Health-Aware Engine Control for Turbocharger Wear Reduction
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Solution Overview
Problem
Modern automotive control methods, such as Model Predictive Control (MPC), can accelerate the deterioration of system components like turbochargers due to performance optimization, competing with health optimization goals, and existing predictive maintenance does not extend component life beyond maintenance intervals.
Innovation Solution
A configurable controller that uses a state observer and optimizer to balance performance and health optimization by incorporating health degradation terms into the optimization process, adjusting actuator settings to minimize health impacts while maintaining performance within allowed deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If performance optimization control methods are used to maintain setpoint tracking quality, then engine performance is improved, but component health deteriorates faster due to large and fast changes in actuator values
Solution Approach 1:
The patent modifies the cost function parameters by adding a health-related term that penalizes large changes in actuator values. This parameter change in the optimization objective balances performance tracking with component health preservation, reducing low-cycle fatigue while maintaining acceptable engine performance.
Solution Approach 2:
The patent implements feedback by monitoring actuator values and their changes, and incorporating this information into the cost function. The health-related term provides feedback on the impact of control actions on component wear, allowing the optimizer to adjust actuator commands to minimize health degradation while maintaining performance.
2Reliability
If predictive maintenance monitoring is performed to detect component degradation, then system reliability is improved, but component life is not extended beyond maintenance intervals
Solution Approach 1:
The patent applies preliminary action by proactively modifying control strategies before component failure occurs. The health-related cost function term anticipates future wear and adjusts actuator commands in advance to minimize degradation, extending component life beyond traditional maintenance intervals rather than merely detecting failure.
Data Source
AI summary
New and/or alternative approaches to physical plant performance control that can account for the health of the physical plant. In one example, a control algorithm is enhanced by inclusion of terms related to optimized performance and terms related to physical plant health. In another example, a performance optimized control solution is determined, a maximum allowed deviation is defined, and a final solution for physical plant control is determined taking into account health factors to minimize health impacts within the maximum allowed deviation from optimized performance, using for example a two-stage analysis. Another example uses a two level system with a low level controller and a supervisory controller, in which the supervisory controller observes health impacts of ongoing operations managed by the low level controller, and modifies one or more parameters used by the low level controller.