Engine Modeling and Control: Modeling and Electronic Management of Internal Combustion Engines

646 Pages·2014·22.868 MB·English

by  Rolf Isermann (auth.)

Rolf Isermann
Engine
Modeling
and Control
Modeling and Electronic Management
of Internal Combustion Engines
Engine Modeling and Control
Rolf Isermann
Engine Modeling
and Control
Modeling and Electronic Management
of Internal Combustion Engines
123
RolfIsermann
TU Darmstadt
Darmstadt
Germany
ISBN 978-3-642-39933-6 ISBN 978-3-642-39934-3 (eBook)
DOI 10.1007/978-3-642-39934-3
LibraryofCongressControlNumber:2014943641
SpringerHeidelbergNewYorkDordrechtLondon
(cid:2)Springer-VerlagBerlinHeidelberg2014
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Preface
Theincreasingrequirementsforautomotivedriveswithinternalcombustionengines
onreducedfuelconsumption,lowemissionsandgooddriveabilityneedcontinuous
improvementofcombustionandexhausttreatmentprocessesandtheircontrol.This
can be reached by a higher variability with an increase of actuators and sensors in
addition to thermodynamic, mechanical and structural improvements. Modern en-
gines have therefore an increasing number of manipulation variables and sensors
andacomplexelectronicmanagement.Thedesignofthemanycontrolfunctionre-
quires good physical understanding and model-based methods taking into account
mechatronicengineeringprinciples.
Thebooktreatsaswellphysical-basedasexperimentalgainedenginemodelsfor
gasoline(sparkignition)anddiesel(compressionignition)enginesandusesthemfor
thedesignofthedifferentcontrolsystems.Theprocedureandtheworkflowfromthe-
oreticalandexperimentalmodelingoversimulationstocalibrationwithtestbenches
is systematically described and demonstrated by many examples. Not only the sta-
tionarybutalsothedynamicnonlinearbehaviorofenginesistakenintoaccount.The
combustionenginemodelsincludetheintakesystem,fuelsupplyandinjection,com-
bustion cycles, mechanical system, turbochargers, exhaust and cooling system and
aremainlygeneratedforreal-timecomputation.Enginecontrolstructuresandengine
control development with different digital feedforward and feedback control meth-
ods,calibration,optimizationandsimulationtoolsareconsideredindetail.Various
control systems are developed for gasoline and diesel engines with both, conven-
tionalandalternativecombustionprocesses,basedonnonlinearstaticanddynamic
multivariableenginemodelsanddemonstratedbyexperimentsontestbenches.
The book is an introduction into the electronic engine management with many
examplesforenginecontrolanditisorientedtoadvancedstudentsworkingincon-
trol,electrical,mechanicalandmechatronicengineeringandwillalsobeusefulfor
practicingengineersinthefieldofengineandautomotiveengineering.
The author is grateful to his research associates, who have performed many
theoretical and experimental research projects on the subject of this book since
1986,amongthemK.U.Voigt,Chr.Schmidt,St.Leonhardt,K.Pfeiffer,O.Nelles,
Chr.Ludwig,St.Sinsel,M.Schu¨ler,M.Willimowski,M.Hafner,O.Jost,J.Schaffnit,
vi Preface
M.Schmidt,N.Mu¨ller,S.To¨pfer,J.A.Kessel,F.Kimmich,A.Schwarte,M.Vogt,
A.Engber,E.Hartmanshenn,M.Weber,R.Zimmerschied,M.Kohlhase,K.v.Pfeil,
M. Leykauf, S. Clever, S. Zahn, A. Schreiber, M. Mrosek, D. Bo¨hme, H. Sequenz,
Chr.Eck,A.Sidorow,M.Kowalczyk,F.KunkelandS.Zydek.
Withouttheircontinuousworkonnewmethodsandbuildingupandmaintaining
thecombustion-enginetestbench,measurementandcomputerequipmenttheresults
ofthisbookwouldnothavebeenpossible.Greatappreciationgoesalsotoourpre-
cisionmechanicsworkshopguidedbyA.Stark.
WealsowouldliketothanktheresearchorganizationsForschungsgemeinschaft
Verbrennungskraftmaschinen(FVV),ArbeitsgemeinschaftindustriellerForschungs-
vereinigungen(AiF),DeutscheForschungsgemeinschaft(DFG),Faudi-Stiftungwho
supportedmanyprojects.Severalresultswereobtainedincooperationprojectswith
industrial companies. Among them are AVL List GmbH, Robert Bosch GmbH,
Daimler AG, Adam Opel AG, Dr.-Ing. h.c. F. Porsche AG, GM Europe, and Volk-
swagenAG.Weappreciatethesecooperationsstronglyastheycontributedpositively
toourownresearch.
IamalsogratefulforproofreadingofsomechaptersbyS.Clever,H.Konrad,M.
Kowalczyk,F.Kunkel,H.Sequenz,H.Stuhler,S.ZahnandS.Zydek.
Finally, I would like to thank Kerstin Keller, Moritz Neeb, Lisa Hesse and es-
peciallyBrigitteHoppeforthelaboriousandprecisetextsetting,SandraSchu¨tzfor
drawingmanyfiguresandSpringerVerlagfortheexcellentcooperation.
Darmstadt,May2014 RolfIsermann
Contents
ListofSymbols .................................................... XV
1 Introduction................................................... 1
1.1 Historicaldevelopments ..................................... 1
1.1.1 Gasolineengines(SI)................................. 2
1.1.2 Dieselengines(CI)................................... 3
1.2 Currentenginedevelopments................................. 5
1.2.1 Gasolineengines..................................... 5
1.2.2 Dieselengines....................................... 7
1.2.3 Alternativedrives .................................... 10
1.3 Enginecontrolanddiagnosis................................. 10
1.3.1 Onthecontrolofgasolineengines ...................... 12
1.3.2 Onthecontrolofdieselengines ........................ 15
1.3.3 Onenginediagnosis.................................. 20
1.3.4 Developmentstepsforenginecontrol ................... 20
1.4 Control-orientedsubdivisionofcombustionengines ............. 22
1.5 Contentsofthisbook ....................................... 22
References..................................................... 26
PartI EngineModelingandIdentificationMethods
2 Ontheoreticalmodelingofmultiple-domainprocesses.............. 31
2.1 Theoreticalandexperimentalmodeling ........................ 31
2.2 Processelementsfromdifferentdomains....................... 33
2.3 Basicequations ............................................ 36
2.3.1 Balanceequations.................................... 36
2.3.2 Constitutiveequations ................................ 37
2.3.3 Phenomenologicalequations........................... 39
2.3.4 Summary........................................... 41
2.4 Time-dependentandrotation-angle-dependentmodels............ 41
viii Contents
2.5 Semi-physicalmodels....................................... 46
References..................................................... 47
3 Experimentalmodelingofengines ............................... 49
3.1 Identificationmethodsforthestationarybehaviorofnonlinear
processes ................................................. 50
3.1.1 Grid-basedlook-uptables(maps)....................... 50
3.1.2 Parameterestimationfornonlinearstaticprocesses ........ 51
3.1.3 Artificialneuralnetworksforidentification............... 53
3.2 Processidentificationmethodsfordynamicprocesses ............ 65
3.2.1 Correlationfunctions ................................. 67
3.2.2 Parameterestimationforlineardynamicprocesses(method
ofleastsquares) ..................................... 69
3.2.3 Parameterestimationfornonlineardynamicprocesses ..... 75
3.3 Localandglobalenginemodels .............................. 80
3.4 Stationaryidentificationproceduresontestbenches.............. 82
3.4.1 Measurementprocedures.............................. 82
3.4.2 Measurementoftheoperationboundaries................ 84
3.4.3 Designofexperimentswithpolynomialmodels........... 89
3.4.4 Reducedgridmeasurement............................ 91
3.4.5 Neuralnetmodelsforthestaticbehavior................. 92
3.4.6 Quasi-stationaryrampmeasurement(sweepmapping) ..... 93
3.5 Dynamicidentificationproceduresontestbenches............... 98
3.5.1 Testsignalsandnonlineardynamicmodels............... 99
3.5.2 Dynamictestplans................................... 102
3.5.3 Influenceofsensordynamics .......................... 105
3.5.4 Extractofstationaryfromdynamicmodels............... 106
3.6 Combinedonlineidentificationproceduresontestbenches........ 108
3.6.1 Onlineiterativemeasurementandmodelingprocedure ..... 110
3.6.2 Target-orienteddesignadaptationbasedonmodelquality .. 110
3.7 Modelanalysisandvalidation ................................ 111
3.7.1 Analysisofsteady-statemeasurementandmodels......... 113
3.7.2 Analysisofdynamicmeasurementsandmodels........... 116
3.8 Examplesforengineidentification ............................ 117
References..................................................... 124
PartII EngineModels
4 Generalcombustionenginemodels............................... 133
4.1 Intakesystems ............................................. 134
4.1.1 Intakesystemforgasolineengines...................... 134
4.1.2 Intakesystemfordieselengines........................ 142
4.2 Combustion ............................................... 156
4.2.1 Operatingcycles..................................... 156
Contents ix
4.2.2 Combustioncyclemodels ............................. 162
4.2.3 Combustionmodelanalysis............................ 168
4.3 Mechanicalsystem ......................................... 173
4.3.1 Meanvaluetorquemodels............................. 173
4.3.2 Dynamictorquemodels............................... 174
4.3.3 Reconstruction of torque oscillations through speed
measurements ....................................... 185
4.4 Turbochargers ............................................. 188
4.4.1 Introduction......................................... 188
4.4.2 Thermodynamicmodelsofturbochargers ................ 194
4.4.3 Fluid-dynamicmodelsofturbochargers ................. 203
4.4.4 Wastegateturbocharger ............................... 210
4.4.5 Identificationofanonlinearthermodynamicturbocharger
model.............................................. 212
4.5 Exhaustsystem ............................................ 216
4.5.1 Flowbehaviorofexhaustpipes......................... 219
4.5.2 Thermalbehaviorofexhaustpipes...................... 221
4.6 Heatexchangers ........................................... 225
4.6.1 Heatexchangertypes................................. 225
4.6.2 Heatexchangermodelsforstationarybehavior ........... 226
4.6.3 Heatexchangermodelsforthedynamicbehaviorwith
lumpedparameters................................... 230
4.6.4 Heatexchangermodelsforthedynamicbehaviorwith
distributedparameters ................................ 230
4.6.5 Dynamicmodelsoftemperaturesensors ................. 237
4.7 Coolingsystem ............................................ 238
4.7.1 Coolingflowmodels ................................. 239
4.7.2 Coolingtemperaturemodels ........................... 243
4.8 Lubricationsystem ......................................... 250
4.9 Drive-traindynamicsandsurgedamping ....................... 257
References..................................................... 266
PartIII EngineControl
5 Enginecontrolstructureandcomponents......................... 275
5.1 Enginecontrolstructuresandfunctionblocks ................... 275
5.1.1 Hardwarestructure................................... 275
5.1.2 Softwarestructure ................................... 279
5.1.3 Enginecontrolfunctionblocks......................... 281
5.2 Actuatorsanddrives ........................................ 285
5.3 Sensors ................................................... 288
5.4 Mechatroniccomponents .................................... 293
5.5 Fuelsupplyandinjectionsystem.............................. 297
5.5.1 Low-pressurefuel-supplysystem....................... 297
x Contents
5.5.2 High-pressurefuelsupplyandinjectionsystemforgasoline
engines............................................. 300
5.5.3 High-pressure common-rail fuel supply and injection
systemfordieselengines.............................. 301
5.6 Variablevalvetimingsystem ................................. 314
5.6.1 Camshaftphasing.................................... 314
5.6.2 Modelsandcontrolofahydrauliccamshaftphasingsystem. 314
References..................................................... 320
6 Engine-controlmethodsandcalibration .......................... 323
6.1 Engine-orientedelectroniccontroldesign ...................... 323
6.1.1 V-developmentmodel ................................ 323
6.1.2 Workflowforcontroldevelopmentandcalibration......... 327
6.2 Basiccontrolstructures...................................... 328
6.3 Linearfeedforwardcontrol................................... 331
6.4 Linearfeedbackcontrol ..................................... 336
6.4.1 Parameter-optimizedcontrollers(POC).................. 337
6.4.2 Internalmodelcontrol(IMC) .......................... 338
6.4.3 Cancelationcontroller(CAC) .......................... 342
6.4.4 State-spacecontrol................................... 342
6.4.5 Interconnectedcontrolsystems......................... 344
6.5 Nonlinearstaticenginefeedforwardcontrol .................... 349
6.5.1 Look-uptables ...................................... 350
6.5.2 Polynomialmodels................................... 366
6.5.3 Comparisonofnonlinearmodelstructures ............... 367
6.6 Nonlineardynamicenginecontrol............................. 368
6.6.1 Locallinearcontrol .................................. 369
6.6.2 Nonlinearcontrolforstaticnonlinearities ................ 370
6.7 Digitalcontrol ............................................. 371
6.7.1 Sampled-dataprocessing.............................. 371
6.7.2 Digitalcontrolalgorithms ............................. 374
6.8 Conventionalandmodel-basedengine-controldesignandcalibration376
6.8.1 Emissionmeasuresandlimits.......................... 376
6.8.2 Calibrationforstationaryoperatingpointsanddrivingcycles 380
6.8.3 Calibrationofthetorque-orientedenginecontrol.......... 384
6.8.4 Model-basedcalibrationprocedures..................... 387
6.9 Optimizationmethods....................................... 391
6.9.1 Optimizationcriteria ................................. 391
6.9.2 Numericaloptimizationmethods ....................... 393
6.10 Testbenches............................................... 397
6.10.1 Dynamometertypes .................................. 397
6.10.2 Test-benchcontrol ................................... 400
6.11 Model-basedcontrol-functiondevelopmentwithspecialdesign
andsimulationtools ........................................ 406
6.11.1 Model-in-the-loopsimulationandcontrolprototyping ..... 406