combustion controller development and application using … · introduction avl the company: avl is...

April, 27th 2010

COMBUSTION CONTROLLER DEVELOPMENT AND APPLICATION USING MODEL-BASED DESIGN

Klaus Rothbart

AGENDA

� Introduction

� Development

� Application on engine test bed

2Combustion Controller Development and Application using Model-Based Design

� Results

� Summary

INTRODUCTIONAVL

� 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.

� Engine Instrumentation and Test Systems: The products of this

business area comprise all the instruments and systems required

for engine and vehicle testing.

Testing

INTRODUCTIONCHALLENGES 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


� 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

INTRODUCTIONCOMBUSTION CONTROLLER ON TEST BED

AVL

ECU


AVL testbed automation system

(AVL PUMA Open)

Combustion

Controller

AGENDA

� Introduction

� Development



� Results

� Summary

DEVELOPMENT OF COMBUSTION CONTROLLER

� MATLAB

Controller

design

Offline

Simulation & Verification

Compilation

for Real-time target

Execution and final tests

on engine test bed

� Real-Time Workshop � MATLAB


� MATLAB

� Simulink

� Stateflow

� Real-Time Workshop

� AVL ARTE.Lab™

� (MATLAB Compiler)

� MATLAB

� Simulink

� Stateflow

ECU

Delta Spark Advance

PIPIPIPI----ControllerControllerControllerController

MFB 50%MFB 50%MFB 50%MFB 50%Actual ValueActual ValueActual ValueActual Value

MFB 50% MFB 50% MFB 50% MFB 50% Demand ValueDemand ValueDemand ValueDemand Value

MFB 50% Control

COMBUSTION CONTROLLERSPARK ADVANCE (1)


KnockKnockKnockKnockLevel 1Level 1Level 1Level 1


Knock Control Knock Control Knock Control Knock Control State MachineState MachineState MachineState Machine

Knock Control

MFB ... Mass Fraction Burned

ECU

Delta Spark Advance

PIPIPIPI----ControllerControllerControllerController

MFB 50%MFB 50%MFB 50%MFB 50%Actual ValueActual ValueActual ValueActual Value

MFB 50% MFB 50% MFB 50% MFB 50% Demand ValueDemand ValueDemand ValueDemand Value

MFB 50% Control

COMBUSTION CONTROLLERSPARK ADVANCE (2)




Knock Control Knock Control Knock Control Knock Control State MachineState MachineState MachineState Machine

Knock Control

MFB ... Mass Fraction Burned

PI-Controller A/F

Rati

o d

em

an

d

PI-Controller

ECU

A/F Ratio Demand

max. Temperature

Demand Value 1

Component Protection A/F RatioControl

max. Temperature

Function Block

COMBUSTION CONTROLLERINJECTION AMOUNT


PI-Controller PI-Controller

ECU

Fueling Factor Demand

A/F Ratio

Actual Value

max. Temperature

Demand Value n

Critical Temperature

Actual Value 1

Critical Temperature

Actual Value n

DEVELOPMENT OF COMBUSTION CONTROLLERSIMULATION AND VERIFICATION

� Simulation in Simulink


Simulink Simulation Environment

(engine, test bed, ...)

AGENDA

� Introduction

� Development



� Results

� Summary

APPLICATION OF COMBUSTION CONTROLLERON ENGINE TESTBED

Development PC

Test Bed PCTest Bed PCTest Bed PCTest Bed PC

compile


ComCon.rta

� MATLAB

� Simulink

� Stateflow

� Real-Time Workshop

� AVL ARTE.Lab™

AVL PUMA Open

COMBUSTION CONTROLLER - OVERVIEW

AVL

ECU

Emissions

Injection amount

Spark advance

to be

calibrated


IndicatingTemperature

Sensor

Lambda

Sensorto be optimized

Fuel Consumption

Emissions

AVL testbed automation system

(AVL PUMA Open)

Combustion

Controller

APPLICATION IN TEST FIELD

� Same controller on different test beds

� Administration of parameters with engine

parameters

2

E n g in e _ p m a n

[b a r ]

1

E n g i n e _ to r q u e

[N m ]

1

0 . 0 1 s + 1

T i m e D e la y

1 0 m s

S u mS a tu ra ti o n

L o o k u p T a b leM 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

F r i c t io n to r q u e

[ Nm ]


E n g in e to r q u e

[ N m ]

In je c t io n

s t a t e

P I

Id l e s p e e d C o n t ro ll e r

9 0 0

Id le s p e e d

[r p m ]

1

E n g i n e _ d e la y . s + 1

E n g in e D e la y

1 5 0 m s

3

E n g in e _ s p e e d

[ rp m ]2

In j e c t io n

[o n /o ff ]

1

T h r o t t le _ p o s it io n _ s e t

[% ]


� Parameters stored in .MAT file

TB1 TB2 TB3

• • •

engine

ComCon

parameters

PARAMETERIZATION

� Parameters in .MAT file

� Changeable at run-time

� Stored with parameters of automation

system


2

E n g i n e _ p m a n[b a r ]

1

E n g in e _ to rq u e

[N m ]

1

0 .0 1 s + 1

T im e D e la y

1 0 m s

S u mS a t u r a tio n

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 ]


F r ic t io n t o r q u e

[ N m ]

L o o k u p T a b l e

E n g in e t o rq u e

[N m ]

In j e c t i o n

s ta t e

P I

Id le s p e e d C o n tr o lle r

9 0 0

Id le s p e e d[ rp m ]

1

E n g in e _ d e la y .s + 1

E n g i n e D e l a y1 5 0 m s

3

E n g in e _ s p e e d

[ rp m ]2

In je c t io n

[ o n / o ff]

1

T h r o tt l e _ p o s i t io n _ s e t

[% ]

ComCon.mat

AGENDA

� Introduction

� Development



� Results

� Summary

MF

B_

DA

CT

0

2

Kn

ock

0

2

MF

B_

50

% [-]

8

16

24

3232

24

16

8

MF

B 5

0%

[deg C

RA

aT

DC

] Knock [-]

2

0

Knock

Contr

ol

on

off

3000 rpm / 18 bar3000 rpm / 18 bar3000 rpm / 18 bar3000 rpm / 18 bar

Full Load Full Load Operating PointOperating Point

SafeSafeOPOP

2000 rpm 2000 rpm 2000 rpm 2000 rpm / 4 bar/ 4 bar/ 4 bar/ 4 bar

SafeSafeOPOP

KC onKC onKC onKC onKC onKC onKC onKC on

MFB50%MFB50%

2000 rpm / 2000 rpm / 2000 rpm / 2000 rpm / 4 bar4 bar4 bar4 bar

KC offKC offKC offKC offKC offKC offKC offKC off

RESULTS (1)


180 210 240 270 300 330 360 390 420 450 480TIME [s ec.]

Sp

ark

Ad

va

nce

[d

eg

CR

A]

0

5

10

15

20

25

de

lta

Sp

ark

Ad

va

nce

[d

eg

CR

A]

-10

-5

0

5

100

8

Spark AdvanceMFB_DACTdelta Spark AdvanceKnockMFB_50%

8

0

[deg C

RA

aT

DC

]S

park

Advance

[deg C

RA

bT

DC

]

25

20

15

10

5

0

5

0

-5

-10

Delta S

park

Advance

[deg C

RA

bT

DC

]

Operating PointOperating Point

Delta Spark AdvanceDelta Spark Advance

Spark AdvanceSpark Advance

MFB50%MFB50%

RESULTS (2)

� 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


� 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 1 day to 30 min has been

encountered

AGENDA

� Introduction

� Development



� Results

� Summary

SUMMARY (1)

� Use of MATLAB and Simulink for faster

and more effective engine calibration

Combustion controller development and application using model-based design


and more effective engine calibration

resolution

� Seamlessly integrated in AVL’s

automation system PUMA Open2

En gine_ pman

[ba r]

1

Engine_ torque

[Nm]

1

0 .01s+1

T ime Dela y

10 ms

SumSatura tion

Loo kup T able

Man ifold pressure

[ba r]

Lo okup Tab le

F riction torque

[Nm]

Loo kup T able

Eng in e torque

[Nm]

Injectio n

sta te

PI

Idle sp eed Co ntro lle r

90 0

Id le spee d

[rpm]

1

En gine_ delay.s+1

En gine De la y

15 0 ms

3

Eng in e_spe ed

[rp m]2

Injection

[o n/off]

1

Throttle_ position _set

[%]

SUMMARY (2)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: [email protected]


Office: +43 (0) 316.787 4175

Fax: +43 (0) 316.787 1796

AVL List GmbH

Hans-List-Platz 1

A-8020 Graz

http://www.avl.com

2

En gine_ pman

[ba r]

1

Engine_ torque

[Nm]

1

0 .01s+1

T ime Dela y

10 ms

SumSatura tion

Loo kup T able

Man ifold pressure

[ba r]

Lo okup Tab le

F riction torque

[Nm]

Loo kup T able

Eng in e torque

[Nm]

Injectio n

sta te

PI

Idle sp eed Co ntro lle r

90 0

Id le spee d

[rpm]

1

En gine_ delay.s+1

En gine De la y

15 0 ms

3

Eng in e_spe ed

[rp m]2

Injection

[o n/off]

1

Throttle_ position _set

[%]

combustion controller development and application using … · introduction avl the company: avl is...

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