Master Thesis Design and Simulation of Engine Control System Major: Automotive Engineering Candidate: Sun Haiteng Student Number: S232225 Tutor: Professor Daniela Maffiodo Professor Raffaella Sesana 2018.01 1 Abstract The objective of this paper is to design and simulate the engine control system for engine test bench, which should be developed for didactic usage. The controlling module or described as the engine control unit of this test bench would be developed on a microcontroller unit called Arduino due to the feasibility and simplicity. The programming language of this microcontroller is based on C++. It is time consuming, difficult for student without solid programming skill and complicated to develop the code of engine control system directly on Arduino. In order to reduce the development time and cost of engine control system, the simulation of engine control system could be accomplished. The model based code of engine control system could be simulated in Matlab/Simulink. This simulation of engine control system could be verified by combination with virtual engine model software. In this paper, different engine control strategies are introduced and air fuel ratio control is utilized since the engine test bench is only for teaching usage and air fuel ratio has better understanding. The engine should be modeled by virtual engine modeling software, GT-Power. The engine would be a 4 cylinders, SI engine with turbocharger. The engine control system should be modeled by Simulink. In this control system, three different engine operating conditions, such as idle speed condition, stable operating condition and transient operating condition, should be considered. After implementation models of engine and engine control system, the simulation results should be demonstrated as desired characteristics of engine performance. At the end of this paper, the simulation results should be compared with on board diagnostic results to verify engine control simulation and to prove that the coupling method of Simulink and GT-Power could provide a stable solution aiming at using an accurate engine model to save development cost and time during early stage of examining the design of control system. 2 Table of Contents List of Figures........................................................................................................................................4 Chapter 1. Introduction ................................................................................................................... 6 1.1 Background .......................................................................................................................... 6 1.2 Introduction of Project .................................................................................................... 6 1.3 Problem Solution ............................................................................................................... 9 1.4 GT-Power and Matlab/Simulink ............................................................................... 10 1.5 Thesis Contributions ...................................................................................................... 11 Chapter 2. Literature Review ...................................................................................................... 13 2.1 Introduction ................................................................................................................ 13 2.2 Review of existing technology ................................................................................... 13 2.3 Engine Modeling .............................................................................................................. 22 2.4 Engine management system ....................................................................................... 23 Chapter 3 Engine Modeling Using Mean Value Method ................................................... 35 3.1 Introduction ....................................................................................................................... 35 3.2 Mean value method and GT-Power ......................................................................... 36 3.3 Mean value gas flow model ......................................................................................... 38 3.4 Crank-based one-zone SI combustion model ...................................................... 43 3.5 Engine Modeling in GT-Power ................................................................................... 48 Chapter 4 Engine control strategy simulation in Simulink ............................................ 56 4.1 Introduction ................................................................................................................... 56 4.2 The modeling of air-fuel ratio control module ............................................... 57 4.3 Control of turbocharger ............................................................................................ 64 Chapter 5 Implementation of Engine model in Simulink environment ................ 69 5.1 Introduction ................................................................................................................... 69 5.2 Set up of GT-Power Model ....................................................................................... 70 5.3 Set up of Simulink Model .......................................................................................... 72 Chapter 6 Final Result and future work .............................................................................. 74 6.1 Simulation Result ............................................................................................................ 74 6.2 Analysis of simulation results .................................................................................... 84 Chapter7 Comparison with On Board Diagnostic Results ..........................................79 7.1 Introduction On Board Diagnostic...............................................................................81 7.2 On Boadr diagnostic results........................................................................................83 7.3 Conclusion and future work........................................................................................85 3 List of Figures Figure 1.1…………………………………………………………………………….Version of Arduino Figure 1.2…………………………………...…………Schematic of Engine Test Bench Project Figure 2.1…………………………………………………….……Objective of Engine Downsizing Figure 2.2…………………………………..................................................................Sankey Diagram Figure 2.3……………..............................................................….Pressure Wave Supercharging Figure 2.4……………..............................................……….Schematic of Turbo Compounding Figure 2.5.............................................................Schematic of Engine Management System Figure 2.6.....................................................................Torque Based Engine Control Module Figure 2.7.....................................................................................Air-Fuel Ratio Control Module Figure 2.8..........................................................................Electronic Throttle Control Module Figure 2.9..........................................................................................................Pedal Map Example Figure 2.10.........................................................................................Idle Speed Control Module Figure 3.1...................................................................Valve Model Accomplished in Simulink Figure 3.2............................................................Manifold Model Accomplished in Simulink Figure 3.3..............................................................................................Stage of Pressure Varying Figure 3.4................................................................................Turbocharger Model in Simulink Figure 3.5............................................................................ Turbocharger Model in GT-Power Figure 3.6........................................................................................ EGR Controller in GT-Power Figure 3.7.............................................................................................. Setting of EGR Controller Figure 3.8............................................................... Intake and Exhaust System in GT-Power Figure 3.9...........................................Overall Engine Model with SimulinkHarness Mode Figure 4.1.......................................................................Overall Controller Model in Simulink Figure 4.2.................................................................Stable Operating Controller in Simulink Figure 4.3..........................................................Transient Operating Controller in Simulink Figure 4.4.........................................................Idle Speed Condition Controller in Simulink Figure 4.5........................................................................Example of Turbocharger Controller Figure 4.6........................................................................................................................Turbine Map Figure 4.7.......................................................................................LQ Compensator in Simulink Figure 4.8...........................................................PID Controller of turbocharger in Simulink Figure 4.9.................................................Overall