Auto-calibration for Diesel truck with Waste Heat Recovery system

In an internal combustion engine approximately 60-70% of the fuel energy is lost through the coolant and exhaust. To recover the exhaust gas energy, a Waste Heat Recovery system is used. A supervisory control strategy maximizes the total powertrain energy efficiency within constraints set for tailpipe emissions.

PhD Candidate: Emanuel Feru
Supervisor: Frank Willems, Bram de Jager
Promotor: prof. Maarten Steinbuch
Project Financing: TNO Automotive
Project Period: September 2011 - 2015

In this project, a Waste Heat Recovery (WHR) system model is developed and validated on a real Euro-VI heavy-duty diesel engine. The model is dynamic and captures the two-phase flow phenomena. It is used for prediction, system optimization and control design. The objective is to maximize the WHR system output power while guaranteeing safe operation in the presence of highly dynamic engine disturbances.

A Model Predictive Control (MPC) strategy is developed to operate the system close to the safety limit for maximum output power and cope with real world driving conditions. Based on simulation results over a World Harmonized Transient Cycle, the developed strategy shows improved performance in terms of output power and safety as compared to a classical PID control strategy.
Furthermore, a supervisory control strategy is developed that minimizes the fuel consumption within the emission constraints set by the legislation. This Integrated Powertrain Control (IPC) strategy combines energy and emission management.