COMBUSTION CONTROLLER DEVELOPMENT AND APPLICATION USING MODEL-BASED DESIGN

COMBUSTION CONTROLLER DEVELOPMENT AND APPLICATION USING MODEL-BASED DESIGN Klaus Rothbart April, 7th 00

AGENDA Introduction Development Application on engine test bed Results Summary

INTRODUCTION AVL The Company: AVL is the world's largest privately owned company for development, simulation and testing technology of powertrains (hybrid, combustion engines, transmission, electric drive, batteries and software) for passenger cars, trucks and large engines. Scope of business: Development of Powertrain Systems: AVL develops and improves all kinds of powertrain systems and is a competent partner to the engine and automotive industry. Simulation: In addition AVL develops and markets the simulation methods which are necessary for the development work. Testing Engine Instrumentation and Test Systems: The products of this business area comprise all the instruments and systems required for engine and vehicle testing. 3

INTRODUCTION CHALLENGES IN ENGINE CALIBRATION Problems: Increasing number of sensors, actuators, control algorithms increase of parameters Find optimal combination of parameters for emission, fuel consumption, performance Manual variation of parameters is very time consuming Manual variation could lead to critical operating states or damage of engine Solution: Development of Combustion Controller to reduce variation parameters on the engine test bed to protect engine even in unsafe operation points Model-based design in development Short development time flexibility 4

INTRODUCTION COMBUSTION CONTROLLER ON TEST BED AVL ECU AVL testbed automation system (AVL PUMA Open) Combustion Controller 5

AGENDA Introduction Development Application on engine test bed Results Summary 6

DEVELOPMENT OF COMBUSTION CONTROLLER Controller Offline Compilation Execution and final tests design Simulation & Verification for Real-time target on engine test bed MATLAB MATLAB Real-Time Workshop Simulink Simulink AVL ARTE.Lab Stateflow Stateflow (MATLAB Compiler) 7

COMBUSTION CONTROLLER SPARK ADVANCE () MFB 50% Control PI-Controller MFB 50% Demand Value ECU Delta Spark Advance MFB 50% Actual Value Knock Control Knock Level Knock Control State Machine Knock Level MFB... Mass Fraction Burned 8

COMBUSTION CONTROLLER SPARK ADVANCE () MFB 50% Control PI-Controller MFB 50% Demand Value ECU Delta Spark Advance MFB 50% Actual Value Knock Control Knock Level Knock Control State Machine Knock Level MFB... Mass Fraction Burned 9

COMBUSTION CONTROLLER INJECTION AMOUNT Component Protection max. Temperature Demand Value max. Temperature Demand Value n Critical Temperature Actual Value Function Block PI-Controller A/F Ratio demand A/F Ratio Control PI-Controller ECU A/F Ratio Demand ECU Fueling Factor Demand Critical Temperature Actual Value n A/F Ratio Actual Value 0

DEVELOPMENT OF COMBUSTION CONTROLLER SIMULATION AND VERIFICATION Simulation in Simulink Simulink Simulation Environment (engine, test bed,...)

AGENDA Introduction Development Application on engine test bed Results Summary

APPLICATION OF COMBUSTION CONTROLLER ON ENGINE TESTBED Development PC Test Bed PC compile ComCon.rta AVL PUMA Open MATLAB Simulink Stateflow Real-Time Workshop AVL ARTE.Lab 3

COMBUSTION CONTROLLER - OVERVIEW AVL Injection amount Spark advance to be calibrated ECU Emissions Fuel Consumption to be optimized Indicating Temperature Sensor Lambda Sensor AVL testbed automation system (AVL PUMA Open) Combustion Controller 4

T h r o t tle _ p o s it io n _ s e t [% ] 3 E n g in e _ s p e e d [ rp m ] L o o k u p T a b le M a n if o l d p re s s u re [ b a r ] L o o k u p T a b le E n g in e to r q u e [ N m ] 9 0 0 Id le s p e e d [r p m ] L o o k u p T a b le F ri c t io n to r q u e [ Nm ] P I 0. 0 s + T i m e D e la y 0 m s Id l e s p e e d C o n t ro ll e r E n g i n e _ d e la y. s + E n g in e D e la y 5 0 m s S a tu ra ti o n S u m In j e c t io n [o n /o ff ] In je c t io n s t a t e E n g in e _ p m a n [b a r] E n g i n e _ to r q u e [N m ] APPLICATION IN TEST FIELD Same controller on different test beds Administration of parameters with engine parameters Parameters stored in.mat file TB TB TB3 ComCon engine parameters 5

T h r o ttl e _ p o s i tio n _ s e t [% ] 3 E n g in e _ s p e e d [ rp m ] L o o k u p T a b l e M a n i fo ld p re s s u r e [b a r] L o o k u p T a b l e E n g in e t o rq u e [N m ] 9 0 0 Id le s p e e d [ rp m ] L o o k u p T a b le F r ic tio n t o r q u e [ N m ] P I 0.0 s + T im e D e la y 0 m s Id le s p e e d C o n tr o lle r E n g in e _ d e la y.s + E n g i n e D e l a y 5 0 m s S a t u r a tio n S u m In je c tio n [ o n / o ff] In j e c ti o n s ta t e E n g i n e _ p m a n [b a r] E n g in e _ to rq u e [N m ] PARAMETERIZATION Parameters in.mat file Changeable at run-time Stored with parameters of automation system ComCon.mat 6

AGENDA Introduction Development Application on engine test bed Results Summary 7

Knock Control MFB_DACT MFB 50% MFB_50% [-] [deg CRA atdc] Spark Advance [deg CRA btdc] Spark Advance [deg CRA] RESULTS () on off 0 3 4 6 8 8 0 0 5 0 5 5 0 0 5 5 0 0 000 rpm / 4 bar Safe OP KC on MFB50% Spark Advance Delta Spark Advance Spark Advance MFB_DACT delta Spark Advance Knock MFB_50% 3000 rpm / 8 bar Full Load Operating Point 000 rpm / 4 bar KC off Safe OP 0 5 0-5 -0 Knock [-] 0 0 5 0-5 -0 Knock delta Spark Advance [deg CRA] Delta Spark Advance [deg CRA btdc] 80 0 40 70 300 330 360 390 40 450 480 TIME [s ec.] 8

RESULTS () Benefits for controller development Reduction in development time by approx. 50% compared to standard programming languages MiL testing in Simulink Reliable failure free behavior due to offline simulation Reduction of expensive test bed time for development by 80% Model-based design eases enhancements Benefits for engine testing Manual variation of spark advance and injected fuel amount not needed anymore Speed up of engine development time decrease of testing time on engine test bed Decrease of approx. 50% In special test bed setups a decrease from day to 30 min has been encountered 9

AGENDA Introduction Development Application on engine test bed Results Summary 0

SUMMARY () Combustion controller development and application using model-based design Use of MATLAB and Simulink for faster and more effective engine calibration resolution 0.0s+ Lookup Table Time Delay Manifold pressure 0 ms [ba r] En gine_ delay.s+ En gine_ pman [ba r] Seamlessly integrated in AVL s automation system PUMA Open Throttle_ position _set [%] Lookup Table Engine torque [Nm] Engine Delay 5 0 ms 90 0 3 Eng in e_spe ed [rp m] Idle speed [rpm] PI Idle speed Controller Satura tion Sum Injection [o n/off] Engine_ torque Injectio n [Nm] sta te Lookup Table Friction torque [Nm]

SUMMARY () NEXT STEPS Ongoing improvement of gasoline engine controller Testing of Diesel-controllers on engine test beds Controller for adjustment of injected fuel amount Controllers to support base emission calibration Controllers to support the DPF-temperature management calibration: Diesel-controller under development Online-optimizer to support the smoke limitation-calibration

CONTACT INFO Dr. Klaus Rothbart Product Manager Control & Simulation Business Unit Powertrain Test Systems email: klaus.rothbart@avl.com Office: +43 (0) 36.787 475 Fax: +43 (0) 36.787 796 Throttle_ position _set [%] 3 Eng in e_spe ed [rp m] 0.0s+ Lookup Table Time Delay Manifold pressure 0 ms [ba r] En gine_ delay.s+ Lookup Table Engine Delay Engine torque 5 0 ms [Nm] 90 0 Idle speed [rpm] PI Sum Idle speed Controller Satura tion Injection [o n/off] Lookup Table Friction torque [Nm] En gine_ pman [ba r] Engine_ torque Injectio n [Nm] sta te AVL List GmbH Hans-List-Platz A-800 Graz http://www.avl.com 3