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2005 American Control Conference ThC14.

1
June 8-10, 2005. Portland, OR, USA

Modeling and Control of Automotive Powertrain Systems: A


Tutorial
Jing Sun, Ilya Kolmanovsky, Jeffrey A. Cook, and Julia H. Buckland

Abstract— This tutorial presents an overview of key issues in III, IV, V, and VI will cover modeling and control for
electronic control of internal combustion engines for automo- port fuel injection spark ignition, gasoline direct injection
tive passenger vehicles, and showcases the control oriented stratified charge, diesel, and turbocharged automotive en-
engine and aftertreatment system models that are useful
in addressing these issues. Beginning with a discussion on gines, respectively. In each section, fundamental system
electronic engine control systems and standard sensors and models will be presented, followed by a discussion of the
actuators, key engine control subsystems and their associated main control issues. Examples of control problems and their
functionalities will be outlined. Models for gasoline and diesel associated solutions will be provided in each section to
engines, lean aftertreatment systems, and turbochargers will demonstrate the multi-faceted nature of automotive engine
be described in more detail. Several representative control
problems will be elaborated through examples. control. The paper will conclude with a short discussion
on emerging powertrain trends and their implications on
I. I NTRODUCTION control system development.
Since its inception in the late 1970s, electronic engine II. E LECTRONIC E NGINE C ONTROL OVERVIEW
control has played a critical role in reducing emissions, Modern electronic engine control involves many func-
improving fuel economy and enhancing performance and tions and leverages multiple sensors and actuators. The
driveability of passenger vehicles. The introduction of new functions of an ECU (engine control unit) range from
hardware innovations and advanced sensors and actuators, delivering the driver demanded torque to monitoring the
coupled with increasingly stringent government regulations emission control systems on board the vehicle, and from
and higher customer expectations, presents serious chal- warming up the catalyst to purging the vapor from the fuel
lenges as well as unprecedented opportunities for power- tank. Due to the introduction of new sensors and actuators,
train control. To satisfy demanding and often competing along with more aggressive regulation, the complexity of
requirements, powertrain control engineers are relying to a engine control functions has dramatically increased.
greater extent on advanced control methodologies, effective
design tools and streamlined processes. The pressure for ECU

reducing product cost and development time has also driven Camshaft
Position Ignition
HEGO
HEGO
control system development processes towards those which Manifold
Pressure
EGR

favor the systematic application of model-based design and Throttle

analysis tools and methodologies.


This tutorial is developed to provide an overview of Mass Air Flow Fuel

fundamental problems in powertrain control, as well as Cylinder Head


Coolant Temperature
Temperature

associated design tools. The goal is to expose powertrain


Crankshaft
control issues to the broader control community and to Position

stimulate interest and activity to address pressing issues and


to develop effective tools. Fundamental powertrain models
will be presented, representative control issues will be
Fig. 1. Electronic engine control system diagram
illustrated, and existing design tools and methodologies will
be highlighted. A recent survey paper [1] provides a more Figure 1 illustrates the key elements of a typical system,
comprehensive summary of powertrain control problems including sensors and actuators. Typical sensors include
and results, including those for alternative powertrain sys- crankshaft and camshaft position sensors; intake mass air
tems such as the fuel cell and the hybrid electric powertrain. flow; manifold pressure; exhaust gas oxygen sensors, both
This tutorial paper is organized as follows. After a brief pre- and post catalyst; coolant and cylinder head tem-
overview of engine control features in Section II, Sections peratures. Conventional actuators include throttle control,
exhaust gas recirculation, ignition and fuel injection control.
Jing Sun is with the Naval Architecture and Marine Engineering
Department Department, The University of Michigan, Ann Arbor, MI Advanced technology engines may incorporate valve timing
48109-2124; jingsun@umich.edu control (intake valves, exhaust valves or both), turbocharger
Ilya Kolmanovsky, Jeffrey A. Cook, and Julia H. Buckland wastegate control, cylinder deactivation control, fuel pres-
are with the Powertrain Control Research and Advanced
Engineering, Ford Motor Company, Dearborn, MI 49121; sure control, swirl control, intake manifold runner control
ikolmano,jcook2,jbucklan@ford.com and fuel pressure control. Advanced sensing technologies
0-7803-9098-9/05/$25.00 ©2005 AACC 3271
include in-cylinder pressure or ionization measurements to the mean value of the rate at which the charge is inducted
optimize combustion. into the cylinders. The flows through the throttle body and
EGR valve are represented by a standard orifice equation:
III. P ORT F UEL I NJECTION E NGINE C ONTROL
For conventional port fuel injection (PFI) engines, three    
Ath Pi Pi Aegr Pe Pi
fundamental control tasks affect emissions, performance, Wa = √ φ , Wegr = √ φ , (2)
and fuel economy: (1) air-fuel ratio (A/F) control, that Ta Pa Te Pe
is, providing the correct ratio of air and fuel for efficient where Ath , Aegr are the effective flow areas for the throttle
combustion and for optimal aftertreatment conditioning; (2) body and EGR valve respectively; Pi , Pe , and Pa are intake
ignition control, which refers to firing the appropriate spark manifold, exhaust manifold and ambient pressures; and Ta
plug at the precise instant required; and (3) control of and Te are the ambient and exhaust temperatures. The
exhaust gas recirculation (EGR) to reduce the formation of function φ represents the effects of the pressure ratio on
the oxides of nitrogen (N Ox ). Other functions, such as the the flow across the valve:
idle speed control, knock control and on-board diagnosis
(OBD), are also essential. These control functions have ⎧   2(γ−1)
γ+1   γ−1
γ

⎨ γ 12 2 2
been greatly augmented, in terms of both performance γ+1 if x ≤ γ+1
φ(x) =
12   γ−1
γ ,
and complexity, with the introduction of new actuators, ⎪
⎩ x γ 2γ 1 − x γ−1
1
2
such as electronic throttle, variable cam timing, variable γ−1
γ if x > γ+1
displacement, etc. In this section, we will first describe a (3)
control oriented engine model which has proven very useful where γ is the ratio of specific heats, which takes different
for control design and performance analysis, followed by values for Wa and Wegr .
a discussion of some control challenges associated with The amount of charge inducted into the cylinders, Wcyl ,
PFI engines. Due to the space limitations, we choose to is a function of engine speed, intake manifold pressure and,
elaborate on two representative control features in this possibly, temperature, where intake manifold temperature
section: A/F control and torque control for engines with depends on mass air flow and EGR. Wcyl is generally
variable cam timing. represented as a static regression equation based on steady-
state mapping data for a particular engine. One commonly
A. Control Oriented Gasoline Engine Models used representation takes the form of
Control oriented engine models refer to the linear and
nonlinear low frequency phenomenological representations Wcyl = (α(N )Pi + β(N ))f (Ti ), (4)
that capture the essential system dynamics required for which is affine in Pi , where α, β are low order polyno-
control development, along with key static behavior such as mials of N , and f (Ti ) is used to compensate for the air
emissions and volumetric efficiency that may be obtained density variation due to temperature variation in the intake
experimentally from steady state mapping on an engine dy- manifold.
namometer. Nonlinear engine models were developed from Engine rotational dynamics follow the equation:
the late 1970s through the 1980s, as reported in many papers
π
such as [2], [3]. The four-stroke engine cycle naturally Je Ṅ = Tb − Tl , (5)
divides the physical process into four events comprising 30
intake, compression, power generation and exhaust. Models where Tb , Tl are the engine brake and load torques in
exploiting the inherently discrete nature of the system by N m, respectively, and the factor π/30 is due to the unit
crank angle based sampling are described, for example, in conversion of engine speed (from rpm to rad/sec). The
[4], [5], [6]. engine brake torque, Tb , is the net torque available on the
The mathematical representation of the conventional, crankshaft to drive the rest of the powertrain, and can be
naturally aspirated engine includes the following elements: decomposed into:
(1) the throttle body, (2) the intake manifold, (3) torque
generation and (4) engine rotational dynamics. The model Tb = Ti − Tf , (6)
may also include the EGR system, exhaust gas temperature
where Ti is the indicated torque, a measure of the total
and pressure dynamics, and feedgas emissions. Figure 2
torque delivered to the piston by burning the fuel and Tf is
shows the block diagram of a phenomenological engine
the total friction which the engine has to overcome when
model.
delivering the torque to the crankshaft. The friction torque
The intake manifold dynamics are derived from the ideal
includes the pumping losses during the intake and exhaust
gas law:
strokes plus mechanical friction and may be regressed as
Ṗi = Ki (Wa + Wegr − Wcyl ), (1)
a function of speed and intake manifold pressure. Brake
where Ki depends on the intake manifold volume and torque is generally represented as a regressed function
temperature; Wa , Wegr are the mass flow rates through the of Wcyl , A/F , N , and ignition timing, based on engine
throttle body and the EGR valve, respectively; and Wcyl is mapping data.
3272
HC
Emissions CO
Feedgas NOx
Generation Temperature

. Injection Timing N
M
Spark
. Fuel Path
mf Delay
Engine Load
ABV DC Pumping
- -
θ P EGR Air Path Engine
f (u,P) . Σ Integrator
g (P,N)
Torque Σ Inertia Speed
m a+ + AFR Delay +
P
Throttle Body Manifold
N N N
and ABV . Dynamics
me

Fig. 2. Block diagram of an engine model

100
the baseline for charge estimation, when intake manifold
90
HC, CO, NO CONVERSION EFFICIENCIES (%)

pressure is measured. The manifold dynamics and the


80
NO x influence of EGR also have to be incorporated. However,
70
HC
it is often insufficient to rely on this model for accurate
60

CO
charge estimation and precise A/F control, as volumetric
50
efficiency and engine breathing characteristics can change
40
with operating conditions and component aging. The ro-
30 bustness of the charge estimation algorithm is significantly
20 enhanced with the incorporation of the mass air flow meter,
10 typically a hot wire anemometer used to measure the
0
14.2 14.4 14.6 14.8
inlet air flow rate. This air meter, while introducing direct
MEAN A/F feedback for charge estimation and significantly simplifying
the estimation algorithm, imposes other issues due to its
Fig. 3. TWC conversion efficiency versus A/F
relatively slow dynamics.
A low frequency model of the induction process is
described in [7]. This model has been used to develop
The engine model described by equations (1)-(6) forms
a compensation scheme for the relatively slow dynamics
the basis of control oriented engine models. Many variations
of the air meter. In [8], a dynamic model incorporating
and modifications have been developed to account for
intake runner acoustic and inertial effects is developed that
various hardware configurations and operating conditions
is capable of describing the induction process in individual
and to serve specific design purposes. These models have
cylinders. Other performance enhancing algorithms devel-
been used successfully for design and analysis of many
oped for diesel [9] or gasoline direct injection engines [10]
control subsystems, including those to be discussed in the
are also applicable to PFI engines with minor modifications.
following subsections.
2) Transient fuel compensation: Transient fuel charac-
B. A/F control for PFI engines teristics for a PFI engine were first reported by Fozo and
Figure 3 underscores the criticality of A/F control for Aquino in [11]. Depending on the operating condition, part
PFI engines. It illustrates that high simultaneous conversion of the fuel injected at the port may not be inducted into
efficiencies for the three regulated species (HC, CO, N Ox ) the cylinder to participate in the immediate combustion
occur only in a narrow band around stoichiometry for event. Instead, a portion may stay on the wall of the intake
a three way catalyst (TWC), which is a standard emis- runner and on the intake valves as fuel puddles, to be
sion control device for PFI engines. A/F control of the subsequently inducted into the cylinder for later combustion
conventional PFI engine encompasses three main aspects: events. This so-called wall-wetting phenomenon acts as
accurate estimation of air charge, compensation for fuel a disturbance to the A/F control system. An empirical
puddling dynamics in the intake manifold runners and on model has been developed [11] to capture the fuel puddling
the intake valves, and closed-loop regulation of A/F for dynamics, and this model has been exploited for transient
high catalyst performance. Each of these three problems is fuel compensation by many authors.
briefly discussed as follows. In [12], a method of adaptive transient compensation
1) Air charge estimation: This refers to the task of for wall-wetting dynamics is described that accounts for
estimating the amount of fresh air that is inducted into the varying fuel properties. The technique requires only a
cylinder for each combustion cycle. This charge estimation heated exhaust gas oxygen (HEGO) sensor1 , which remains
forms the basis for fuel scheduling and A/F control. The 1 A HEGO is a switching sensor that indicates if the mixture is lean or
model for Wcyl given by equation (4) is often used as rich of stoichiometry, but not by how much.

3273
A/F A/F
the prevalent feedback sensor for closed-loop A/F control. Engine TWC
The approach described in [12] uses the feedback signal to
evaluate changes in A/F during driver induced transients Noise + Bias + Noise
in closed loop, and stores corrections to the compensation
algorithm indexed by engine temperature for use in the next A/F A/F
Sensor Sensor
transient or during open-loop cold start operation.
3) Closed-loop A/F control: The precipitous falloff of Fore Aft
TWC efficiency away from stoichiometry (see Figure 3) ne- + Controller
Controller
cessitates tight regulation of A/F around the stoichiometric
value. Closed-loop A/F control, now a standard feature for Fig. 4. Dual UEGO Fore-Aft Controller
automotive engines, was made possible by the invention
of the HEGO sensor. Due to the switching nature of the
sensor, most of the standard control design methodologies to simultaneously maximize the conversion efficiencies of
based on linear system theory cannot be applied directly. HC, CO and N Ox , and to obtain steady-state A/F con-
Consequently, many of the HEGO based A/F feedback trol that is robust with respect to disturbances. A series
control strategies are designed based on heuristic rules and controller topology is adopted as illustrated in Figure 4.
physical insights. The objective of the first block, the Fore Controller, is
Another issue that complicates the HEGO based A/F to respond relatively quickly to A/F disturbances on the
control system is the shift of the sensor switch point. In basis of measured feedgas oxygen level. The objective
[13], it was shown that cylinder-to-cylinder A/F differences of the second block, the Aft Controller, is to adjust the
result in a closed-loop lean shift in controlled A/F due setpoint of the fore controller, on the basis of both A/F
to preferential diffusion of H2 and CO across the HEGO measurements, so that the TWC achieves simultaneously
sensor upstream of the catalyst. Typically, this effect is mit- high conversion efficiencies for HC and N Ox . The aft
igated by biasing the A/F setpoint slightly rich, at a cost in controller is composed of a bias estimator and a proportional
fuel economy and conversion efficiency of the other exhaust term. The bias estimator uses the upstream and downstream
constituents. An alternative solution is to address the root A/F measurements to correct the error in the upstream
cause by eliminating or minimizing the cylinder-to-cylinder oxygen sensor. The proportional controller feeds back the
A/F variations. In [14], an approach to achieving uniform post-catalyst UEGO sensor measurement and establishes the
cylinder-to-cylinder A/F control for a 4-cylinder engine in reference for the fore controller.
the presence of injector mismatch and unbalanced air flow
due to engine geometry is presented. The method recognizes C. Torque Control for PFI engines with Variable Cam
that the individual cylinder representation of the fueling Timing
process describes a periodically time varying system due to Variable cam timing provides improved performance and
the unequal distribution of A/F from cylinder to cylinder. reduced feedgas emissions using an electro-hydraulic mech-
The key features of the controller are the construction of a anism to rotate the camshaft relative to the crankshaft and
time-invariant representation of the process and event-based retard cam timing with respect to the intake and exhaust
sampling and feedback. In [15], the method was extended strokes of the engine. In this manner, the amount of residual
to an 8-cylinder engine in which exhaust manifold mixing gas trapped in the cylinder at the end of the exhaust stroke
dynamics were significant. is controlled, suppressing N Ox formation [21]. In addition,
A significant advancement in A/F feedback control VCT allows the engine designer to optimize cam timing
capability is the introduction of the Universal Exhaust Gas over a wide range of engine operating conditions, providing
Oxygen (UEGO) sensor in production vehicles. Unlike the both good idle quality (minimal overlap between the intake
conventional HEGO sensor, which simply switches about and exhaust events) and improved wide-open throttle per-
stoichiometry, the UEGO is a linear device that permits an formance (maximum inducted charge). Properly controlled,
actual measurement of A/F . The use of UEGO allows ap- the variable cam can be used to operate the engine at higher
plication of many advanced control design methodologies. intake manifold pressures, reducing pumping losses at part
Unique challenges associated with A/F control, such as the throttle conditions to provide a fuel economy improvement.
inherent transport delays and robustness over the lifetime of Uncompensated, however, VCT acts as a disturbance to the
the vehicle, have motivated many research efforts and led breathing process, compromising drivability and substan-
to fruitful results (see [16] and the references therein). tially reducing its effectiveness in emission control.
Another issue that is closely related to A/F control is Four versions of VCT are available: phasing only the
catalyst conditioning and monitoring. Control and diag- intake cam (intake only), phasing only the exhaust cam
nosis of catalysts using UEGO sensors are described by (exhaust only), phasing the intake and exhaust cams equally
[17], [18]. In [19], Fiengo and co-authors use the catalyst (dual equal), and phasing the two camshafts independently
model described in [20], along with pre- and post-catalyst (dual independent). A low order nonlinear model of a dual-
UEGO sensors, to develop a controller with two objectives: equal VCT engine is derived in [22]. The model forms the
3274
Shaft torque (Nm)
Conventional Engine (base timing)
basis for active compensation of VCT induced cylinder air
60
charge variation employing electronic throttle control (ETC) 40
[23]. The balance of this section will review the coordinated 20
0
ETC/VCT control for torque compensation.
20
The basic equations of the PFI engine model can be 0 0.5 1 1.5 2 2.5

Shaft torque (Nm)


VCT Engine - controller off
modified to incorporate the effects of the cam actuator on 60
engine breathing. For the VCT engine, the mass air flow 40
rate into the cylinders is represented as a function of cam 20
0
phasing, ζcam , in addition to manifold pressure, Pi , and 20
0 0.5 1 1.5 2 2.5
engine speed, N :

Shaft torque (Nm)


VCT Engine - controller on
Wcyl = (α1 (N, ζcam )Pi + α2 (N, ζcam ))f (Ti ), (7) 60
40
where α1 and α2 are low-order polynomials in N and ζcam . 20
0
Typically, the cam timing reference, ζref , is scheduled
0 0.5 1 1.5 2 2.5
based on engine speed and driver demanded throttle posi- Time (s)
tion, θ0 . The cam schedule reaches maximal cam retards
at part throttle to provide maximal internal EGR; close to Fig. 5. Torque response of the VCT engine to cam phasing steps with
idle and at wide open throttle, the cam phasing is at zero or and without compensation
slightly advanced. Scheduling cam with throttle causes it to
change when the pedal is depressed or released. It is this
torque variation caused by the cam transient that results in
undesirable engine response and driveability problems.
engine can, depending on speed and load, operate in one
To minimize this torque variation, the throttle angle is
of three combustion modes: homogeneous stoichiometric
comprised of the throttle position due to the driver’s request
(A/F ≈ 14.64), homogeneous lean (A/F between sto-
(θ0 ) and an additive term due to the compensation (θ∗ ),
ichiometry and about 20) or stratified (A/F ≥ 20). A
θ = θ0 + θ∗ . homogeneous A/F mixture is achieved by injecting fuel
early in the intake stroke, while stratification is achieved
The throttle flow equation is represented as functions of by injecting late, during the compression stroke [24]. The
pressure and flow area geometry, as in the conventional torque and emission characteristics corresponding to homo-
engine model given by (2)-(3). geneous and stratified operation are so distinct that different
A feedforward compensator is designed to recover the control strategies are required to optimize performance in
drivability of the conventional engine by eliminating the the two regimes [25]. Note also that, in addition to the usual
effect of the cam transients on cylinder mass air flow. control variables such as throttle position, ignition timing,
The algorithm employs θ∗ as a virtual actuator, according exhaust gas recirculation (EGR) and fueling rate, the DISC
to [23]. That is, a control law is developed for θ∗ such engine requires new inputs including injection timing, fuel
that the rate of change of Wcyl coincides with that of rail pressure and swirl control at a minimum [26]. Finally,
the conventional engine. Specifically, compensation θ∗ is the ultra-lean A/F operation of the direct injection engine
evaluated: mandates the use of a lean N Ox trap (LNT) to manage
∂α 
1
P i + ∂α2
φ(P̃ ) emission of the oxides of nitrogen. The LNT, as a N Ox
θ∗ = g −1
∂ζ ∂ζ i
cam cam
ζ̇cam + g(θ0 ) − θ0 , storage device, needs to be purged periodically to regenerate
Ki φ(Pi )α1 φ(Pi )
(8) its storage capacity.
where P̃i is a fictitious reference manifold pressure which These special features of DISC engine operation have
should be equal to the manifold pressure of the conventional important control implications and lead to several unique
engine driven with the throttle angle, θ0 , and engine speed, control problems, such as mode transition between strat-
N . This reference manifold pressure is generated by ified and homogeneous operations, aftertreatment system
  management, etc. In this section, we will concentrate on
P̃˙ i = Ki φ(P̃i )g(θ0 ) − α1 (N, 0)P̃i − α2 (N, 0) . (9) the aftertreatment system for the DISC powertrain. We will
first present a lean aftertreatment model, then delineate the
Figure 5 shows the reduction of the torque fluctuation pertinent control issues.
during cam transients achieved by the compensation.
IV. G ASOLINE D IRECT I NJECTION E NGINE C ONTROL A. A Phenomenological LNT Model
A direct injection stratified charge (DISC) engine, like The typical aftertreatment system for a lean-burn engine
a diesel, injects fuel directly into the combustion chamber. with a commonly used sensor configuration is shown in
It is different from a conventional PFI engine discussed in Figure 6. It consists of a conventional three-way catalytic
Section III in several aspects. Most importantly, the DISC converter (usually closely coupled to the engine for opti-
3275
UEGO HEGO HEGO
efficiency is described by the function
Exhaust
TWC LNT
flow e−αx − e−α
Ttemperature (13) ηs =
sensor
1 − e−α
where α is a parameter that incorporates the effects of the
Fig. 6. Aftertreatment system schematic: components and sensor locations trap temperature on storage efficiency.

T =353.9 °C data
mal cold start performance) and an underbody LNT, with m
model

oxygen and temperature sensors in various locations. 1

The LNT is a special catalyst used to complement the


TWC functions and is critical in meeting the N Ox standards 0.8

storage capacity [g/liter]


for lean burn gasoline engines. The key chemical reactions
involved in LNT operation can be summarized as follows.: 0.6

• N Ox storage phase: under lean conditions, N O is 0.4

oxidized in the gas phase and the resulting N O2 is


then adsorbed on storage sites as barium nitrate. As 0.2

the N Ox stored in the LNT increases, the storage effi- Ts=280.3 °C

ciency drops and the trap must be purged to regenerate 0


100 150 200 250 300 350 400 450 500 550 600
trap temperature [ °C]
its capacity.
• LNT purge phase: under rich conditions, the barium
1
nitrate becomes thermodynamically unstable and re- 237
306
°C
°C
0.9 °C
leases N O2 to form BaO. BaO then combines with 341
391 °C
431 °C
CO2 in the exhaust to form BaCO3 , thereby regener- 0.8
460
476
°C
°C

ating the storage sites. The released N Ox is converted 0.7 513 °C

to N2 over the precious metal sites by reductants (CO


storage efficiency

0.6

or H2 ) in the engine exhaust stream. 0.5

A control oriented representation of the LNT exhaust 0.4

aftertreatment system was first developed in [27], and later 0.3

expanded by the authors of [28]. The model developed in 0.2

[28] is briefly reviewed here. 0.1

During the storage phase, let x be the fraction of occupied 0


0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
storage sites which represents the loading status of the LNT. x

We define the instantaneous efficiency, ηs , as


Fig. 7. LNT storage capacity and efficiency as functions of trap loading
ṁN Ox,in − ṁN Ox,tp
ηs = (10)
ṁN Ox,in
During the purge phase, the stored N Ox is released from
then the storage dynamics can be described as the storage sites. Assuming a release rate of ṁN Ox ,r , we
have
1 dCLN T 1 dx 1 dCLN T ṁN Ox,r
ẋ = − ·x+ · ηs · ṁN Ox,in . (11) =− ·x− . (14)
CLN T dt CLN T dt CLN T dt CLN T
The storage capacity CLN T for a typical trap is a function The release rate, ṁN Ox,r , depends on the trap state x, as
of the trap temperature, as shown in Figure 7. It can be well as the trap capacity, among other variables. It is shown
modeled as a Gaussian function that has center Tm [◦ C], in [28] that introduction of the normalized release rate
span Ts [◦ C], and peak capacity Cm [g]:  ṁN Ox,r
  kr =
2  CLN T
T − Tm
CLN T = Cm · exp − . (12) results in a release model that is independent of CLN T .
Ts
The normalized release rate is identified in [28] with the
following function:
For a given trap, parameters Tm , Ts , Cm can be identified
from experimental data. 1 − eβx
kr = · (1 − xoxy ) · fr (λin , Wa , T ), (15)
1 − ex
The instantaneous storage efficiency ηs , on the other where xoxy is the oxygen storage level in the LNT, λin is
hand, changes as a function of the LNT state x and the the relative A/F at the LNT entrance, Wa is the mass air
trap temperature, as shown in Figure 7. In [28], the storage flow rate, and β is a parameter depending on the catalyst
3276
EGR Valve Intake Manifold
physical properties, such as formulation, geometry, etc. The
second term on the right hand-side (1 − xoxy ) captures the EGR Cooler

interactions between N Ox and oxygen storage mechanisms. Intercooler

For LNTs with small oxygen storage capacity, xoxy can be


neglected. The function fr (λin , Wa , T ) takes into account
the effect of A/F at the LNT entrance, space velocity and
temperature.
The last step in trap regeneration is to convert the released Exhaust Manifold

N Ox into non-pollutant species. The efficiency of this


process, defined as: Compressor Variable
Geometry

ṁN Ox,r − ṁN Ox,tp


Turbine

ηc = (16)
ṁN Ox,r Fig. 8. Schematics of a modern variable geometry turbocharged diesel
engine with exhaust gas recirculation.
can be represented by an empirical function of x, A/F, Wa
and exhaust temperature.
By using the indicator function I{A} (I{A} = 1, if A is the parameters of the LNT model [27] can be identified
satisfied; I{A} = 0, otherwise) the dynamics of the LNT on-line using a conventional switching exhaust gas oxygen
can be described by: sensor. For the model structure and uncertainty representa-
dx 1 dCLN T ṁN Ox,in tions used in [30], a nonlinear parametric model results. An
= − · x + I{λin >1} ηs
dt CLN T dt CLN T on-line recursive algorithm is developed to improve the ro-
ṁN Ox,r bustness of the model-based feedforward control and to ease
−I{λin ≤1} (17) the computational requirement of parameter identification
CLN T
for the nonlinear parametric model. Persistent excitation, a
for both storage and purge operation. The N Ox flow rate
condition normally required for parameter convergence, is
leaving the LNT, ṁN Ox,tp , is
established in [30] by changing purge thresholds.
ṁN Ox,tp = I{λin >1} (1 − ηs )ṁN Ox,in In an effort to relax the computational intensity associated
+I{λin ≤1} (1 − ηc )ṁN Ox,r (18) with the nonlinear parametric model used in [30], a new
purge model [28] is exploited by the authors of [31] to
B. Aftertreatment Control and Adaptation develop an adaptive control strategy that is more feasible
The requirements for DISC aftertreatment control include for real-time implementation in a computationally resource-
(1) periodically running the engine rich of stoichiometry constrained environment. By incorporating the physical
to regenerate LNT trap capacity, (2) dealing with the properties of the system and properly choosing the structure
sulphur poisoning problem to maintain LNT efficiency, and for the LNT model and parameterization for the uncer-
(3) assuring that the LNT operates within its temperature tainties, a linear parametric model is developed in [31]
window to maintain high efficiency and to avoid thermal for on-line adaptation. Results show that, when integrated
degradation. with model-based LNT control, the adaptation improves the
To achieve the best tradeoff among competing require- aftertreatment control robustness by maintaining the desired
ments such as fuel economy, emissions and driveability, tradeoffs between fuel economy and emissions.
the LNT control strategy must manage the purge starting
time and duration, and purge conditions (such as A/F ), V. D IESEL E NGINE C ONTROL
and at the same time provide a bumpless transition between Diesel engines offer superior fuel economy compared to
the lean and purge modes. The main challenges of LNT their conventional gasoline counterparts. Their drawbacks
control stem from the lack of on-board measurements of are associated with higher cost and complexity of the
key variables and uncertainties in the characteristics of aftertreatment system. Despite earlier skepticism, diesel
key components. The N Ox storage capacity of the LNT, engines have achieved a remarkable passenger car market
one of the most critical parameters for control design and penetration in Europe thanks to technology improvements.
calibration, varies dynamically. In particular, the trap is The consensus is that their penetration in North America
susceptible to sulfur poisoning [29] and the capacity of will grow too, albeit at a slower pace due to differences in
the trap is reduced as sulfates accumulate. In addition, fuel cost and taxation.
ambient conditions and component-to-component variations Figure 8 shows a schematic of a modern diesel en-
can affect the LNT operation and lead to deteriorated gine and its major control components, including the vari-
performance. able geometry turbine (VGT). Diesel engines are typically
In the absence of real-time measurements, the aftertreat- turbocharged or supercharged to improve power density
ment control has to rely on feedforward and model-based (turbocharging will be discussed in Section VI). Operated
control, making the system performance vulnerable to un- on the compression ignition principle, diesel engines have
certainties and model inaccuracies. In [30], it is shown that many distinct features compared to spark ignited gasoline
3277
engines. In particular, the following characteristics of diesel The exhaust flow, We , and burned gas fraction in the flow
engines have strong control implications. First, they operate from the engine into the exhaust manifold, Fn , appearing on
lean (A/F must usually stay significantly above the stoi- the right hand side of the state equations (19) are nonlinear
chiometry), and therefore require a different aftertreatment functions of the states and inputs:
system. Second, N Ox control, to a much greater extent
than conventional gasoline engines, relies on high EGR, We (t) = Wcyl (t − t1 ) + Wf (t − t2 ),
which due to lean operation contains significant amounts of Fi (t−t1 )Wcyl (t−t1 )+Wf (t−t2 )(Φs+1)
Fn(t) = min{ , 1},
air. Third, fueling rate is an independent and fast actuator Wcyl (t − t1 ) + Wf (t − t2 )
for torque management, as long as A/F is maintained
within its limits. Modern common rail fuel injection systems where Φs is the stoichiometric value of A/F , and t1 =
permit fuel rate shaping and multiple injections per cycle 3 N30 30
(t) and t2 = N (t) are introduced to account for delays,
for torque, noise and emission controls. which may not be negligible at low engine speeds. The flow
through the EGR valve is modeled by the orifice equations
A. Diesel Engine Model (2)-(3) given in Section III. The EGR cooler efficiency, ,
is a function of the flow rate, Wegr , and is determined
For compression ignited, turbocharged, diesel engines experimentally with engine testing.
operating with high EGR, the effects of gas temperature The cylinder flow, Wcyl , is represented as
and gas composition become more dominant and additional
Vd N
states have to be introduced to characterize the engine Wcyl = ηvol (Pi , Pe , Ti , Te , N )Pi , (20)
dynamics. The main difference between the diesel model 120RTi
introduced here and the naturally aspirated gasoline engine where ηvol is the nonlinear volumetric efficiency function
model discussed in Section III is the introduction of new and Vd is the engine cylinder displacement volume, while
states, specifically, ρi (intake density), Fi (intake burned gas the exhaust temperature model has the following form
fraction), ρe (exhaust density), Fe (exhaust burned gas frac-
Te = Ti + ∆Trise (N, Wf , Wcyl , Fi , δ), (21)
tion), Pe (exhaust pressure) and Ntc (turbocharger speed).
The state equations are obtained based on the ideal gas law, where δ is the timing of the main injection. To improve
mass and energy balances and the assumption of uniform the transient accuracy of the exhaust temperature model,
distribution of pressure, composition and temperature in the one may augment the wall temperature dynamics with a
intake and exhaust manifolds. transient heat transfer model in the following form
Wc + Wegr − Wcyl Q̇e = k · (Te − Twall ),
ρ̇i = , (22)
 Vi Ṫwall = −αTwall + αTe ,
γR
Ṗi = Wc Tc + Wegr ((1 − )Te + TECT ) where Twall is the wall temperature of the exhaust manifold,
Vi
 while k and α are parameters.
Q̇i The engine rotational dynamics are essentially the same
−Wcyl Ti − ,
cp as those for PFI engines. The engine torque, T , can be
−Fi Wc + (Fe − Fi )Wegr modeled similarly as that for the PFI engines based on
Ḟi = , (19)
ρi V i engine mapping data, except that a different set of variables
We − Wt − Wegr will be used for the functional representation of T :
ρ̇e = ,
Ve T = Tind (Wf , N, δ, Fi ) + Tpump (P2 , P1 , N )
(Fn − Fe )We
Ḟe = , + Tf ric (N ). (23)
ρe V e
 
γR Q̇e The models (20), (21) and (23) represent key static
Ṗe = We Teng − Wt Te − Wegr Te − , characterizations of the diesel engine and they are typically
Ve cp
embedded into the engine control strategy. These models
where (Wc , Tc ), (Wegr , Tegr ), (Wt , Teng ), (Wcyl , Ti ), are usually generated via regression of steady-state engine
(We , Teng ) are the rates and corresponding temperatures of mapping data. It is important to note that having physics-
the flows through the compressor, EGR valve, turbine, to based functional forms in these models enables extrapola-
the cylinder and to the exhaust manifold, respectively. Here, tion during transient conditions.
the temperatures of Wcyl , Wt are assumed to be equal to
the gas temperatures in the intake and exhaust manifolds B. Control Problems for Diesel Engines
respectively. TECT is the engine coolant temperature and Diesel engines provide many challenging control prob-
is the efficiency of the EGR cooler. Q̇i , Q̇e are the heat lems. The number of inputs (degrees of freedom) which
transfer rates from the intake manifold and the exhaust man- needs to be dynamically controlled in a diesel engine is
ifold, respectively. Turbocharger dynamics are discussed in typically between 8 and 20, depending on the engine con-
Section VI. figuration. An increase in modeling, control and calibration
3278
complexity occurs with each degree of freedom. Diesel The simplest analysis procedure is to determine the
engine dynamics are not only highly nonlinear but they are steady-state sensitivities of key performance variables (such
higher order than the ones for naturally aspirated gasoline as fuel consumption and emissions) to the uncertainties for
engines. different sensor and controller configurations. The underly-
In this section, we will briefly discuss several unique ing assumption in this analysis is that a measured internal
diesel engine control problems. More detailed discussion variable is maintained by the controller at the desired
on coordinated VGT and EGR control will be postponed setpoint despite the effects of the uncertainties. In order for
until Section VI, after a turbocharger model is presented. this analysis to lead to meaningful conclusions, the relative
1) Static and dynamic interactions: Figure 9 illustrates importance of performance variables and the expected size
the effect of static interactions for the diesel engine shown of uncertainties need to be established. Note also that the
in Figure 8. Note that at operating point “b” when the EGR best sensor configuration or controller architecture may, in
valve is fully open, opening the VGT results in an increase general, depend on the engine operating point, as was noted
in compressor flow. However, exactly the opposite happens previously for DISC gasoline engines.
at operating points “a” (when the EGR valve is closed) and Other related procedures include the use of control-
“c” (when the EGR valve is fully open and the VGT is theoretic techniques such as Relative Gain Array (RGA)
more than half open). This behavior is referred to as “dc analysis [32] and µ-analysis [34]. The value of µ is
gain reversal” and it complicates control development [32]. computed in [34] for different sensor configurations and
at different operating points wherein low µ implies high
robustness against uncertainties and small tracking errors.
It is shown that although the numerical value of µ changes
with the operating point, the relative ranking of the dif-
ferent configurations remains the same, thus permitting the
identification of the best sensor configuration across the full
engine operating range.
In addition to formal procedures that consider the effect
of uncertainties, the direct analysis of interactions and
properties of the system may lead to an effective control
architecture. In [35], the feedback architecture is designed
based on consideration of available actuator authority at the
optimal setpoints. It is shown that locally at these optimal
setpoints, the EGR valve and the VGT become limited in
Fig. 9. The steady-state dependence of compressor mass air flow, Wc1 , their ability to independently affect the performance vari-
on the VGT position, χvgt for different positions of the EGR valve, χegr . ables. This analysis leads to a feedback controller architec-
ture reliant on a single integrator instead of two. In reference
The dynamic interactions are illustrated in [32], where [36], the exhaust pressure measurement is introduced to
it is shown that engine dynamics become slower when the avoid the nonminimum-phase dynamics associated with the
EGR valve is more open, and that for a usual selection standard sensor configuration (compressor mass air flow
of outputs the system may exhibit non-minimum phase and intake manifold pressure) and to take advantage of the
behavior. It was also shown through numerical optimal relative degree properties of the re-defined output set. This
control-based analysis [33], that the optimal operation of the enables application of effective robust nonlinear control
VGT during a tip-in may not be its immediate closing (as design techniques. References [37], [38] propose combining
the purely steady-state analysis would suggest). If the VGT switching logic and PID controllers to provide fast boost
is closed immediately during the tip-in, the exhaust pressure pressure response with small overshoot. Reference [39]
may increase rapidly in advance of the intake pressure utilizes an air-fuel ratio sensor positioned after the turbine
increase thereby “depressing” the volumetric efficiency, and an LQG/LTR controller for the EGR valve in an engine
increasing pumping losses and increasing the turbo-lag. A with a conventional turbocharger. The use of the air-fuel
more optimal operation of the VGT during this transient ratio sensor can improve the system robustness and reduce
is to initially open it, then close it and reopen it again at calibration effort, although transient performance may be
higher rpm to prevent over-boost. limited due to delay and sensor dynamics.
2) Selection of Sensor Configuration and Control System The guidelines resulting from numerical optimal control
Architecture: In view of static and dynamic interactions [33] can also be useful in comparing different controller
in the diesel engine, the proper selection of sensor con- architectures in terms of their capability to generate an
figuration and control system architecture is particularly optimal behavior and for ease of subsequent controller
important. Various internal variables may be used for feed- calibration. For example, it is shown in [33] that the
back and they result in different levels of sensitivity to conventional decentralized architecture, wherein the VGT
uncertainties and transient performance. is controlled using a proportional plus integral feedback on
3279
intake manifold pressure and the EGR valve is controlled where Pb is the compressor exit pressure, typically referred
using a proportional plus integral feedback on the compres- to as boost pressure, Pa and Ta are the compressor inlet
sor mass air flow, is limited in its ability to generate the conditions, which in most cases are assumed to be ambient,
optimal behavior. and Ntc is the turbocharger shaft speed.
VI. T URBOCHARGED AUTOMOTIVE P OWERTRAIN The compressor exit temperature can be calculated as
S YSTEMS    γ−1 
1 Pb γ
Boosting intake manifold pressure increases the density Tc = Ta 1 + −1 (25)
of the air entering the engine and allows a smaller displace- ηcisen Pa
 
ment engine to produce torque similar to that of a higher Pb
displacement naturally aspirated engine. For diesel engines ηcisen = fηc , Ntc , Ta (26)
Pa
which operate lean of stoichiometry, boosting is necessary
to meet power density requirements. where ηcisen is the isentropic efficiency of the compressor.
Turbocharging is an efficient method to boost intake The power consumed by the compressor, P owerc , is cal-
pressure, as it extracts energy from the exhaust gases to culated via the first law of thermodynamics,
drive a compressor to pressurize ambient air. It has been
applied to both gasoline and diesel engines for automotive P owerc = cp,c Wc (Tc − Ta )
applications. Given the wide range of speed and load
operating conditions for automotive applications, a design where, cp,c is the specific heat at constant pressure of the
challenge is to develop a system that provides adequate air in the compressor.
boost at low speed and load without creating an over- The turbine is described in a similar fashion. The mass
boost situation at high speed and loads. Typically, the flow through the turbine, Wt , is modeled as
amount of boost delivered by a turbocharger is controlled
by a wastegate for gasoline engines and a VGT for diesel  
Pe Pt Ntc
engines. In any event, the advantages of turbocharging are Wt = √ ft ,√ , (27)
Te Pe Te
accompanied by an increase in complexity of the control
design and calibration. where Pe and Te are the pressure and temperature at
Complexity is also introduced by other phenomena asso- the inlet of the turbine, respectively, which are typically
ciated with turbocharging. For example, increasing charge assumed equal to the exhaust manifold conditions, and Pt
density increases propensity for engine knock in gasoline is the turbine exit pressure.
engines, particularly at high loads. This phenomenon is The turbine exit temperature is given by
alleviated in many applications by passive or active thermal
management with a charge cooling device, such as an    γ−1
  
γ
Pt
intercooler. In direct injection engines, fuel injection control Tt = 1− 1− isen
ηt Te (28)
may also provide some benefit [40]. Pe
 
Transient response is another factor, as turbocharger Pt Ntc
inertia leads to a phenomenon known as “turbo lag”. Turbo ηtisen = fηt ,√ , (29)
Pe Te
lag describes the delay in torque response due to the time
required for the turbocharger to change speed and thus affect where ηtisen is the isentropic efficiency of the turbine.
boost pressure. In gasoline applications, control objectives The power generated by the turbine, P owert , is calcu-
for fast response to minimize this effect are tempered lated from the first law of thermodynamics,
by limits on boost pressure overshoot, which can lead to
unacceptable torque disturbances [41], [42]. P owert = cp,t Wt (Te − Tt ),
In this section, we will first describe a turbocharger model
that is applicable to both gasoline and diesel applications. where cp,t is the specific heat at constant pressure of the
We will then discuss representative control problems, one gas in the turbine.
for a gasoline engine with wastegate, another for a diesel The dynamics of the turbocharger shaft are given by
engine with coordinated VGT/EGR control.
A. Turbocharger Models P owert − P owerc
Ṅtc = π , (30)
The representation of the turbocharger consists of models Jtc Ntc 30
of the compressor and turbine, and includes the dynamic
where Jtc is the inertia of the turbocharger.
coupling of the compressor and turbine. The mass flow rate
through the compressor, Wc , is described by This turbocharger model can be appended to the gasoline
  engine model given in Section III or the diesel engine model
Pb described in Section V to form the boosted gasoline or
Wc = fc , Ntc , Ta , (24)
Pa diesel engine model, respectively.
3280
to achieve an approximation of the multivariable controller.
Piref θthr Although robustness to unmeasured disturbances needs to
PI Pi be further explored, a simplified controller that exhibits
some of the characteristics of the multivariable control is
wgff
Filter Plant obtained.

ref
Pb wglift C. Coordinated EGR-VGT control
PI
Pb
For boosted diesel engines, coordination of EGR and
VGT represents a challenge, because of their complicated
close coupling (see discussion in Section V). Both linear
Fig. 10. Block diagram of decentralized boost control and nonlinear controllers have been developed for coor-
dinated control of EGR valve and VGT. Reference [44]
compares several different linear and nonlinear control
B. Control of Boosted Gasoline Engines with Wastegate designs.
The turbocharger model can be augmented by a wastegate One control approach, [44], relies on a multivariable lin-
model to represent a typical boosted gasoline engine. The ear proportional-plus-integral (MIMO PI) controller for the
wastegate can be modeled with the standard orifice flow EGR valve position, χegr , and VGT position, χvgt , which
equations (2)-(3), as described in Section III. Measurements uses the measurements of the intake manifold pressure,
needed to derive the effective orifice area may be difficult Pi , and compressor mass air flow, Wc , for feedback. This
to obtain; nonetheless, an effective model can be developed controller has the following form,
with selected use of estimated variables, such as exhaust       
χegr χegr,f f k1 0 Pi,d − Pi
flow rate. = +G
χvgt χvgt,f f 0 k2 Wc,d − Wc
Model integration requires an exhaust manifold model  
k3 0
and a model to represent the volume between the compres- +G ν(t). (32)
0 k4
sor and the throttle. This can be done in a fashion similar
to that discussed in Section V for diesel engines. where χegr,f f , χvgt,f f are the feedforward positions of the
A turbocharged system model of this type is used by EGR and VGT, respectively; Pi,d , Wc,d denote the set-
the authors of [41] to analyze system characteristics and points for the intake manifold pressure and compressor mass
develop charge control algorithms for a wastegated tur- air-flow, respectively; G is a 2 × 2 gain matrix; k1 , k2 , k3
bocharged system equipped with electronic throttle. Boost and k4 are scalar gains; and ν is the state of the integrator,
pressure and intake manifold pressure are both measured  
Pi,d − Pi
and conventional decentralized PI control with feedforward ν(t + Ts ) = ν(t) + Ts . (33)
Wc,d − Wc
on the wastegate is used to regulate these measured vari-
ables to desired setpoints, which are chosen to achieve fuel Note that (32), (33) can represent either a MIMO PI
economy, emissions and driveability objectives. The control controller or two SISO decentralized loops. In the former
structure is shown in Figure 10. case, the matrix G is selected as an inverse of the (static)
This approach produces acceptable performance, however dc gain of the plant for different operating conditions,
the wastegate is prone to saturation. Multivariable control
techniques can be used to analyze the system to guide G = G(N, Wf ) = (Cy A−1 Bu )−1 ,
formulation of a modified controller that maintains a simple
where (A, Bu , Cy , Duy ) is a linearization of the plant model
structure desirable for implementation, and yet benefits from
at the operating point corresponding to the given engine
a centralized control methodology. Such an approach is
speed N and fueling rate Wf . For the decentralized control,
described in [43]. This technique reformulates full state
G can be chosen as diagonal with each diagonal element
feedback integral control as an output feedback control by
being an inverse of the dc gain for the corresponding
 K input/output pair. Since the matrix G decouples the plant
Ceq = −Ksf (sI − (A − BKsf )) B + I
−1 i
, (31) at low frequencies, only 4 master gains, k1 , k2 , k3 and k4 ,
s need to be tuned on the engine. For the case of decentralized
where Ksf is the gain corresponding to the plant states PI control, reference [33] proposes the use of a transient
and Ki is the gain corresponding to the error states. Both governor which dynamically modifies the set-points, Pi,d
are obtained from full state feedback design. A and B are and Wc,d for the EGR valve and VGT positions to provide
matrices appearing in a state-variable representation of a a faster tip-in response.
linear model of the sytem. Another approach can be developed based on Control
This Ceq controller is examined to identify prominent Lyapunov Functions (CLF) method [45]. This method is
behavior. Key controller characteristics are emulated with applied to a reduced order model with three states P̄i =
Pamb , P̄e = Pamb and P owerc , where the turbine flow
Pi Pe
simple linear elements such as low- and high-pass filters,
3281
(Wt ) and the EGR flow (Wegr ) are treated as control inputs. control applications should only grow not only in terms
A Lyapunov function, of delivering improved performance, accommodating more
c1 c2 c3 complex powertrain systems and satisfying more stringent
V = (Wc − Wc,d )2 + (P̄e − P̄e,d )2 + (P̄iµ − P̄i,d µ 2
) requirements, but also in terms of improving control system
2 2 2
implementation process including the reduction in calibra-
is constructed for the closed-loop system with a feedback
tion time and effort.
linearizing controller. Following the CLF design procedure2 ,
a controller for the desired mass flow rate of EGR, Wegr , VIII. C ONCLUSION
and the desired mass flow rate through the turbine, Wt , can
Powertrain control has been and will remain a dynamic
be derived. The EGR valve and turbine flow characteristics
and exciting research topic. For many years, automotive sys-
are then inverted to backtrack the desired EGR valve and
tems have been used as ideal platforms for motivating and
VGT positions from Wegr and Wt . This controller enjoys
validating theoretic control research. Hardware innovations
robustness properties (to input uncertainties) guaranteed for
and product demands will continue to offer opportunities for
the CLF controllers with infinite gain margin and 60 deg
the powertrain control engineering community. We expect
phase margin. It also suggests the advantages of using the
that the demand for education of control engineers with well
exhaust manifold pressure measurement for feedback [45].
balanced automotive and dynamics perspectives will grow,
VII. CONTROL IMPLEMENTATION as will the demand for tool development that can integrate
CONSIDERATIONS the most recent control theoretical advancements into pow-
ertrain control development processes. Many interesting re-
There are important considerations in implementing au-
search topics with direct applications to powertrain control,
tomotive powertrain controllers that need to be taken into
such as data-driven model development methodologies and
account during the development and technology transfer of
tools, hybrid system analysis, integrative control strategies
the algorithms. They include computations, calibration and
for complex systems, and effective embedded optimization
process issues, among others. Specifically, automotive micro
algorithms, remain open and under-explored; and advances
controllers provide only limited computational resources
in these directions could have significant impact on the
(in terms of chronometrics and available RAM and ROM
automotive industry.
size). They are highly optimized for reliability and cost but
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