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Intake Air Mass Observer Design Based on Extended Kalman Filter for Air-Fuel Ratio Control on SI Engine

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Intake Air Mass Observer Design Based on Extended Kalman Filter for Air-Fuel Ratio Control on SI Engine energies Article Intake Air Mass Observer Design Based on Extended Kalman Filter for Air-Fuel Ratio Control on SI Engine Lei Meng , Jie Luo, Xu Yang * and Chunnian Zeng * School of Automation, Wuhan University of Technology, Wuhan 430070, China * Correspondence: [email protected] (X.Y.); [email protected] (C.Z.) Received: 13 August 2019; Accepted: 3 September 2019; Published: 6 September 2019 Abstract: Air-fuel ratio (AFR) control is important for the exhaust emission reduction while using the three-way catalytic converter in the spark ignition (SI) engine. However, the transient cylinder air mass is unable to acquire by sensors directly and it may limit the accuracy of AFR control. The complex engine dynamics and working conditions make the intake air estimation a challenge work. In this paper, a novelty design of intake air observer is investigated for the port-injected SI engine. The intake air dynamical modeling and the parameter fitting have been carried out in detail. Extended Kalman Filter (EKF) has been used to optimize the instantaneous cylinder charge estimation and minimize the effort of pump gas fluctuation, random noise, and measurement noise. The experiment validation has been conducted to verify the effectiveness of the proposed method. Keywords: intake air mass observer; Extended Kalman Filter; air-fuel ratio control; SI engine 1. Introduction The spark ignition (SI) engine emission is reduced by using the three-way catalytic converter (TWC) based on electronic fuel injection control to meet the strict emission requirements. However, the conversion efficiency of TWC depends on the engine air-fuel ratio (AFR) significantly. The maximum converter efficiency and fuel economy could be guaranteed by regulating the AFR at a very narrow band around the stoichiometric value. One of the important practical aspects for the accurate AFR control is the correct intake air mass estimation in the engine cylinder [1]. However, the transient cylinder air mass is difficult to measure by sensors, due to the intake manifold dynamics. Practically, there are two kinds of method for the intake air measurement on production engines. Using the mass air flow (MAF) sensor that was installed before the throttle can directly measure the mass flow entering the intake system, but the result has a tremendous error against the actual cylinder air mass under the transient state. The other method is using the manifold air pressure (MAP) sensor to calculate the cylinder air mass based on the speed-density approach, which is widely used on the existing engine control system, has a faster response time, and costs less. Both of the technical methods mentioned above could not directly acquire the instant cylinder air mass. In addition, the complex engine working conditions and tremendous measurement noise make the cylinder air mass estimation a challenging task and have captured enormous attention recently. On the production engine management system, the intake air mass estimation is based on the well-calibrated look-up tables at different engine operating states. However, the dramatic change of intake dynamics and parameter varying makes a challenging problem for the traditional air estimation. Many approaches have been proposed in the literature on the air charge estimation to improve the accuracy at both the transient and steady state [2,3]. Hendricks [4] has emphasized that the pressure transducer response time existed and it was impossible to follow rather slow throttle angle transients and proposed the necessary of intake air observer to eliminate the sensor response characteristic. Energies 2019, 12, 3444; doi:10.3390/en12183444 www.mdpi.com/journal/energies Energies 2019, 11, x FOR PEER REVIEW 2 of 12 Energiescharacteristic.2019, 12, 3444 An adaptive observer is proposed to estimate the intake oxygen concentration of a2 lean- of 12 burn engine while using existing sensors with minimum computational load [5]. The research [6] proposed an air mass flow estimator design with model bias correction for a turbocharged diesel Anengine adaptive by off-line observer calculation. is proposed An to in-cylinder estimate the air intake mass oxygen observer concentration was implemented of a lean-burn in [7],engine which whilecombined using the existing feedforward sensors neural with minimumstatic model computational and a linear load parameter [5]. The varying research (LPV) [6] proposedpolytopic anobserver. air mass Some flow air estimator charge observers design with have model been reported bias correction in [8,9] on for the a turbocharged SI engine and dieselthe experimental engine by oresultsff-line calculation.showed that An the in-cylinder input estimation air mass techniqu observeres could was implemented enhance the incontrol [7], which performance. combined Using the feedforwardthe Kalman neuralfilters to static develop model the and intake a linear air parametermass observer varying have (LPV) been polytopicreported an observer. effective Some way air to chargesolve the observers problem, have as it been is difficult reported to obtain in [8,9 ]measurements on the SI engine in time and thefor experimentalthe accurate cylinder results showedair mass thatflow the [6,10,11] input estimation. Although techniques there was couldsome enhancework about the controlthe engine performance. air charge, Using the complex the Kalman intake filters air todynamics develop and the accurate intake air AFR mass control observer demand have still been arou reportedsed interest an eff forective the wayresearch to solve of accurate the problem, intake asair it estimation. is difficult to obtain measurements in time for the accurate cylinder air mass flow [6,10,11]. AlthoughIn this there paper, was a somenovelty work design about of detailed the engine air aircharge charge, estimation the complex observer intake is investigated air dynamics for and the accurateport-injected AFR controlSI engine. demand The intake still aroused air dynamica interestl for modeling the research and ofthe accurate parameter intake fitting air estimation. have been carriedIn this out. paper, Extended a novelty Kalman design Filter of detailed(EKF) has air b chargeeen used estimation to optimize observer the instantaneous is investigated cylinder for the port-injectedintake air estimation. SI engine. TheFurthermore, intake air dynamicalthe experime modelingntal validation and the parameter invested fittingthe effectiveness have been carried of the out.proposed Extended intake Kalman air mass Filter observer (EKF) design has been method. used to optimize the instantaneous cylinder intake air estimation. Furthermore, the experimental validation invested the effectiveness of the proposed intake air2. Air mass Path observer Modelling design of method. the SI Engine 2. Air Path Modelling of the SI Engine 2.1. System Description of the Engine Air Path 2.1. SystemFor the Description port injected of the SI engine, Engine AirFigure Path 1 shows a brief structure of the entire system. The SI engine α is controlled,For the port followed injected by SI the engine, throttl Figuree movement1 shows aand brief the structure position of angle the entire ( ) system.affects the The relative SI engine air ismass controlled, supply. followedAt different by engine the throttle operation movement conditio andns, thethe positionintake air angle passes (α through) affects the throttle relative and air massgoes supply.into the Atcylinder different during engine the operation inlet valves conditions, opening. the The intake electronic air passes control through unit (ECU) the throttle calculates and m goesand controls into the cylinderthe fuel injection during theamount inlet valves( fcmd ) opening.based on the The intake electronic air mass control and unit AFR (ECU) control calculates strategy. andThe controlsair and theinjected fuel injectionfuel mix amountin the intake (m f cmd manifold) based on in the front intake of the air intake mass and valves, AFR and control then strategy. the gas Themixture air and enters injected the engine fuel mix cylinder. in the The intake mixture manifold is ig innited front by ofthe the spark intake plug valves, to release and thenthe chemical the gas mixtureenergy and enters produces the engine the cylinder.engine output The mixture torque. isUs igniteding theby exhaust the spark gas plugoxygen to release(EGO) sensor the chemical before φ energythe TWC and to produces measure the the engine exhaust output oxygen torque. content Using the ( exhaustexh ) for gasrepresenting oxygen (EGO) the sensorAFR during before thethe TWCcombustion to measure process the can exhaust provide oxygen the fe contentedback ( φofexh the) for fuel representing and the air themixing AFR ratio. during In addition, the combustion engine processfueling cancontrol provide is a the fundamental feedback of theissue fuel in and SI theengine air mixingand has ratio. to depend In addition, on enginethe cylinder fueling air control mass isestimation, a fundamental which issue also in has SI a engine strong and impact has toon dependthe combustion, on the cylinder efficiency, air mass and emission estimation, performances which also hasof the a strong SI engine. impact on the combustion, efficiency, and emission performances of the SI engine. FigureFigure 1.1. StructureStructure ofof thethe SISI engineengine airair path.path. EnergiesEnergies 20192019, 11, ,12 x ,FOR 3444 PEER REVIEW 3 of3 12 of 12 However, the cylinder air mass, which is controlled by the inlet and outlet valves, is difficult to However, the cylinder air
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