DISSERTATION APPLICATIONS OF FIELD PROGRAMMABLE GATE ARRAYS FOR ENGINE CONTROL Submitted by Matthew Viele Department of Mechanical Engineering In partial fulfillment of the requirements For the Degree of Doctor of Philosophy Colorado State University Fort Collins, Colorado Summer 2012 Doctoral Committee: Advisor: Bryan D. Willson Anthony J. Marchese Robert N. Meroney Wade O. Troxell ABSTRACT APPLICATIONS OF FIELD PROGRAMMABLE GATE ARRAYS FOR ENGINE CONTROL Automotive engine control is becoming increasingly complex due to the drivers of emissions, fuel economy, and fault detection. Research in to new engine concepts is often limited by the ability to control combustion. Traditional engine-targeted micro controllers have proven difficult for the typical engine researchers to use and inflexible for advanced concept engines. With the advent of Field Programmable Gate Array (FPGA) based engine control system, many of these impediments to research have been lowered. This dissertation will talk about three stages of FPGA engine controller appli- cation. The most basic and widely distributed is the FPGA as an I/O coprocessor, tracking engine position and performing other timing critical low-level tasks. A later application of FPGAs is the use of microsecond loop rates to introduce feedback con- trol on the crank angle degree level. Lastly, the development of custom real-time computing machines to tackle complex engine control problems is presented. This document is a collection of papers and patents that pertain to the use of FPGAs for the above tasks. Each task is prefixed with a prologue section to give the history of the topic and context of the paper in the larger scope of FPGA based engine control. The author of this study founded, built up, and eventually sold Drivven Inc., a company dedicated to the implementation of FPGAs in engine control. As a result, this study spans a decade of time where we see the first few papers related to FPGA ii based engine control, and concludes with FPGA based engine controllers being the de facto standard for advanced combustion research. iii ACKNOWLEDGEMENTS I would like to thank John Silvestri at Gamma Technologies for allowing the use of GT-SUITE over the many years it took to complete this work. iv DEDICATION To my dad who taught me to never give up on a project, no matter how long it takes. v TABLE OF CONTENTS 1 Introduction . .1 1.1 The history of electronic engine control with a focus on FPGAs . .1 1.1.1 Automotive Microcontrollers . .1 1.1.2 FPGA . .3 1.2 FPGAs in engine control . .5 1.3 Advantages of FPGA based engine controllers . 10 1.4 Impact of Drivven FPGA based engine controllers . 12 2 Engine Control Co-Processing . 16 3 SAE2005-01-0067 . 19 3.1 Synopsis . 19 3.2 Introduction . 19 3.3 Overview . 21 3.4 Technology Background . 22 3.4.1 LabVIEW . 22 3.4.2 Compact RIO . 22 3.4.3 FPGA . 23 3.5 Research and I/O Module Creation . 24 3.5.1 Fuel Injector Driver Module . 24 3.5.2 Spark Module . 27 3.5.3 Input Module . 27 3.6 Mapping . 28 3.6.1 Mapping Method . 29 3.6.2 Data Collection . 30 3.6.3 Post Processing . 31 vi 3.7 Engine Controller . 34 3.7.1 Basic Engine Control Algorithms . 36 3.7.2 Speed-Density . 36 3.7.3 Alpha-N . 37 3.7.4 MAF . 39 3.7.5 Transient Compensation . 40 3.7.6 Closed Loop . 41 3.7.7 Fuel Calculation . 41 3.7.8 Transient Fuel Compensation . 44 3.7.9 Spark Control . 45 3.7.10 Rev Limiter . 47 3.7.11 Startup and Idle Control . 47 3.7.12 Other I/O . 48 3.7.13 User Interface . 48 3.8 FPGA Fuel and Spark Control . 49 3.9 Conclusion . 55 3.10 Acknowledgments . 55 3.11 Contact . 56 4 ICEF2011-60225 . 57 4.1 Synopsis . 57 4.2 Introduction . 57 4.2.1 Why a Free-Piston . 58 4.2.2 Breif Free-Piston History . 58 4.3 ATS HiPerTEC Engine . 60 4.4 Control System Overview . 64 4.4.1 Hardware . 64 4.4.2 Software . 66 vii 4.5 Engine Position Tracking . 70 4.5.1 Types of Outputs . 73 4.5.2 Free-Piston EPT . 74 4.6 Control System Operation . 74 4.6.1 Valve Operation and Timing Control . 84 4.7 Conclusion . 88 4.8 Future Work . 89 4.9 Acknowlegments . 89 5 Digital Signal Processing and Control . 90 6 ICEF2010-35119 . 92 6.1 Synopsis . 92 6.2 Introduction . 93 6.3 System Overview . 94 6.4 Next-Cycle Control Description . 97 6.5 Next-Cycle Results . 98 6.6 Same-Cycle Requirement . 101 6.7 Heat Release Calculations . 103 6.8 Conclusion . 113 6.9 Future Work . 117 6.10 Acknowlegments . 117 7 Custom Computing Machines . 118 8 FCCM2012 . 121 8.1 Synopsis . 121 8.2 Introduction . 122 8.3 Related Work . 125 8.4 Background . 127 8.4.1 One-Dimensional Computational Fluid Dynamics . 127 viii 8.4.2 Precision Timed Architecture . 129 8.5 Design Flow and Architecture . 130 8.5.1 System Description and Design Flow . 131 8.5.2 System Hardware Architecture . 134 8.5.3 Software Design . 138 8.6 Experimental Results and Discussion . 140 8.6.1 Setup . 141 8.6.2 Timing Requirement Validation . 142 8.6.3 Resource Utilization . 143 8.7 Conclusions and Future Work . 145 9 ICES2012-81138 . 147 9.1 Synopsis . 147 9.2 Introduction . 148 9.3 Computational Model . 150 9.3.1 One-Dimensional Computational Fluid Dynamics . 151 9.3.2 Mechanical Subsystem . 154 9.3.2.1 Mechanical Equilibrium Governing Equation . 154 9.3.2.2 Numerical Integration . 155 9.3.2.3 Modeling a Hydraulic Damper . 157 9.4 Real-Time Implementation . ..