<b>Advanced Control Strategies For Heavy Duty Diesel Powertrains</b>
Creators: name: Ashta, Shubham
Publisher: name: Purdue University Graduate School
Year: 2024
Subjects: classificationCode: 401799
subject: Mechanical engineering not elsewhere classified

description: The automotive industry has incorporated controls since the 1970s, starting with the pioneering application of an air-to-fuel ratio feedback control carburetor. Over time, significant advancements have been made in control strategies to meet industry standards for reduced fuel consumption, exhaust emissions, and enhanced safety. This thesis focuses on the implementation of advanced control strategies in heavy-duty diesel powertrains and their advantages over traditional control methods commonly employed in the automotive industry.The initial part of the thesis demonstrates the utilization of model predictive control (MPC) to generate an optimized velocity profile for class 8 trucks. These velocity profiles are designed to minimize fuel consumption along a given route with known grade conditions, while adhering to the time constraints comparable to those of standard commercial cruise controllers. This methodology is further expanded to include the platooning of two trucks, with the rear truck following a desired gap (variable or fixed), resulting in additional fuel savings throughout the designated route. Through collaborative efforts involving Cummins, Peloton Technology, and Purdue University, these control strategies were implemented and validated through simulation, hardware-in-the-loop testing, and ultimately, in demonstration vehicles.MPC is highly effective for vehicle-level controls due to the accurate plant model used for optimization. However, when it comes to engine controls, the plant model becomes highly nonlinear and loses accuracy when linearized [20]. To address this issue, robust control techniques are introduced to account for the inherent inaccuracies in the plant model, which can be represented as uncertainties.The second study showcases the application of robust controllers in diesel engine operations, focusing on a 4.5L John Deere diesel engine equipped with an electrified intake boosting system. The intake boosting system is selectively activated during transient operations to mitigate drops in the air-to-fuel ratio (AFR), which can result in smoke emissions. Initially, a two-degree-of-freedom robustsingle-input single-output (SISO) eBooster controller is synthesized to control the eBooster during load transients. Although the robust SISO controller yields improvements, the eBooster alone does not encompass all factors affecting the gas exchange process. Other actuators, such as the exhaust throttle and EGR valve, need to be considered to enhance the air handling system. To achieve this, a robust model-basedmultiple-input multiple-output (MIMO) controller is developed to regulate the desired AFR, engine speed, and diluent air ratio (DAR) using various air handling actuators and fueling strategies. The robust MIMO controller is synthesized based on a physics-based mean value engine model, which has been calibrated to accurately reflect high-fidelity engine simulation software. The robust SISO and MIMO controllers are implemented in simulation using the high-fidelity engine simulation software. Following the simulation, the controllers are validated through experimental testing conducted in an engine dynamometer at University of Wisconsin. Results from these controllers are compared against a non-eBoosted engine, which serves as the baseline. While both the SISO and MIMO controllers show improvements in AFR (Air-Fuel Ratio), DAR (Diluent Air Ratio), and engine speed recovery during the load transients, the robust MIMO controller outperforms them by demonstrating the best overall engine performance. This superiority is attributed to its comprehensive understanding of the coupling between each actuator input and the model output. When the MIMO controller operates alongside the electrified intake boosting system, the engine exhibits remarkable enhancements. Not only does it recover back to a steady state 70% faster than the baseline, but it also reduces engine speed droop by 45%. Consequently, the engine's ability to accept load torque increases significantly.As a result, a single robust MIMO controller can efficiently perform the same task instead of employing multiple PIDs or look-up tables for each actuator.