propulsión híbrido y en un vehículo real. Los resultados muestran mejoras signicativas en el rendimiento del sistema de propulsión en términos de ahorro de combustible y emisiones en comparación con los métodos empleados en el estado del arte actual.[CA] La necessitat de millorar el consum de combustible i les emissions dels sistemes propulsius d'automoció en condicions reals de conducció és la base d'aquesta tesi. Per a això, s'exploren dos eixos: En primer lloc, el control dels sistemes de propulsió. L'estat de l'art de control en els sistemes propulsius d'automoció es basa en gran manera en l'ús de tècniques d'optimització que busquen les lleis de control que minimitzen una funció de cost en un conjunt de condicions d'operació denides a priori. Aquestes lleis s'emmagatzemen en les Ecus de producció en forma de mapes de calibratge dels diferents actuadors del motor. Les incerteses associades al conjunt limitat de condicions en el procés de calibratge donen lloc a un funcionament subòptim del sistema de propulsió en condicions de conducció real. Per tant, en aquest treball es proposen mètodes de control adaptatiu que optimitzen la gestió de la planta propulsiva a les condicions esperades de funcionament per a un usuari i un cas determinat en lloc d'un conjunt genèric de condicions. El segon eix es refereix a optimitzar, en lloc dels paràmetres de control del sistema propulsiu, la demanda de potència d'aquest, introduint al propi conductor en el bucle de control, suggerint-li les accions a prendre. En particular, aquest segon eix es refereix al control de la velocitat del vehicle (conegut popularment com Eco-*Driving en la literatura) en condicions reals de conducció. Es proposen sistemes d'avís en temps real al conductor sobre la velocitat òptima per a minimitzar el consum del vehicle. Els mètodes de control desenvolupats per a cada aplicació es descriuen detalladament en la tesi i es mostren assajos experimentals de validació en els casos d'estudi dissenyats. Tots dos eixos representen un problema de control òptim, denit per un sistema dinàmic, unes restriccions a complir i un cost a minimitzar, en aquest sentit les eines desenvolupades en la tesi són comunes als dos eixos: Un model de vehicle, una eina de predicció del cicle de conducció i mètodes de control òptim (Programació Dinàmica, Principi Mínim de *Pontryagin i Estratègia de Consum Equivalent Mínim). Depenent de l'aplicació, els mètodes desenvolupats es van implementar en diversos entorns experimentals: un motor tèrmic en sala d'assajos simulant la resta del vehicle, incloent la resta del sistema de propulsió híbrid i en un vehicle real. Els resultats mostren millores signicatives en el rendiment del sistema de propulsió en termes d'estalvi de combustible i emissions en comparació amb els mètodes emprats en l'estat de l'art actual.[EN] The need of improving the real-world fuel consumption and emission of automotive applications is the basis of this thesis. To this end, two verticals are explored: First is the online control of the powertrain systems. In state-of-the-art Optimal Control techniques (such as Dyanmic Programming, Pontryagins Minimum Principle, etc...) are extensively used to formulate the optimal control laws. These laws are stored in the production ECUs in the form of feedforward calibration maps. The unaccounted uncertainities related to the real-world during the powertrain calibration result in suboptimal operations of the powertrain in actual driving. Therefore, adaptive control methods are proposed in this work which, optimise the energy management of the conventional and the HEV powertrain control on real driving mission. The second vertical is regarding the vehicle speed control (popularly known as Eco-Driving in the literature) methods in real driving condition. In particular, speed advisory systems are proposed for real time application on a vehicle. The control methods developed for each application are described in details with their verication and validation on the designed case studies. Apart from the developed control methods, there are three tools that were developed and used at various stages of this thesis: A vehicle model, A driving cycle prediction tool and optimal control methods (dynamic programming, PMP and ECMS). Depending on the application, the developed methods were implemented on the Hardware-In-Loop Internal Combustion Engine testing setup or on a real vehicle. The results show signicant improvements in the performance of the powertrain in terms of fuel economy and emissions in comparison to the state-of-the-art methods.Pandey, V. (2021). Online Control of Automotive systems for improved Real-World Performance [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/173716TESI

DRIVE: Data-driven Robot Input Vector Exploration

An accurate motion model is a fundamental component of most autonomous navigation systems. While much work has been done on improving model formulation, no standard protocol exists for gathering empirical data required to train models. In this work, we address this issue by proposing Data-driven Robot Input Vector Exploration (DRIVE), a protocol that enables characterizing uncrewed ground vehicles (UGVs) input limits and gathering empirical model training data. We also propose a novel learned slip approach outperforming similar acceleration learning approaches. Our contributions are validated through an extensive experimental evaluation, cumulating over 7 km and 1.8 h of driving data over three distinct UGVs and four terrain types. We show that our protocol offers increased predictive performance over common human-driven data-gathering protocols. Furthermore, our protocol converges with 46 s of training data, almost four times less than the shortest human dataset gathering protocol. We show that the operational limit for our model is reached in extreme slip conditions encountered on surfaced ice. DRIVE is an efficient way of characterizing UGV motion in its operational conditions. Our code and dataset are both available online at this link: https://github.com/norlab-ulaval/DRIVE.Comment: 6 pages, 7 figures, submitted to 2024 IEEE International Conference on Robotics and Automation (ICRA 2024

Vehicle Parameters Estimation and Driver Behavior Classification for Adaptive Shift Strategy of Heavy Duty Vehicles

Commercial vehicles fulfill the majority of inland freight transportation in the United States, and they are very large consumers of fuels. The increasingly stringent regulation on greenhouse-gas emission has driven manufacturers to adopt new fuel efficient technologies. Among others, advanced transmission control strategy can provide tangible improvement with low incremental cost. An adaptive shift strategy is proposed in this work to optimize the shift maps on-the-fly based on the road load and driver behavior while reducing the initial calibration efforts. In addition, the adaptive shift strategy provides the fleet owner a mean to select a tradeoff between fuel economy and drivability, since the drivers are often not the owner of the vehicle. In an attempt to develop the adaptive shift strategy, the vehicle parameters and driver behavior need to be evaluated first. Therefore, three research questions are addressed in this dissertation: (i) vehicle parameters estimation; (ii) driver behavior classification; (iii) online shift strategy adaption. In vehicle parameters estimation, a model-based vehicle rolling resistance and aerodynamic drag coefficient online estimator is proposed. A new Weighted Recursive Least Square algorithm was developed. It uses a supervisor to extracts data during the constant-speed event and saves the average road load at each speed segment. The algorithm was tested in the simulation with real-world driving data. The results have shown a more robust performance compared with the original Recursive Least Square algorithm, and high accuracy of aerodynamic drag estimation. To classify the driver behavior, a driver score algorithm was proposed. A new method is developed to represent the time-series driving data into events represented by symbolic data. The algorithm is tested with real-world driving data and shows a high classification accuracy across different vehicles and driving cycles. Finally, a new adaptive shift scheme was developed, which synthesizes the information about vehicle parameters and driver score developed in the previous steps. The driver score is used as a proxy to match the driving characteristics in real time. Drivability objective is included in the optimization through a torque reserve and it is subsequently evaluated via a newly developed metric. The impact of the shift maps on the objective drivability and fuel economy metrics is evaluated quantitatively in the vehicle simulation. The algorithms proposed in this dissertation are developed with practical implementation in mind. The methods can reduce the initial calibration effort and provide the fleet owner a mean to select an appropriate tradeoff between fuel economy and drivability depending on the vocation

MODELING OF THERMAL DYNAMICS IN CHEVROLET VOLT GEN II HYBRID ELECTRIC VEHICLE FOR INTEGRATED POWERTRAIN AND HVAC OPTIMAL OPERATION THROUGH CONNECTIVITY

Integrated thermal energy management across system level components in electric vehicles (EVs) and hybrid electric vehicles (HEVs) is currently an under explored space. The proliferation of connected vehicles and accompanying infrastructure in recent years provides additional motivation to explore opportunities in optimizing thermal energy management in EVs and HEVs with the help of this newly available connected vehicle data. This thesis aims to examine and analyze the potential to mitigate vehicle energy consumption and extend usable driving range through optimal control strategies which exploit physical system dynamics via controls integration of vehicle subsystems. In this study, data-driven and physics-based models for heating, ventilation and air-conditioning (HVAC) are developed and utilized along with the vehicle dynamics and powertrain (VD\&PT) models for a GM Chevrolet Volt hybrid electric vehicle to enable co-optimization of HVAC and VD\&PT systems of HEVs. The information available in connected vehicles like driver schedules, trip duration and ambient conditions is leveraged along with the vehicle system dynamics to predict operating conditions of the vehicle under study. All this information is utilized to optimize the operation of an integrated HVAC and VD\&PT system in a hybrid electric vehicle to achieve the goal of reduced energy consumption. For achieving the goals outlined for this thesis, an integrated HVAC and VD\&PT model is developed and the various components, sub-systems and systems are validated against real world test data. Then, integrated relationships relevant to the thermal dynamics of an HEV are established. These relationships comprise the combined operational characteristics of the internal combustion (IC) engine coolant and the cabin electric heater for cabin heating, coordinated controls of IC engine using engine coolant and catalyst temperatures for cabin thermal conditioning in cold ambient conditions and the combined operational characteristics of the air-conditioning compressor for conditioning both cabin and high-voltage battery in an HEV. Next, these sub-system and system relationships are used to evaluate potential energy savings in cabin heating and cooling when vehicle\u27s operating schedule is known. Finally, an optimization study is conducted to establish an energy efficient control strategy which maximizes the HVAC energy efficiency whilst maintaining occupant comfort levels according to ASHRAE standards, all while improving the usable range of the vehicle relative to its baseline calibration. The mean energy savings in overall vehicle energy consumption using an integrated HVAC - Powertrain control strategy and a coordinated thermal management strategy proposed in this work are $3$\% and $14$\% respectively

Energy management system optimization based on an LSTM deep learning model using vehicle speed prediction

The energy management of a Hybrid Electric Vehicle (HEV) is a global optimization problem, and its optimal solution inevitably entails knowing the entire mission profile. The exploitation of Vehicle-to-Everything (V2X) connectivity can pave the way for reliable short-term vehicle speed predictions. As a result, the capabilities of conventional energy management strategies can be enhanced by integrating the predicted vehicle speed into the powertrain control strategy. Therefore, in this paper, an innovative Adaptation algorithm uses the predicted speed profile for an Equivalent Consumption Minimization Strategy (A-V2X-ECMS). Driving pattern identification is employed to adapt the equivalence factor of the ECMS when a change in the driving patterns occurs, or when the State of Charge (SoC) experiences a high deviation from the target value. A Principal Component Analysis (PCA) was performed on several energetic indices to select the ones that predominate in characterizing the different driving patterns. Long Short-Term Memory (LSTM) deep neural networks were trained to choose the optimal value of the equivalence factor for a specific sequence of data (i.e., speed, acceleration, power, and initial SoC). The potentialities of the innovative A-V2X-ECMS were assessed, through numerical simulation, on a diesel Plug-in Hybrid Electric Vehicle (PHEV) available on the European market. A virtual test rig of the investigated vehicle was built in the GT-SUITE software environment and validated against a wide database of experimental data. The simulations proved that the proposed approach achieves results much closer to optimal than the conventional energy management strategies taken as a reference

Advanced Control and Estimation Concepts, and New Hardware Topologies for Future Mobility

According to the National Research Council, the use of embedded systems throughout society could well overtake previous milestones in the information revolution. Mechatronics is the synergistic combination of electronic, mechanical engineering, controls, software and systems engineering in the design of processes and products. Mechatronic systems put “intelligence” into physical systems. Embedded sensors/actuators/processors are integral parts of mechatronic systems. The implementation of mechatronic systems is consistently on the rise. However, manufacturers are working hard to reduce the implementation cost of these systems while trying avoid compromising product quality. One way of addressing these conflicting objectives is through new automatic control methods, virtual sensing/estimation, and new innovative hardware topologies

Advances in Intelligent Vehicle Control

This book is a printed edition of the Special Issue Advances in Intelligent Vehicle Control that was published in the journal Sensors. It presents a collection of eleven papers that covers a range of topics, such as the development of intelligent control algorithms for active safety systems, smart sensors, and intelligent and efficient driving. The contributions presented in these papers can serve as useful tools for researchers who are interested in new vehicle technology and in the improvement of vehicle control systems

Connected Hybrid Electrical Vehicle: Powertrain Optimization Strategy and Experiment

University of Minnesota Ph.D. dissertation.August 2017. Major: Mechanical Engineering. Advisor: Zongxuan Sun. 1 computer file (PDF); ix, 101 pages.Power-split Hybrid Electric Vehicle (HEV), which accounts for almost 40% of US hybrid-car total sales in 2013, has the ability to store excess energy during driving and braking, and to split the demanded power between the engine and battery. With the advent of connected vehicles, traffic information can be shared and utilized to further optimize HEV’s energy use, by predicting the demanded power and optimizing the power-split. However, traffic conditions, and therefore the demanded power, are constantly changing. As a result, the optimization method not only has to account for optimality and charge-sustaining conditions, but also driving-cycle sensitivity and speed of calculation for real-time implementation. This research therefore proposes fast HEV powertrain optimization to improve fuel economy for connected vehicle applications. Additionally, in order to measure the performance of connected vehicle applications, a hardware-in-the-loop system (HiLS), that combines an existing laboratory powertrain research platform with a microscopic traffic simulator, is developed. A computationally-efficient analytical solution to the HEV powertrain optimization problem utilizing vehicle speed prediction based on Inter-Vehicle Communications and Vehicle-Infrastructure Integration is proposed for real-time implementation. First, Gipps’ car following model for traffic prediction is used to predict the interactions between vehicles, combined with the cell-transmission-model for the leading vehicle trajectory prediction. Secondly, a computationally efficient charge-sustaining (CS) HEV powertrain optimization strategy is analytically derived and simulated, based on the Pontryagin’s Minimum Principle (PMP) and a CS-condition constraint. A 3D lookup-map, generated offline to interpolate the optimizing parameters based on the predicted speed, is also utilized to speed up the calculations. Simulations are conducted for 6-mile and 15-mile cases with different prediction update timings to test the performance of the proposed strategy against a Rule-Based (RB) control strategy on a Toyota Prius engine. Results for accurate-prediction cases show 9.6% average fuel economy improvements in miles-per-gallon (MPG) over RB for the 6-mile case and 7% improvements for the 15-mile case. Prediction-with-error cases show smaller average MPG’s improvements, with 1.6% to 4.3% improvements for the 6-mile case and 2.6% to 3.4% improvements for the 15-mile case. For practical purposes, the HEV engine operating range and transient response have to be considered, which introduces additional optimization constraints. Solving a nonlinear optimization problem with constraints analytically is difficult, while numerically is computational heavy and time consuming. Therefore, the nonlinear HEV optimization problem with constraints is expressed and solved as a Separable Programming (SP) problem. First, given the flexibility of the power-split HEV powertrain, the relationship between the minimum fuel consumption and the power-split levels between the engine and battery is calculated and stored offline for all possible vehicle power demands. Therefore, the relationship between HEV power-split levels and engine operating points with minimum fuel consumption for a given vehicle power demand is obtained. Secondly, the problem is formulated with fuel consumption as the cost and power-split level as the optimizing input and solved using SP. In SP, the nonlinear fuel cost and battery charging rate relationships with the power-split levels are approximated as linear-piecewise functions which introduce dimensionless variables that are linear to the input and outputs of the nonlinear functions. The input range constraint and the engine transient dynamics are also formulated. The optimization problem is then solved as a large-dimension linear problem with linear constraints using efficient Linear Programming solvers. The proposed optimization method is then simulated in a receding horizon fashion with various vehicle speed profiles and a case study was tested on a real John Deere diesel engine. Comparable fuel economy with Dynamic Programming is shown with significantly less calculation time and fuel savings of 4.0% and 10.4% over PMP and RB optimizations are observed. A HiLS testbed to evaluate the performance of connected vehicle applications is proposed. A laboratory powertrain research platform, which consists of a real engine, an engine-loading device (hydrostatic dynamometer) and a virtual powertrain model to represent a vehicle, is connected remotely to a microscopic traffic simulator (VISSIM). Vehicle dynamics and road conditions of a target vehicle in the VISSIM simulation are transmitted to the powertrain research platform through the internet, where the power demand can then be calculated. The engine then operates through an engine optimization procedure to minimize fuel consumption, while the dynamometer tracks the desired engine load based on the target vehicle information. Test results show fast data transfer at every 200 milliseconds and good tracking of the optimized engine operating points and the desired vehicle speed. Actual fuel and emissions measurements, which otherwise could not be calculated precisely by fuel and emission maps in simulations, are achieved by the testbed. In addition, VISSIM simulation can be implemented remotely while connected to the powertrain research platform through the internet, allowing easy access to the laboratory setup

Towards Supervisory control for complex Propulsion subsystems

Powertrain subsystem complexity has been on the rise with increasing legal requirements and meeting disruptive market trends. There is greater potential for cost efficient robust operation with integrated control units and software development. For systems that are interdependent, operating towards the common goal of fuel optimal operation under controlled exhaust emissions, it would be natural to integrate controls using a supervisory controller with a holistic overview of subsystem operation that utilised synergies and optimal trade-offs. Connected cars have grown exponentially owing to consumer demand which offers rich data on vehicle operation and enables the possibility of tailoring systems to individual optimum operation. The possibility to feed external data, such as traffic information combined with the specific vehicle historic operation, enables prediction of the future vehicle trip and operating condition with greater accuracy. A supervisory control framework for a diesel powertrain that is capable of utilising predicted look ahead information is developed. The look ahead information as a time trajectory of vehicle speed and load is considered. The supervisory controller considers a discrete control action set over the first segment of the trip ahead. The cost to optimise is defined and pre-computed off-line for a discrete set of operating conditions. A full factorial optimisation carried out off-line is stored on board the vehicle and applied in real time. In the first approach, a set of predefined trip segments with off-line optimisation is considered. Here a library of segments is considered which would need to provide sufficient coverage of all possible trip characteristics along with a pattern matching or clustering algorithm. Another approach, to use a lumped parameter based model that can characterise the behaviour of the subsystems over the trajectory, is also examined for real-time on-line application. Simulation comparison of both controllers with the baseline controller indicates a 1% total fuel equivalent cost improvement while offering the flexibility to tailor the controller for different cost objective and improving robustness of exhaust emission control