2012 doe merit review – accessenergy.gov/sites/prod/files/2014/03/f10/ace066_yilmaz_2012_o.pdf ·...
TRANSCRIPT
Hakan Yilmaz Global Technology Management
Gasoline Systems, Robert Bosch LLC
Contract: DE-EE0003533 Project ID: ACE066
2012 DOE Vehicle Technologies Program Review
Advanced Combustion Concepts - Enabling Systems and Solutions (ACCESS) for High Efficiency Light Duty Vehicles
Arlington, Virginia May 18th, 2012
“This presentation does not include any confidential material”`
2012 DOE Merit Review – ACCESS
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 1
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2012 DOE Merit Review – ACCESS
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Accomplishments and Future Work
• Summary
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 2
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2012 DOE Merit Review – ACCESS – Overview
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Budget Barriers
Timeline Partners
• US Department of Energy • Robert Bosch LLC • AVL • University of Michigan, Ann Arbor • Stanford University • Emitec
Barriers
Fuel efficiency as key market driver Stringent emission requirements System cost of advanced combustion
Targets >25% fuel efficiency improvement SULEV emissions capability Commercially viable system solution
$24,556,737 – Total Project Budget • $11,953,784 – DOE Funding • $12,602,954 – Partner Funding
$9,987,412 – Phase I
• $4,764,644 DOE Budget • ~ $4,586,000 invoiced to DOE
$7,441,808 – Phase II $7,127,518 – Phase III
Phase 3 (1.5 yrs)
Application
Implementation and
Vehicle Demo
Phase 1 (1.5 yrs) Concept
Fundamental Research
Phase 2 (1 yr)
Development
Technology Development
Phase 3 (1.5 yrs)
Application
Implementation and
Vehicle Demo
Phase 1 (1.5 yrs) Concept
Fundamental Research
Phase 2
Development
Technology Development
9/30/2010- 02/28/2012
03/01/2012- 02/28/2013
03/01/2013 – 09/29/2014
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4
2012 DOE Merit Review – ACCESS – Relevance
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Accomplishments and Future Work
• Summary
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 4
Combustion Concept – Boosted Lean HCCI + Engine Downsizing
Homogenous pre-mixture of air, fuel & residuals Controlled auto-ignition and flameless combustion
2012 DOE Merit Review – ACCESS – Relevance
100 %
125 %
1) w/ 2xVVT in/out, 20% Downsizing 2) w/ 2xVVT in/out, 30% Downsizing 4) w/ 2xVVT 5) w/ 2xVVT, 2x 2 - - step VVL, ext. EGR, PDI 6) Dual Fuel System, Start - Stop
Port Inj . Direct Injection 0 %
25 %
50 %
75 %
100 %
Hom .
102 %
Lean Stratified
Spray Guided 4 )
117 %
3) w/ VVT in/VVL out, 40% Downsizing
Lean Hom .
HCCI 5 )
116 %
HCC I
Basic System
Hom . Turbo
Extr . DZ 3 )
3.5L
Hom . Turbo DZ 1)
115 %
2.8L
Hom . Turbo DZ 2)
117 %
2.5L
122 %
2.0L
Lean Hom . HCCI Turbo DZ 3)+ 5 )
HCC I
12 8 %
Lean Stratified
Turbo DZ 3)+ 4 )
127%
Lean Hom . HCCI Turbo
DZ 3)+ 5 )+6)
HCC I
13 0 %
Port Inj . Direct Injection 0 %
25 %
50 %
75 %
100 %
Hom .
102 %
Lean Stratified
Spray Guided 4 )
117 %
3) w/ VVT in/VVL out, 40% Downsizing
Lean Hom .
HCCI 5 )
116 %
HCC I
Basic System
Hom . Turbo
Extr . DZ 3 )
3.5L
Hom . Turbo DZ 1)
115 %
2.8L
Hom . Turbo DZ 2)
117 %
2.5L
122 %
2.0L
Lean Hom . HCCI Turbo DZ 3)+ 5 )
HCC I
12 8 %
Lean Stratified
Turbo DZ 3)+ 4 )
127%
Lean Hom . HCCI Turbo
DZ 3)+ 5 )+6)
HCC I
13 0 %
1 2 3
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 5
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2012 DOE Merit Review – ACCESS – Relevance
Overall Project Objectives • Baseline Powertrain: 3.6L V6, PFI, 6 Speed • Target Powertrain: 2.0L I4, DI, Turbo, 6 Speed –Multi Mode Combustion SI/HCCI • >25% Fuel Economy Improvement Compared to Baseline • SULEV Emissions Capability • By mid 2014 commercially viable, production feasible, system solution
Annual Objectives – March 2012 to March 2013 • Finalize control strategy architecture for a multi-mode combustion engine • Integration of proposed air path and HCCI combustion control strategies into ECU software • Prototype level 2 updates and proof of combustion concept for vehicle readiness • Implementation of rCFD LES Combustion model
Phase 2 Targets for Phase 3 Go/No Go Decision • Modeling, simulation, or test results of selected technologies indicate technical feasibility of
achieving project goals. • The cost benefit analysis shows that the project is on a specific path to deliver a
commercially viable engine and vehicle system.
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 6
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2012 DOE Merit Review – ACCESS – Approach
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Accomplishments and Future Work
• Summary
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 7
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Customized Engine Management (ECU)
Novel combustion algorithms Model based control
Boosting Device
2-stage TCSC system HCCI map extension
Solenoid Multi-Hole DI Central mount Split injection small pulse Laser drilled holes Simultaneous DI+PFI inj.
DI + PFI Injection
In-Cylinder Pressure Sensing
Direct combustion feedback Closed loop control
Three-way catalyst Optimized for multi-mode
combustion
Advanced Aftertreatment
2x Var. phasing (CamPhasers) 2x Var. lift (TwinLift or cont. var.) Fast and accurate actuation
Variable Valve Actuation
EGR control EGR cooling Map extension
External EGR System
ACCESS Multi Mode Combustion System Configuration
2012 DOE Merit Review – ACCESS – Approach
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 8
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Multi Mode Combustion System Configuration – Prototype 1 Architecture
2012 DOE Merit Review – ACCESS – Approach
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 9
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2012 DOE Merit Review – ACCESS – Collaboration
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Accomplishments and Future Work
• Summary
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 10
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2012 DOE Merit Review – ACCESS – Collaboration
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
ACCESS Project Organization
University of Michigan - Sub Advanced Powertrain Controls Laboratory
- Control Oriented Models - HCCI / SIDI Engine Controls - Engine Sub - System Controls
US OEM’s
- Information Exchange - Technology Alignment
Robert Bosch LLC - Sub Research and Technology Center (RTC)
- HCCI and Bio Fuels Thermodynamics - Combustion Modeling and Simulations
- HCCI Engine Controls
Stanford University - Sub
- HCCI and Bio Fuels Thermodynamics - Combustion Modeling and Simulations
- Single Cylinder Engine Operation
AVL - Sub Powertrain Engineering
- Engine & Vehicle Simulations - HCCI Combustion System Research
- HCCI Engine Design and Development
US Department of Energy
- Project / Contract Management - Technical Merit / Milestone Reviews
Steering Committee - Project Scope Definition
- Technical Merit / Milestone Reviews
Robert Bosch LLC - Prime Gasoline Systems (GS)
- Project Lead - Engine Management System Concept
- Engine Controls & Application
Chevron Energy Technology Company External Support
- Fuel Property Consultation - Fuel Samples for Combustion Testing
University of Michigan - Sub Walter E. Lay Automotive Laboratory - Physics Based Combustion Modeling - Combustion Development & Testing
- Single / Multi Cylinder Engine Research
Emitec - Sub
- After - Treatment System and Simulation - 3 - Way Catalyst Development
- Lean NOx After - Treatment Development
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2012 DOE Merit Review – ACCESS – Collaboration
University of Michigan, Ann Arbor Advanced Powertrain Controls Laboratory
Anna Stefanopoulou – Co – PI – Engine Controls Eric Hellström – Research Fellow –
Engine Controls Yi Chen – Air Path Modelling / Controls Patrick Gorzelic – Combustion Mode Switching Shyam Jade – Combustion Modelling /
Controls Jacob Larimore – Combustion Mode Switching
US OEMs
– Information Exchange – Technology Alignment
Robert Bosch LLC Research and Technology Center (RTC)
Joel Oudart – Advanced Combustion/Biofuels Nalin Chatuverdi – Modeling and Controls Aleksander Kojic – Controls Nikhil Ravi – Controls
Stanford University
Heinz Pitsch – Co - PI – CFD Simulations Mittal Varun – CFD Simulations
Eric Doran – CFD Simulations
Chris Edwards – Thermodynamics Julie Blumreiter – Thermodynamics
AVL Powertrain Engineering
Dusan Polovina – Co - PI – Combustion Roger Faber – Project Management Vasile Frasinel – Design Kevin Roth – Calibration Chris Erhardt – Engine Assembly & Dyno
Robert Bosch LLC Gasoline Systems (GS)
Hakan Yilmaz – PI Li Jiang – Co - PI – Engine Controls Oliver Miersch-WIemers – Co - PI – System Angela Dragan – Project Management Jeff Sterniak – Combustion Concept Julien Vanier – System Integration Alan Mond – System Concept
Chevron Energy Technology Company (ETC)
– Technical Consultation – Advisory and Information Exchange
University of Michigan, Ann Arbor Walter E. Lay Automotive Laboratory
Stani Bohac – Co - PI – Combustion Jason Martz – Combustion Simulation
Janardhan Kodavasal – Chemical Kinetics Modelling Prasad Shingne – 1D Engine Simulation Adam Vaughan – Experimental Research Vijai Manikandan – Multi-Mode Operation
Optimization
Emitec
Ulrich Pfahl – Co - PI – After - Treatment Jan Kramer – Co - PI – After - Treatment Markus Downey – System Application
– Experimental Research
Ben Kessel – Thermodynamics
David Cook – Co- PI - CFD Simulations
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Vasileios Triantopoulos
Arjun Sharma – CFD Simulations
ACCESS Project Organization
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• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Accomplishments and Future Work
• Summary
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
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15 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
COMBUSTION CONTROLS
SOFTWARE ARCHITECTURE
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16 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
• Control-Oriented Modeling • Engine Control Development • Control Validation
• Real-time Controls in ECU
• Concept Feasibility • Fuel Econ. And Emissions • Experimental Validation • Biofuels investigation • rCFD – LES and RANS
• Base Engine Control Unit • Controls Implementation • Vehicle Interface
• Multi-Mode Combustion ECU
Demo Vehicle
•Optimal Combustion Mode Switch Strategies
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Engine Test Cells at University Partners • Single-cylinder research engine lab with Fully Flexible
Valve Actuation (FFVA) at Stanford operational
• Two multi-cylinder engine dynamometers (one steady-state, one fully transient) operational at University of Michigan Automotive Research Laboratory
• Prototype 1 engine operational at University of Michigan since 03/2012
• Resident Bosch engineers at Stanford University and University of Michigan Stanford University University of Michigan
Engine Test Cells at Industry Partners • HCCI combustion development and parameterization with
Prototype 1 engine at AVL test cell since 10/2011
• SI calibration with Prototype 2 engine at Bosch test cell scheduled 07/2012
• All experimental set-ups have same Engine HW and Engine Management System Bosch test cell AVL test cell
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Transient Dyno Cell
2012 DOE Merit Review – ACCESS – Accomplishments
Industry support enables university researchers to focus on innovation
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18 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
Fundamental Combustion & Fuels Approach
Strategies for low load at 1500rpm Results Future Work • Engine test bench operational with DI + PFI
Injection, Fully Flexible VVA, Boost (<3000rpm) • Key fuel injection strategy for low load HCCI
identified • rCFD RANS: HCCI Combustion model applied for
baseline case • rCFD LES: Gas exchange validated
4 4.5 5 5.5 6 6.5280
300
320
340
360
380
400
mfuel [mg/cyc]
isfc
[g/k
Wh]
Fuel Mass [mg/cyc] Spec
ific
Fuel
Con
sum
ptio
n [g
/kW
h]
Reduction iSFC with multiple injection
Single injection Multiple injection
Strategies for low load at 1500rpm
• Single cylinder research engine (SCRE) with
Fully Flexible Variable Valve actuators (Stanford University)
• Investigation of injection strategies for robust HCCI under low load condition
• rCFD RANS to investigate extreme high and low load HCCI
• Development of rCFD LES method for engine simulation in SI and HCCI modes
• Define optimized valve lift profiles for Prototype 2 engine
• Investigation of SI/HCCI mode switch • HCCI investigation with biofuels • Investigate low load HCCI operation with rCFD
RANS • Develop boosted HCCI operation strategies
LES of HCCI Gas Exchange
18
200220240260280300320340360SOI [bTDC]
240
260
280
300
320
19 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Prototype I Injector Prototype II Injector
2012 DOE Merit Review – ACCESS – Accomplishments
Stock Injector Stock injector Prototype 1 injector
1500RPM
6.0 bar BMEP
200220240260280300320340SOI [bTDC]
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
SMO
KE [FSN
] BSF
C [g
/kW
-hr]
Spray Development for Direct Injection
Better mixture preparation in SI mode shows 1-3% BSFC gains on Prototype 1 engine
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20 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
2-stage Turbocharger
Back- pressure
MechanicalFriction
higher losses
Supercharger + Turbocharger
+ Turbocharger
- -
Boosting Strategy for Lean HCCI
Boost pressure From turbocharger
Flow Rate [kg/hr]
Pre
ssur
e R
atio
Supercharged HCCI shows high potential when assisted by low-pressure turbocharger
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21 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments Experimental Fuel Economy Results from Prototype 1 Engine
BS
FC [g
/kW
-hr]
0
50
100
150
200
250
300
350
400
450
500
550
600
1500 RPM2.0 bar BMEP
2000 RPM3.0 bar BMEP
2500 RPM 2.0 bar BMEP
Baseline 3.6L PFI EngineSI - Prototype 1 EngineHCCI - Prototype 1 Engine
40% 33%
40%
* Optimized to 50ppm NOx; Further optimization of boosting system in progress to reduce to 10ppm NOx
* *
*
Steady-state results show > 33% FE improvement with downsized HCCI over baseline
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Overview – Combustion System Approach
Major Accomplishments Future Work
• Steady state and transient boosted HCCI operation used to achieve BSFC targets with optimized NOx emissions.
• High fidelity combustion model for fundamental multi-mode combustion.
• Simulation of FTP75 cycle on UofM transient dyno to develop boosted HCCI concepts.
• Demonstration vehicle to validate final results.
• Prototype 1 engine built successfully and
operational at AVL since 10/2011
• Transient dynamometer was commissioned at University of Michigan and operational
• Boosted HCCI comparison (SC vs TC) completed at University of Michigan
• CFD models validated for baseline operation
• Experiment optimized TC-SC boosting system
• Combustion development and validation of Prototype 1 engine on transient dynamometer
• Parameterization of multi mode combustion
• Prototype level 2 updates and proof of combustion concept for vehicle readiness
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
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23 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
• Control-Oriented Modeling • Engine Control Development • Control Validation
• Real-time Controls in ECU
• Concept Feasibility • Fuel Econ. And Emissions • Experimental Validation • Biofuels investigation • rCFD – LES and RANS
• Base Engine Control Unit • Controls Implementation • Vehicle Interface
• Multi-Mode Combustion ECU
•Optimal Combustion Mode Switch Strategies
23
RBNA/GOV | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
Model-based control to enable fast and robust HCCI transitions
HCCI Control Architecture
Operating Coordination
Driver Demands
Engine Torque
Structure
N, M* BMOD
+SOI [MR] MFB50-EVC FB Controller
(Reference Cylinder)
ENG
INE
Exhaust Valve Controller
Combustion Feature
Calculation
pcyl
State Estimator(Cylinder Individual)+ MFB50-SOI FB Controller
(Cylinder Individual)MFB50*
MFB50
MFB50-SOI FF Controller (Cylinder Individual)
NMEP FB Controller(Cylinder Individual)
NMEP FF Controller(Reference Cylinder)
+NMEP*
NMEP
+ Injector Controller
Reference Cylinder Identificaiton
+
λ* Wcyl,air
N, pint
φINJ
ΔtINJ
WINJ,FF
WINJ,FB
φINJ,FF
φINJ,FB
Torque Structure Air System Fuel System
EVC Coordinate exhaust valve and injection timing with mid-ranging control strategy
Cylinder-to-cylinder balancing with cylinder-individual fuel control with reference cylinder approach
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RBNA/GOV | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
Reduced-order model enables model-based control of HCCI combustion
254 256 258 260 262 264 266-2
-1
0
1
2
3
4
EVC (CAD)
CA
50 (C
AD
)
Control modelData
7.5 8 8.5 9 9.5 10 10.5-5
-4
-3
-2
-1
0
1
2
3
4
Fuel quantity (mg)C
A50
(CA
D)
Control modelData
95 100 105 110
2
4
6
8
10
12
CA
50 (C
AD
)
Engine cycle
Control modelExperiment
Reduced-order model
Experiment
1100 1200 1300 1400 1500 1600 1700 1800 1900 20001
2
3
4
5
6
7
8
Engine speed (rpm)
CA
50 (C
AD
)
Control modelExperiment
Single-C
ylinder Engine
Transient from 1600 to 1900 RPM
Multi-C
ylinder Engine
Steady-State Engine Speed Sweep
Steady-State EVC Sweep
Steady-State Fuel Quantity Sweep
Control-Oriented Modeling of HCCI Combustion
Main Combustion States (state): T, [O2], [fuel] Main Actuator (inputs): EVC, SOI, mfuel Target Performance Variable (output): CA50
Model Structure
25
RBNA/GOV | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
Robust control to enable stable HCCI combustion at boundary conditions
Modeling and Control for HCCI with High Cycle-to-Cycle Variation Single-Cylinder Engine (UM) Observation
High cycle-to-cycle variations were observed on both single and multi-cylinder engine at HCCI boundary operation conditions
Simulation-based performance evaluation of controllers with injection timing as the key actuator
26
RBNA/GOV | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
Simulation of model-based control of throttle and turbocharger wastegate
Model-based boost control improves air charge transient response
Boost Control with 2-stage TC-SC Air Path System
Engine Management System for target engine platform
27
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Overview – Control System Approach • Simulation / Experiment based system dynamics
and control sensitivity analysis
• Model-based combustion / air path control with cylinder pressure sensing feedback
• Engine-in-the-loop control algorithm validation via rapid prototyping techniques
• Control-Oriented HCCI combustion model validated
for low/part load and light boost at varying speeds
• Control-oriented air path model and controls established for target engine configuration
• Actuator sensitivity analysis under HCCI combustion for Prototype 1 engine in progress
• Establish controls for HCCI /SI combustion
mode switch
• Finalize control strategy architecture for a multi-mode combustion engine
• Validate transient HCCI operation with Engine-in-the-loop vehicle simulation
Accomplishments Future Work
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
States X: T, [O2], [fuel]Inputs U: IVO, EVC, SOI, fuel, Sp
SC-Byp, WG, Thr, Egr,CP-Int, CP-Exh, SC-C
Outputs Y: CA50, NMEP
Model Xk+1 = f(Xk, Uk); Yk = g(Xk, Uk)Control Uk = h(Xk, Yk,ss)
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29 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
• Control-Oriented Modeling • Engine Control Development • Control Validation
• Real-time Controls in ECU
• Concept Feasibility • Fuel Econ. And Emissions • Experimental Validation • Biofuels investigation • rCFD – LES and
RANS
• Base Engine Control Unit • Controls Implementation • Vehicle Interface
• Multi-Mode Combustion ECU
• Optimal Combustion Mode Switch Strategies
29
30 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
CPU: Infineon TriCore1797 microcontroller, 32 Bit, 180 MHz 6 HP injectors (HDEV5) 2 High pressure pump drivers (HDP5) 3 H-Bridges for electronic valves (DV-E) 18 low-side power stages 2 broad band O2 sensors (LSU4.9) 2 two-step O2 sensors (LSF4.2) 4 Variable camshaft controls (VVT) 6 Igniter drivers 4 CAN drivers 1 Hall-effect crankshaft sensor 4 Hall-effect camshaft sensors 6 Cylinder Pressure Sensors
Motronic MED 17 Engine Control Unit (ECU) for Advanced Projects
Bosch ECU enables advanced combustion controls
30
31 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments Bosch ECU Advanced Capabilities
Up to 4 injections per cycle Precise control of
small quantities
Direct Injection
Supercharging & Turbocharging
Coordination of multiple boost devices
In-Cylinder Pressure Sensing
Cycle-to-cycle closed-loop combustion control
Electric valve timing (VVT) for fast transients 2-step valve lift for HCCI
mode switch
Variable Valve Actuation
ETK Calibration Interface
Enables Rapid Prototyping
Computation power for model-based controls
Tricore Micro- controller
All engine component drivers and advanced controls running on single Bosch ECU
31
32 RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
RP Software INTECRIO
Models •Simulink •ASCET
Calibration Software
INCA
ECU
Controls Rapid Prototyping (RP) Setup at the University of Michigan Test Cell
RP Hardware ES910
Prototype Engine
Transient Dynamometer Innovative ideas of researchers are quickly tested on the engine
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Overview - Software Architecture Approach
Accomplishments Future Work
• Bosch Motronic engine control platform to be
used for Engine and Vehicle level development with all sub-system and system level functions
• Engine Control Unit with integrated algorithms for multi mode combustion for production feasible proof of concept
• Common ECU platform for all partners’ research
• Prototype Engine Control Unit (ECU) used by the
project is built with additional drivers
• Integrated ECU software for Prototype 1 engine, including base HCCI control algorithms
• Rapid-Prototyping hardware operational on University of Michigan transient test cell
• Successful operation of prototype 1 engine with Bosch ECU
• Integration of proposed air path and HCCI
combustion control strategies into ECU software
• Evaluation of multi-mode combustion switch with engine-in-the-loop rapid prototyping
• Verification of engine management system for Prototype 2 engine architecture
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
2012 DOE Merit Review – ACCESS – Accomplishments
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2012 DOE Merit Review – ACCESS – Summary
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Accomplishments and Future Work
• Summary
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 34
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2012 DOE Merit Review – ACCESS – Summary
RBNA / GOV1 | 3/1/2012 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Team Competence / Project Management
Base Engine Hardware
Engine Mgmt. System Hardware
Emission System
Control Strategy
Software Architecture
Combustion Strategy
Bio-Fuel Combustion
>25% improved FE SULEV Capable Commercially Viable
Target Phase 3(1.5 yrs)
Application
Implementationand
Vehicle Demo
Phase 1(1.5 yrs)Concept
FundamentalResearch
Phase 2(1 yr)
Development
TechnologyDevelopment
Phase 3(1.5 yrs)
Application
Implementationand
Vehicle Demo
Phase 1(1.5 yrs)Concept
FundamentalResearch
Phase 2(1 yr)
Development
TechnologyDevelopment
35