Powertrain Control Reducing Complexity via Offline Pre-optimization
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Solution Overview
Problem
Current powertrain control systems in industrial and commercial vehicles fail to optimize combustion engine operation due to the lack of consideration for the interaction between the engine and aftertreatment systems (ATS), leading to excessive fuel consumption and conservative engine operation to meet pollutant limits, which complicates the optimization process with many engine control inputs and operational limits.
Innovation Solution
A method involving offline pre-optimization and online control using a predictive supervisory controller that reduces the complexity of the optimal control problem by transforming engine control inputs into engine strategy inputs, focusing on minimizing fuel consumption and NOx emissions while maximizing ATS enthalpy, and ensuring compliance with mechanical, thermal, and emissions limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed engine calibration(s) are used to meet pollutant limits conservatively, then pollutant emissions constraints are satisfied, but fuel consumption increases excessively
Solution Approach 1:
The patent replaces fixed engine calibrations with dynamic, adaptive calibrations that adjust in real-time based on ATS temperature, driving mission, and predicted emissions requirements. The system continuously optimizes engine control inputs (fuel injection timing, EGR rate, VGT position) to match actual operating conditions, enabling the engine to operate at optimal points rather than conservative fixed settings.
Solution Approach 2:
The system implements feedback mechanisms by monitoring ATS temperature, predicted emissions, and actual engine operation to continuously adjust control strategies. The predictive controller uses feedback from sensors and mission data to refine engine calibration in real-time, ensuring both emissions compliance and fuel efficiency.
2Productivity
If multiple engine control inputs are optimized online considering all operational limits, then optimal fuel consumption and emissions are achieved, but computational complexity becomes too high for online solving
Solution Approach 1:
The patent segments the control problem into two parts: an offline pre-optimization phase that handles complex calculations and limit constraints, and an online execution phase that only needs to retrieve pre-computed optimal control inputs. This segmentation moves computational complexity from online to offline, enabling real-time optimal control without excessive computational burden.
Solution Approach 2:
The system performs preliminary optimization offline by pre-calculating optimal engine control inputs for various operating conditions and storing them in lookup tables or maps. During online operation, the system simply queries these pre-computed results based on current conditions, avoiding the need to solve the complex optimization problem in real-time.
Data Source
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AI summary
Method for controlling a powertrain including an internal combustion engine and a relating After Treatment System (ATS), the method including an engine pre-optimization identifying feasible and Pareto optimal engine operation in such a way as to minimize fuel consumption and engine-out NOx emissions and to maximize the enthalpy provided to the ATS, and an on-line controlling of the power-train on the basis of said pre-optimization.