Increasing exhaust temperature to enable after-treatment operation on a two-stage turbo-charged medium speed marine diesel engine

Nitrogen-oxides (NOx) are becoming more and more regulated. In heavy duty, medium speed engines these emission limits are also being reduced steadily: Selective catalytic reduction is a proven technology which allows to reduce NOx emission with very high efficiency. However, operating temperature of the catalytic converter has to be maintained within certain limits as conversion efficiency and ammonia slip are very heavily influenced by temperature. In this work the engine calibration and hardware will be modified to allow for a wide engine operating range with Selective catalytic reduction. The studied engine has 4MW nominal power and runs at 750rpm engine speed, fuel consumption during engine tests becomes quite expensive (+- 750kg/h) for a measurement campaign. This is why a simulation model was developed and validated. This model was then used to investigate several strategies to control engine out temperature: different types of wastegates, injection variation and valve timing adjustments. Simulation showed that wastegate application had the best tradeoff between fuel consumption and exhaust temperature. Finally, this configuration was built on the engine test bench and results from both measurements and simulation agreed very well

Flexible and robust control of heavy duty diesel engine airpath using data driven disturbance observers and GPR models

Diesel engine airpath control is crucial for modern engine development due to increasingly stringent emission regulations. This thesis aims to develop and validate a exible and robust control approach to this problem for speci cally heavy-duty engines. It focuses on estimation and control algorithms that are implementable to the current and next generation commercial electronic control units (ECU). To this end, targeting the control units in service, a data driven disturbance observer (DOB) is developed and applied for mass air ow (MAF) and manifold absolute pressure (MAP) tracking control via exhaust gas recirculation (EGR) valve and variable geometry turbine (VGT) vane. Its performance bene ts are demonstrated on the physical engine model for concept evaluation. The proposed DOB integrated with a discrete-time sliding mode controller is applied to the serial level engine control unit. Real engine performance is validated with the legal emission test cycle (WHTC - World Harmonized Transient Cycle) for heavy-duty engines and comparison with a commercially available controller is performed, and far better tracking results are obtained. Further studies are conducted in order to utilize capabilities of the next generation control units. Gaussian process regression (GPR) models are popular in automotive industry especially for emissions modeling but have not found widespread applications in airpath control yet. This thesis presents a GPR modeling of diesel engine airpath components as well as controller designs and their applications based on the developed models. Proposed GPR based feedforward and feedback controllers are validated with available physical engine models and the results have been very promisin

Meta-heuristic algorithms in car engine design: a literature survey

Meta-heuristic algorithms are often inspired by natural phenomena, including the evolution of species in Darwinian natural selection theory, ant behaviors in biology, flock behaviors of some birds, and annealing in metallurgy. Due to their great potential in solving difficult optimization problems, meta-heuristic algorithms have found their way into automobile engine design. There are different optimization problems arising in different areas of car engine management including calibration, control system, fault diagnosis, and modeling. In this paper we review the state-of-the-art applications of different meta-heuristic algorithms in engine management systems. The review covers a wide range of research, including the application of meta-heuristic algorithms in engine calibration, optimizing engine control systems, engine fault diagnosis, and optimizing different parts of engines and modeling. The meta-heuristic algorithms reviewed in this paper include evolutionary algorithms, evolution strategy, evolutionary programming, genetic programming, differential evolution, estimation of distribution algorithm, ant colony optimization, particle swarm optimization, memetic algorithms, and artificial immune system

Low Complexity Model Predictive Control of a Diesel Engine Airpath.

The diesel air path (DAP) system has been traditionally challenging to control due to its highly coupled nonlinear behavior and the need for constraints to be considered for driveability and emissions. An advanced control technology, model predictive control (MPC), has been viewed as a way to handle these challenges, however, current MPC strategies for the DAP are still limited due to the very limited computational resources in engine control units (ECU). A low complexity MPC controller for the DAP system is developed in this dissertation where, by "low complexity," it is meant that the MPC controller achieves tracking and constraint enforcement objectives and can be executed on a modern ECU within 200 microseconds, a computation budget set by Toyota Motor Corporation. First, an explicit MPC design is developed for the DAP. Compared to previous explicit MPC examples for the DAP, a significant reduction in computational complexity is achieved. This complexity reduction is accomplished through, first, a novel strategy of intermittent constraint enforcement. Then, through a novel strategy of gain scheduling explicit MPC, the memory usage of the controller is further reduced and closed-loop tracking performance is improved. Finally, a robust version of the MPC design is developed which is able to enforce constraints in the presence of disturbances without a significant increase in computational complexity compared to non-robust MPC. The ability of the controller to track set-points and enforce constraints is demonstrated in both simulations and experiments. A number of theoretical results pertaining to the gain scheduling strategy is also developed. Second, a nonlinear MPC (NMPC) strategy for the DAP is developed. Through various innovations, a NMPC controller for the DAP is constructed that is not necessarily any more computationally complex than linear explicit MPC and is characterized by a very streamlined process for implementation and calibration. A significant reduction in computational complexity is achieved through the novel combination of Kantorovich's method and constrained NMPC. Zero-offset steady state tracking is achieved through a novel NMPC problem formulation, rate-based NMPC. A comparison of various NMPC strategies and developments is presented illustrating how a low complexity NMPC strategy can be achieved.PhDAerospace EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/120832/1/huxuli_1.pd

Model predictive emissions control of a diesel engine airpath: Design and experimental evaluation

Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/163480/2/rnc5188.pdfhttp://deepblue.lib.umich.edu/bitstream/2027.42/163480/1/rnc5188_am.pd

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.

Systematic hyperparameter selection in Machine Learning-based engine control to minimize calibration effort

For automotive powertrain control systems, the calibration effort is exploding due to growing system complexity and increasingly strict legal requirements for greenhouse gas and real-world pollutant emissions. These powertrain systems are characterized by their highly dynamic operation, so transient performance is key. Currently applied control methods require tuning of an increasing number of look-up tables and of parameters in the applied models. Especially for transient control this state-of-the-art calibration process is unsystematic and requires a large development effort. Also, embedding models in a controller can set challenging requirements to production control hardware. In this work, we assess the potential of Machine Learning to dramatically reduce the calibration effort in transient air path control development. This is not only done for the existing benchmark controller, but also for a new preview controller. In order to efficiently realize preview, a strategy is proposed where the existing reference signal is shifted in time. These reference signals are then modeled as a function of engine torque demand using a Long Short-Term Memory (LSTM) neural network, which can capture the dynamic input–output relationship. A multi-objective optimization problem is defined to systematically select hyperparameters that optimize the trade-off between model accuracy, system performance, calibration effort and computational requirements. This problem is solved using an exhaustive search approach. The control system performance is validated over a transient driving cycle. For the LSTM-based controllers, the proposed calibration approach achieves a significant reduction of 71% in the control calibration effort compared to the benchmark process. The expert effort and turbocharger experiments used in calibrating transient compensation maps in physics-based feedforward controller are replaced by little simulation time and parametrization effort in ML-based controller, which requires significantly less expert effort and system knowledge compared to benchmark process. The best trade-off between multi-objective cost terms is achieved with one layer and 32 cells LSTM neural network for both non-preview and preview control. For non-preview control, a comparable control system performance is achieved with the LSTM-based controller, while 5% reduction in cumulative NOx emissions and similar fuel consumption is achieved with preview controller

Urban and extra-urban hybrid vehicles: a technological review

Pollution derived from transportation systems is a worldwide, timelier issue than ever. The abatement actions of harmful substances in the air are on the agenda and they are necessary today to safeguard our welfare and that of the planet. Environmental pollution in large cities is approximately 20% due to the transportation system. In addition, private traffic contributes greatly to city pollution. Further, “vehicle operating life” is most often exceeded and vehicle emissions do not comply with European antipollution standards. It becomes mandatory to find a solution that respects the environment and, realize an appropriate transportation service to the customers. New technologies related to hybrid –electric engines are making great strides in reducing emissions, and the funds allocated by public authorities should be addressed. In addition, the use (implementation) of new technologies is also convenient from an economic point of view. In fact, by implementing the use of hybrid vehicles, fuel consumption can be reduced. The different hybrid configurations presented refer to such a series architecture, developed by the researchers and Research and Development groups. Regarding energy flows, different strategy logic or vehicle management units have been illustrated. Various configurations and vehicles were studied by simulating different driving cycles, both European approval and homologation and customer ones (typically municipal and university). The simulations have provided guidance on the optimal proposed configuration and information on the component to be used