Coordinated multivariable control of fuel and air in engines

• US 7,275,374 B2
• Filed: 03/30/2005
• Issued: 10/02/2007
• Est. Priority Date: 12/29/2004
• Status: Active Grant

• Current Assignee: Garrett Transportation I Inc. (Garrett Motion, Inc.)
• Original Assignee: Honeywell International Inc.
• Inventors: Borrelli, Francesco, Stewart, Gregory E., Shahed, Syed M.
• Primary Examiner(s): TRIEU, THAI BA
• Application Number:
  US11/094,350
• Publication Number:
  US 20060137347A1
• Time in Patent Office: 916 Days
• Field of Search: 60600-603, 60280-295, 607/73, 606/052, 123/299, 123/456, 123/684, 123/352, 123/478, 123/492, 123/399, 123/357, 123/435, 477/905, 701/111, 701/108, 290/40.A, 700/45
• US Class Current: 60/601
• CPC Class Codes: F02B 29/0406 Layout of the intake air cooling or coolant circuit
• CPC Class Codes: F02B 29/0493 Controlling the air charge temperature
• CPC Class Codes: F02B 39/16 Other safety measures for, or other control of, pumps
• CPC Class Codes: F02D 2041/1415 using a state feedback or a state space representation
• CPC Class Codes: F02D 2041/1416 Observer
• CPC Class Codes: F02D 2041/1433 using a model or simulation of the system
• CPC Class Codes: F02D 23/00 Controlling engines characterised by their being supercharged
• CPC Class Codes: F02D 23/02 the engines being of fuel-injection type
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/0047 Controlling exhaust gas recirculation [EGR] temperature control with cooler in recirculation circuit F02M26/33
• CPC Class Codes: F02D 41/005 according to engine operating conditions
• CPC Class Codes: F02D 41/1401 characterised by the control or regulation method F02D41/1473, F02D41/1477 take precedence
• CPC Class Codes: F02D 41/40 with means for controlling injection timing or duration
• CPC Class Codes: F02D 43/00 Conjoint electrical control of two or more functions, e.g. ignition, fuel-air mixture, recirculation, supercharging or exhaust-gas treatment
• CPC Class Codes: F02M 26/05 High pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust system upstream of the turbine and reintroduced into the intake system downstream of the compressor
• CPC Class Codes: F02M 26/23 Layout, e.g. schematics
• CPC Class Codes: F02M 26/33 controlling the temperature of the recirculated gases
• CPC Class Codes: F02M 26/48 EGR valve position sensors details of the sensor installation in the valve housing F02M26/72
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems
• CPC Class Codes: Y10S 477/905 : Acceleration of throttle signal

Abstract

Methods and systems for controlling a diesel engine using a combined fuel and air-side controller are disclosed. An illustrative method may include the steps of providing a combined fuel and air-side controller adapted to coordinate both the fuel and air-side control of an engine, sensing one or more parameters, and outputting a fuel profile signal and one or more air-side control signals for controlling at least a part of the fuel-side and at least a part of the air-side of the engine. By centrally coordinating both the fuel and air-side control of the engine, the system can be configured to anticipate future fuel and/or air-side needs of the engine, thus improving system response, performance, and/or emissions.

Claims

1. A method for controlling a diesel engine system, the diesel engine system including a diesel engine having a fuel-side and an air-side, the fuel-side of said diesel engine including at least one fuel injector, the air-side of said diesel engine including an intake manifold, an exhaust manifold, and a turbine adapted to drive a compressor for providing compressed air to the intake manifold, the method comprising the steps of:

providing a combined fuel and air-side controller adapted to coordinate both the fuel-side and air-side control of the engine;

sensing one or more fuel-side parameters and one or more air-side parameters; and

outputting a fuel profile signal and one or more air-side control signals for controlling at least a part of the fuel-side and at least a part of the air-side of the engine;

wherein the combined fuel and air-side controller includes a multivariable Model Predictive Controller adapted to compute both the fuel and air-side parameters using a central optimization algorithm or routine.

2. The method of claim 1, wherein said one or more fuel-side parameters includes a pedal rate signal.

3. The method of claim 1, wherein said one or more fuel-side parameters includes a brake position signal.

4. The method of claim 1, wherein said one of more fuel-side parameters is selected from the group of signals consisting of a pedal position signal, a MAF signal, an engine speed signal, an AFR low limit signal, a pedal rate signal, and a brake position signal.

5. The method of claim 1, wherein said one or more air-side parameters includes a NO_X emission signal.

6. The method of claim 1, wherein said one or more air-side parameters includes a particulate matter (PM) emission signal.

7. The method of claim 1, wherein said one or more air-side parameters is selected from the group of signals consisting of a MAF signal, a MAP signal, a MAT signal, a NO_X signal, a PM signal, a turbo speed signal, a VNT position signal, and an EGR position signal.

8. The method of claim 1, wherein said one or more air-side control signals are selected from the group of signals consisting of a VNT set signal, a VGC set signal, an EGR set signal, an ETURBO set signal, a compressor cooler set signal, and an EGR cooler signal.

14. The method of claim 1, wherein the diesel engine further includes an adjustable exhaust gas recirculation (EGR) valve adapted to receive exhaust gas via the exhaust manifold.

15. The method of claim 14, wherein the EGR valve provides a selective amount of exhaust gas to the intake manifold determined by a set position of the EGR valve.

9. A method for controlling a diesel engine system, the diesel engine system including a diesel engine having a fuel-side and an air-side, the fuel-side of said diesel engine including at least one fuel injector, the air-side of said diesel engine including an intake manifold, an exhaust manifold, and a turbine adapted to drive a compressor for providing compressed air to the intake manifold, the method comprising the steps of:

providing a combined fuel and air-side controller adapted to coordinate both the fuel-side and air-side control of the engine;

sensing one or more fuel-side parameters and one or more air-side parameters; and

outputting a fuel profile signal and one or more air-side control signals for controlling at least a part of the fuel-side and at least a part of the air-side of the engine;

wherein the combined fuel and air-side controller includes a multivariable Model Predictive Controller that includes a fuel-side map and an air-side map, the fuel and air-side maps adapted to translate a pedal position signal and/or pedal rate signal into one or more fuel-side set points and one or more air-side parameters for use by the combined fuel and air-side controller.

10. The method of claim 9, wherein the fuel and air-side maps each comprise a dynamic map.

11. The method of claim 9, wherein the fuel and air-side maps each comprise a static map.

12. The method of claim 9, wherein the fuel and air-side maps comprise a single map.

13. The method of claim 9, further comprising at least one air-side set point map adapted to provide one or more air-side set points to the combined fuel and air-side controller.

16. A method for controlling a diesel engine system, the diesel engine system including a diesel engine having a fuel-side and an air-side, the fuel-side of said diesel engine including at least one fuel injector, the air-side of said diesel engine including an intake manifold, an exhaust manifold, an adjustable exhaust gas recirculation (EGR) valve adapted to receive exhaust gas via the exhaust manifold and provide a selective amount of exhaust gas to the intake manifold determined by a set position of the EGR valve, and a turbine adapted to drive a compressor for providing compressed air to the intake manifold, the method comprising the steps of:

providing a combined fuel and air-side controller adapted to coordinate both the fuel-side and air-side control of the engine;

sensing one or more fuel-side parameters and one more air-side parameters, the one or more air-side parameters including a sensed NO_x and/or PM emissions parameter;

outputting a fuel profile signal and one or more air-side control signals for controlling at least a part of the fuel-side and at least a part of the air-side of the engine; and

setting a current set position for the turbine and/or a current set position of the EGR valve to effect a future value of at least one of the one or more fuel and/or air-side parameters, wherein the current set position(s) is/are dependent on the one or more sensed fuel and/or air-side parameters including the sensed NO_X and or PM emissions parameter.

17. The method of claim 16, wherein the intake manifold has an intake manifold air pressure (MAP), and wherein the current set position for the turbine and the current set position for the EGR valve are dependent on the one or more sensed parameters and the MAP.

18. The method of claim 16, wherein the intake manifold has an intake manifold air flow (MAF), and wherein the current set position for the turbine and the current set position for the EGR valve are dependent on the one or more sensed parameters and the MAF.

19. The method of claim 16, wherein the combined fuel air-side controller is adapted to predict the current set position for the turbine and the current set position for the EGR valve.

20. A method for controlling a diesel engine system, the diesel engine system including a diesel engine having a fuel-side and an air-side, the fuel-side of said diesel engine including at least one fuel injector, the air-side of said diesel engine including an intake manifold, an exhaust manifold, a turbine adapted to drive a compressor for providing compressed air to the intake manifold, and an exhaust gas recirculation valve adapted to receive exhaust gas via the exhaust manifold, the method comprising the steps of:

providing a combined fuel and air-side controller adapted to coordinate both the fuel-side and air-side control of the engine;

sensing one or more fuel-side parameters and one or more air-side parameters, the one or more air-side parameters including a sensed NO_x and/or PM emission parameter;

setting a current set position for the turbine and a current set position of the exhaust gas recirculation valve to effect a future value of at least one of the one or more fuel and/or air-side parameters, the current set positions for the turbine and exhaust gas recirculation valve depending at least in part on one or more sensed fuel and air-side parameters;

predicting a current set point for the turbine and a current set point for the exhaust gas recirculation valve based at least in part on said NO_X and/or PM emission parameter; and

outputting a fuel profile signal and one or more air-side control signals for controlling at least a part of the fuel-side and at least a part of the air-side of the engine.

21. An engine system, comprising:

an engine having a fuel side and an air side, the fuel side of said engine including at least one fuel injector, the air side of said engine including an intake manifold, an exhaust manifold, and a turbine adapted to drive a compressor for providing compressed air to the intake manifold;

at least one sensor for sensing one or more fuel-side parameters and one or more air-side parameters of the engine;

a combined fuel and air-side controller adapted to output a fuel profile signal and at least one air-side control signal based at least in part on the fuel-side parameters and air-side parameters received by the at least one sensor; and

one or more actuators for controlling at least part of the operation of the engine based on the outputted fuel profile signals and the air-side control signals;

wherein the combined fuel and air-side controller includes a Model Predictive Controller adapted to compute both the fuel and air-side parameters using a central optimization algorithm or routine.

22. An engine system, comprising:

an engine having a fuel side and an air side, the fuel side of said engine including at least one fuel injector, the air side of said engine including an intake manifold, an exhaust manifold, and a turbine adapted to drive a compressor for providing compressed air to the intake manifold;

a combined fuel and air-side controller adapted to output a fuel profile signal and at least one air-side control signal based on feedback signals from one or more actuators and/or sensors,

said combined fuel and air-side controller including a Model Predictive Controller.

23. An engine system, comprising:

an engine having a fuel side and an air side, the fuel side of said engine including at least one fuel injector, the air side of said engine including an intake manifold, an exhaust manifold, and a turbine adapted to drive a compressor for providing compressed air to the intake manifold;

a combined fuel and air-side controller adapted to output a fuel profile signal and at least one air-side control signal, said combined fuel and air-side controller including a multivariable Model Predictive Controller adapted to compute both the fuel and air-side parameters using a central optimization algorithm or routine.

24. The engine system of claim 23, further including at least one sensor for sensing one or more fuel-side parameters and/or one or more air-side parameters of the engine.

25. The engine system of claim 24, further including one or more actuators for controlling at least part of the operation of the engine.

26. The engine system of claim 25, wherein the engine system is a closed loop system, and wherein at least one of the actuators provides feedback for the one or more of the fuel-side and/or air-side parameters.

27. The engine system of claim 24, wherein said one or more fuel-side parameters includes a pedal rate signal.

28. The engine system of claim 24, wherein said one or more fuel-side parameters includes a brake position signal.

29. The engine system of claim 24, wherein said one of more fuel-side parameters is selected from the group of signals consisting of a pedal position signal, a MAF signal, an engine speed signal, an AFR low limit signal, a pedal rate signal, and a brake position signal.

30. The engine system of claim 24, wherein said one or more air-side parameters includes a NO_X emission signal.

31. The engine system of claim 24, wherein said one or more air-side parameters includes a particulate matter (PM) emission signal.

32. The engine system of claim 24, wherein said one or more air-side parameters is selected from the group of signals consisting of a MAF signal, a MAP signal, a MAT signal, a NO_X signal, a PM signal, a turbo speed signal, a VNT position signal, and an EGR position signal.

33. The engine system of claim 23, wherein said one or more air-side control signals is selected from the group of signals consisting of a VNT set signal, a VGC set signal, an EGR set signal, an ETURBO set signal, a compressor cooler set signal, and an EGR cooler signal.

34. The engine system of claim 23, wherein said engine is a diesel engine.