HCCI Engine Control and Optimization


Book Description

The lack of a direct combustion trigger makes control of combustion timing during transients especially challenging. To aid in HCCI engine control during transients, we have developed a model that can be used to derive a controller for a thermally-managed, gasoline and natural gas fueled HCCI engine. The model uses an ignition threshold derived from detailed chemical kinetic simulations of HCCI engine combustion to provide an estimate for the combustion timing. The ignition threshold is a function of both temperature and pressure. An estimate of the residual gas fraction from the previous cycle can also be obtained, which is essential information due to the strong temperature sensitivity of HCCI ignition. This model allows the synthesis of nonlinear control laws, which can be utilized for control of an HCCI engine during transients.




Control and Robustness Analysis of Homogeneous Charge Compression Ignition Using Exhaust Recompression


Book Description

There has been an enormous global research effort to alleviate the current and projected environmental consequences incurred by internal combustion (IC) engines, the dominant propulsion systems in ground vehicles. Two technologies have the potential to improve the efficiency and emissions of IC engines in the near future: variable valve actuation (VVA) and homogeneous charge compression ignition (HCCI). IC engines equipped with VVA systems are proven to show better performance by adjusting the valve lift and timing appropriately. An electro-hydraulic valve system (EHVS) is a type of VVA system that possesses full flexibility, i.e., the ability to change the valve lift and timing independently and continuously, making it an ideal rapid prototyping tool in a research environment. Unfortunately, an EHVS typically shows a significant response time delay that limits the achievable closed-loop bandwidth and, as a result, shows poor tracking performance. In this thesis, a control framework that includes system identification, feedback control design, and repetitive control design is presented. The combined control law shows excellent performance with a root-mean-square tracking error below 40 [Mu]m over a maximum valve lift of 4 mm. A stability analysis is also provided to show that the mean tracking error converges to zero asymptotically with the combined control law. HCCI, the other technology presented in this thesis, is a combustion strategy initiated by compressing a homogeneous air-fuel mixture to auto-ignition, therefore, ignition occurs at multiple points inside the cylinder without noticeable flame propagation. The result is rapid combustion with low peak in-cylinder temperature, which gives HCCI improved efficiency and reduces NOx formation. To initiate HCCI with a typical compression ratio, the sensible energy of the mixture needs to be high compared to a spark ignited (SI) strategy. One approach to achieve this, called recompression HCCI, is by closing the exhaust valve early to trap a portion of the exhaust gas in the cylinder. Unlike a SI or Diesel strategy, HCCI lacks an explicit combustion trigger, as autoignition is governed by chemical kinetics. Therefore, the thermo-chemical conditions of the air-fuel mixture need to be carefully controlled for HCCI to occur at the desired timing. Compounding this challenge in recompression HCCI is the re-utilization of the exhaust gas which creates cycle-to-cycle coupling. Furthermore, the coupling characteristics can change drastically around different operating points, making combustion timing control difficult across a wide range of conditions. In this thesis, a graphical analysis examines the in-cylinder temperature dynamics of recompression HCCI and reveals three qualitative types of temperature dynamics. With this insight, a switching linear model is formulated by combining three linear models: one for each of the three types of temperature dynamics. A switching controller that is composed of three local linear feedback controllers can then be designed based on the switching model. This switching model/control formulation is tested on an experimental HCCI testbed and shows good performance in controlling the combustion timing across a wide range. A semi-definite program is formulated to find a Lyapunov function for the switching model/control framework and shows that it is stable. As HCCI is dictated by the in-cylinder thermo-chemical conditions, there are further concerns about the robustness of HCCI, i.e., the boundedness of the thermo-chemical conditions with uncertainty existing in the ambient conditions and in the engine's own characteristics due to aging. To assess HCCI's robustness, this thesis presents a linear parameter varying (LPV) model that captures the dynamics of recompression HCCI and possesses an elegant model structure that is more amenable to analysis. Based on this model, a recursive algorithm using convex optimization is formulated to generate analytical statements about the boundedness of the in-cylinder thermo-chemical conditions. The bounds generated by the algorithm are also shown to relate well to the data from the experimental testbed.




Performance Evaluation and Optimization of Diesel Fuel Properties and Chemistry in an HCCI Engine


Book Description

The nine CRC fuels for advanced combustion engines (FACE fuels) have been evaluated in a simple, premixed HCCI engine under varying conditions of fuel rate, air-fuel ratio, and intake temperature. Engine performance was found to vary mainly as a function of combustion phasing as affected by fuel cetane and engine control variables. The data was modeled using statistical techniques involving eigenvector representation of the fuel properties and engine control variables, to define engine response and allow optimization across the fuels for best fuel efficiency. In general, the independent manipulation of intake temperature and air-fuel ratio provided some opportunity for improving combustion efficiency of a specific fuel beyond the direct effect of targeting the optimum combustion phasing of the engine (near 5 CAD ATDC). High cetane fuels suffer performance loss due to easier ignition, resulting in lower intake temperatures, which increase HC and CO emissions and result in the need for more advanced combustion phasing. The FACE fuels also varied in T90 temperature and % aromatics, independent of cetane number. T90 temperature was found to have an effect on engine performance when combined with high centane, but % aromatics did not, when evaluated independently of cetane and T90.




Computational Optimization of Internal Combustion Engines


Book Description

Computational Optimization of Internal Combustion Engines presents the state of the art of computational models and optimization methods for internal combustion engine development using multi-dimensional computational fluid dynamics (CFD) tools and genetic algorithms. Strategies to reduce computational cost and mesh dependency are discussed, as well as regression analysis methods. Several case studies are presented in a section devoted to applications, including assessments of: spark-ignition engines, dual-fuel engines, heavy duty and light duty diesel engines. Through regression analysis, optimization results are used to explain complex interactions between engine design parameters, such as nozzle design, injection timing, swirl, exhaust gas recirculation, bore size, and piston bowl shape. Computational Optimization of Internal Combustion Engines demonstrates that the current multi-dimensional CFD tools are mature enough for practical development of internal combustion engines. It is written for researchers and designers in mechanical engineering and the automotive industry.







Optimization and Optimal Control in Automotive Systems


Book Description

This book demonstrates the use of the optimization techniques that are becoming essential to meet the increasing stringency and variety of requirements for automotive systems. It shows the reader how to move away from earlier approaches, based on some degree of heuristics, to the use of more and more common systematic methods. Even systematic methods can be developed and applied in a large number of forms so the text collects contributions from across the theory, methods and real-world automotive applications of optimization. Greater fuel economy, significant reductions in permissible emissions, new drivability requirements and the generally increasing complexity of automotive systems are among the criteria that the contributing authors set themselves to meet. In many cases multiple and often conflicting requirements give rise to multi-objective constrained optimization problems which are also considered. Some of these problems fall into the domain of the traditional multi-disciplinary optimization applied to system, sub-system or component design parameters and is performed based on system models; others require applications of optimization directly to experimental systems to determine either optimal calibration or the optimal control trajectory/control law. Optimization and Optimal Control in Automotive Systems reflects the state-of-the-art in and promotes a comprehensive approach to optimization in automotive systems by addressing its different facets, by discussing basic methods and showing practical approaches and specific applications of optimization to design and control problems for automotive systems. The book will be of interest both to academic researchers, either studying optimization or who have links with the automotive industry and to industrially-based engineers and automotive designers.




Flex Fuel Optimized SI and HCCI Engine


Book Description

The central objective of the proposed work is to demonstrate an HCCI (homogeneous charge compression ignition) capable SI (spark ignited) engine that is capable of fast and smooth mode transition between SI and HCCI combustion modes. The model-based control technique was used to develop and validate the proposed control strategy for the fast and smooth combustion mode transition based upon the developed control-oriented engine; and an HCCI capable SI engine was designed and constructed using production ready two-step valve-train with electrical variable valve timing actuating system. Finally, smooth combustion mode transition was demonstrated on a metal engine within eight engine cycles. The Chrysler turbocharged 2.0L I4 direct injection engine was selected as the base engine for the project and the engine was modified to fit the two-step valve with electrical variable valve timing actuating system. To develop the model-based control strategy for stable HCCI combustion and smooth combustion mode transition between SI and HCCI combustion, a control-oriented real-time engine model was developed and implemented into the MSU HIL (hardware-in-the-loop) simulation environment. The developed model was used to study the engine actuating system requirement for the smooth and fast combustion mode transition and to develop the proposed mode transition control strategy. Finally, a single cylinder optical engine was designed and fabricated for studying the HCCI combustion characteristics. Optical engine combustion tests were conducted in both SI and HCCI combustion modes and the test results were used to calibrate the developed control-oriented engine model. Intensive GT-Power simulations were conducted to determine the optimal valve lift (high and low) and the cam phasing range. Delphi was selected to be the supplier for the two-step valve-train and Denso to be the electrical variable valve timing system supplier. A test bench was constructed to develop control strategies for the electrical variable valve timing (VVT) actuating system and satisfactory electrical VVT responses were obtained. Target engine control system was designed and fabricated at MSU for both single-cylinder optical and multi-cylinder metal engines. Finally, the developed control-oriented engine model was successfully implemented into the HIL simulation environment. The Chrysler 2.0L I4 DI engine was modified to fit the two-step vale with electrical variable valve timing actuating system. A used prototype engine was used as the base engine and the cylinder head was modified for the two-step valve with electrical VVT actuating system. Engine validation tests indicated that cylinder #3 has very high blow-by and it cannot be reduced with new pistons and rings. Due to the time constraint, it was decided to convert the four-cylinder engine into a single cylinder engine by blocking both intake and exhaust ports of the unused cylinders. The model-based combustion mode transition control algorithm was developed in the MSU HIL simulation environment and the Simulink based control strategy was implemented into the target engine controller. With both single-cylinder metal engine and control strategy ready, stable HCCI combustion was achived with COV of 2.1% Motoring tests were conducted to validate the actuator transient operations including valve lift, electrical variable valve timing, electronic throttle, multiple spark and injection controls. After the actuator operations were confirmed, 15-cycle smooth combustion mode transition from SI to HCCI combustion was achieved; and fast 8-cycle smooth combustion mode transition followed. With a fast electrical variable valve timing actuator, the number of engine cycles required for mode transition can be reduced down to five. It was also found that the combustion mode transition is sensitive to the charge air and engine coolant temperatures and regulating the corresponding temperatures to the target levels during the combustion mode transition is the key for a smooth combustion mode transition. As a summary, the proposed combustion mode transition strategy using the hybrid combustion mode that starts with the SI combustion and ends with the HCCI combustion was experimentally validated on a metal engine. The proposed model-based control approach made it possible to complete the SI-HCCI combustion mode transition within eight engine cycles utilizing the well controlled hybrid combustion mode. Without intensive control-oriented engine modeling and HIL simulation study of using the hybrid combustion mode during the mode transition, it would be impossible to validate the proposed combustion mode transition strategy in a very short period.




HCCI Combustion


Book Description

Homogeneous charge compression ignition (HCCI) is a new combustion technology that may develop as an alternative to diesel engines with high efficiency and low NOx and particulate matter emissions. This paper describes the HCCI research activities being currently pursued at Lawrence Livermore National Laboratory and at the University of California Berkeley. Current activities include analysis as well as experimental work. On analysis, we have developed two powerful tools: a single zone model and a multi-zone model. The single zone model has proven very successful in predicting start of combustion and providing reasonable estimates for peak cylinder pressure, indicated efficiency and NOX emissions. This model is being applied to develop detailed engine performance maps and control strategies, and to analyze the problem of engine startability. The multi-zone model is capable of very accurate predictions of the combustion process, including HC and CO emissions. The multi-zone model h as applicability to the optimization of combustion chamber geometry and operating conditions to achieve controlled combustion at high efficiency and low emissions. On experimental work, we have done a thorough evaluation of operating conditions in a 4-cylinder Volkswagen TDI engine. The engine has been operated over a wide range of conditions by adjusting the intake temperature and the fuel flow rate. Satisfactory operation has been obtained over a wide range of operating conditions. Cylinder-to-cylinder variations play an important role in limiting maximum power, and should be controlled to achieve satisfactory performance.




Advanced Start of Combustion Sensor Phases I and II-A


Book Description

Homogeneous Compressed Charge Ignition (HCCI) has elevated the need for Start of Combustion (SOC) sensors. HCCI engines have been the exciting focus of engine research recently, primarily because HCCI offers higher thermal efficiency than the conventional Spark Ignition (SI) engines and significantly lower NOx and soot emissions than conventional Compression Ignition (CI) engines, and could be fuel neutral. HCCI has the potential to unify all the internal combustion engine technology to achieve the high-efficiency, low-emission goal. However, these advantages do not come easy. It is well known that the problems encountered with HCCI combustion center on the difficulty of controlling the Start of Combustion. TIAX has an SOC sensor under development which has shown promise. In previous work, including a DOE-sponsored SBIR project, TIAX has developed an accelerometer-based method which was able to determine SOC within a few degrees crank angle for a range of operating conditions. A signal processing protocol allows reconstruction of the combustion pressure event signal imbedded in the background engine vibration recorded by the accelerometer. From this reconstructed pressure trace, an algorithm locates the SOC. This SOC sensor approach is nonintrusive, rugged, and is particularly robust when the pressure event is strong relative to background engine vibration (at medium to high engine load). Phase I of this project refined the previously developed technology with an engine-generic and robust algorithm. The objective of the Phase I research was to answer two fundamental questions: Can the accelerometer-based SOC sensor provide adequate SOC event capture to control an HCCI engine in a feedback loop? And, will the sensor system meet cost, durability, and software efficiency (speed) targets? Based upon the results, the answer to both questions was 'YES'. The objective of Phase II-A was to complete the parameter optimization of the SOC sensor prototype in order to reach a juncture where plans can be and are discussed with an industry partner for how best to perform a more detailed implementation of the TIAX SOC technology on an HCCI engine system. This occurred, as evidenced the number of potential commercialization partners shown in Table 4. Potential Commercialization Partners Contacted (up to date as of January 31, 2010). During the two phases, a robust, engine-generic algorithm was developed that met the desired targets and was shown to work extremely well for HCCI engine operation.




Artificial Intelligence and Data Driven Optimization of Internal Combustion Engines


Book Description

Artificial Intelligence and Data Driven Optimization of Internal Combustion Engines summarizes recent developments in Artificial Intelligence (AI)/Machine Learning (ML) and data driven optimization and calibration techniques for internal combustion engines. The book covers AI/ML and data driven methods to optimize fuel formulations and engine combustion systems, predict cycle to cycle variations, and optimize after-treatment systems and experimental engine calibration. It contains all the details of the latest optimization techniques along with their application to ICE, making it ideal for automotive engineers, mechanical engineers, OEMs and R&D centers involved in engine design. - Provides AI/ML and data driven optimization techniques in combination with Computational Fluid Dynamics (CFD) to optimize engine combustion systems - Features a comprehensive overview of how AI/ML techniques are used in conjunction with simulations and experiments - Discusses data driven optimization techniques for fuel formulations and vehicle control calibration