Engine Control Unit Research Articles

Vehicle power supply management strategies

Introduction. To optimize the performance of the vehicle electrical system, it is necessary to improve the control principles and strategies. The control principles may be based on voltage constancy, ensuring battery charge, reducing fuel consumption, etc.Materials and methods. A distinctive feature of the first level control strategy is the absence of additional sensors in the power supply system. Their occurence led to the emergence of the second level control strategy aimed at ensuring the starter battery charge, which is achieved by organizing the interaction between the electronic engine control unit and the generator. In the control strategy of the third level the first place is given to the reduction of the vehicle fuel consumption. The target functions of the listed control strategies are considered.Results. The fourth level management strategy, the purpose of which is to reduce the costs of power supply system operation at all stages of the life cycle, is proposed. The structure of power supply system operation costs is considered, which includes the costs of fuel overconsumption caused by malfunctions in the operation of units, as well as the costs of maintenance, diagnostics, repair (replacement) and utilization.Discussion and conclusions. Practical application of the proposed strategy will make it possible to take into account all types of costs and minimize the cost of operating the power supply system for both vehicles with internal combustion engines and hybrid and electric vehicles, in which electricity is even more important.

Adaptive control concepts using radial basis functions and a Kalman filter for embedded control applications

Look-up tables or semi-physical models are used in engine control application to enhance the transient control performance. However, the calibration of these look-up tables and/or semi-physical models is highly data dependent, requires significant calibration effort, and does not account for effects such as hardware aging, drifts, fuel variations, etc. To address these challenges, this paper presents a generic adaptive control concept for real-time engine control applications. The boundary conditions for the operation on a state-of-the-art engine control unit (ECU) are considered and Radial Basis Function (RBF)-based neural networks are identified for the approximation of non-linear models. To ensure optimal convergence and un-susceptibility to signal noise, a Kalman filter (KF) is exploited for training the RBF network and a modified approximation is derived in this work. The derived KF approximation shows ∼30% better training performance in comparison to the approximation without variable noise consideration. The developed control concept is validated on an engine test bench and a demonstrator vehicle using a Rapid Control Prototyping (RCP) system. The potential of the developed control concept to ensure optimal control response and robustness has been demonstrated.

Real-time vehicular fuel consumption estimation using machine learning and on-board diagnostics data

Instantaneous fuel consumption estimation of fleet vehicles provides essential tools for fleet operation optimization and intelligent fleet management. This study aims to develop practical and accurate models to estimate instantaneous fuel consumption based on on-board diagnostics (OBD) data. Fuel consumption data is measured by a high-precision fuel flow meter. Two machine learning algorithms of Random Forest (RF) and Artificial Neural Networks (ANN) are trained with real-world urban and highway driving data of four fleet vehicles with different types and powertrain systems. In addition, the cold-start period of the vehicle operation is included to cover the fuel consumption penalty in the warm-up period. The validation results show that the RF method is more accurate than the ANN method, and both of the machine learning models have a better accuracy compared to the existing fuel consumption calculation methods based on the engine control unit (ECU) parameters.

Operational Control of Power Indicators of Diesel Engines with Common Rail Fuel System

Introduction. Operational methods to monitor the power indicators of engines for continuous diagnosis of their technical condition are of particular interest for creating optimal operating conditions of motor and tractor machinery. The methods are characterized by the mechanical efficiency, determined in the conditions of repair shops with the use of complex braking devices. Aim of the Article. To present the results of research on the development of an operational method for determining the mechanical efficiency of diesel engines with batteryoperated electronically controlled fuel supply systems. Materials and Methods. The Bashkir State Agrarian University proposed and successfully tested an operational method for assessing the technical condition of diesel engines with direct-acting fuel equipment on their mechanical efficiency, which is determined by the performance of their fuel equipment adjusted using the diesel itself as an adjusting stand. The possibility of using the proposed method for diesel engines with storage fuel systems was investigated. Results. The accuracy of determining the mechanical efficiency of diesel engines by electronically controlled fuel systems of battery type can be affected by the features of their work – the correction of cyclic feeds by the electronic engine control unit depending on the technical condition of the cylinders and high fuel injection pressure. To test this hypothesis, there were carried out studies on a four-cylinder D4EA 2.0 engine of a Hyundai Tuscon car with a Common Rail type storage fuel system. The engine fuel supply system was supplemented with an electronic unit integrated between the injector and the standard engine control unit, which interrupted the transmission line of the control signal to the injector according to a given algorithm without the standard unit transition to emergency mode. It has been found that the proposed method can successfully determine the technical condition of the engine as a whole and of its individual cylinders (alternating disabled and working cylinders). Discussion and Conclusion. The proposed operational method for determining the mechanical efficiency can be successfully used for diesel engines with accumulator electronically controlled fuel supply systems. At the same time, an increase in the cyclic supply by the electronic control unit of the engine fuel supply system reduces the mechanical efficiency slightly, and it can be taken into account only in special cases.

On the Increase in the Renewable Fraction in Diesel Blends using Aviation Fuel in a Common Rail Engine

Biodiesel has gained wide acceptance as an alternative to petroleum-derived fuel due to its environmentally friendly characteristics such as low aromatic and sulfur content, biodegradability and low exhaust gas emission. Although many types of feedstock could be used to produce biodiesel, waste cooking or frying oil (WCO) is a promising multiple-advantage solution. However, the use of WCO biodiesel has some drawbacks: the high viscosity and the low volatility create difficulties in atomization and in fuel–air mixing. Experiments were performed to investigate the potential employment of aviation fuels in blends with biodiesel obtained from WCO, renewable diesel and petrol diesel. The objective of the research was to evaluate Jet A’s potential to improve the blend properties, thus helping to overcome the difficulties in biodiesel usage, enabling the percentage of renewable fuel in the blend to be increased and therefore allowing a reduction in the engine’s environmental impact. The experimental activity was carried out on a small-displacement, common rail diesel engine; during the tests, the engine control unit settings were unchanged, with the aim of reproducing the engine behavior when it operated with different fuels.

Design and implementation of a wireless CAN module for marine engines using ZigBee protocol

AbstractThis paper describes the design and implementation of a wireless control area network (CAN bus) protocol for communication between the smart NOx (nitrogen oxide) sensor on diesel engines and the engine control unit (ECU). In this research, the approach taken is based on a case study of Wärtsilä's smart NOx sensor on a W4L20 diesel engine with the objective of replacing the wired CAN protocol with a wireless CAN communication node. In the current setup, the smart NOx sensor is connected to the engine control unit (ECU) with a wired CAN bus connection. The XBee module, which uses the ZigBee (IEEE 802.15.4) technology was used in the design and implementation of the wireless CAN prototype. With the emergence of 5G networks and the era of IoT, the topic of wireless industrial automation becomes essential in the modern industry. In addition to the great advantages and opportunities that the use of wireless nodes has in automation systems, there are many real challenges. The practical design challenges have been addressed in this paper.

Experimental Study of Spark Ignition Engine Performance under Different Electronic Control Units, Hole Injectors and Spark Plugs

The passage discusses the use of technology in vehicle fuel systems, specifically the injection system technology that is replacing conventional fuel systems. One crucial component of the fuel injection system is the Engine Control Unit (ECU), which controls the distribution of current to all engine components. While standard ECUs used on motorcycles today have limitations, racing ECUs provide more quality and can improve engine performance. The study aims to evaluate the engine's performance after modifications with an upgraded racing ECU using an 8-hole injector and racing spark plugs in the ignition system to enhance the motorcycle's performance. The methods and analysis section details the tools utilized, including the chassis dynamometer, and the parameters used in the study. The results and discussions section presents the collected data and compares it with previous studies to validate the observations.

Machine-Learning-Based Digital Twins for Transient Vehicle Cycles and Their Potential for Predicting Fuel Consumption

Transient car emission tests generate huge amount of test data, but their results are usually evaluated only using their “accumulated” cycle values according to the homologation limits. In this work, two machine learning models were developed and applied to a truck RDE test and two light-duty vehicle chassis emission tests. Different from the conventional approach, the engine parameters and fuel consumption were acquired from the Engine Control Unit, not from the test measurement equipment. Instantaneous engine values were used as input in machine-learning-based digital twins. This novel approach allows for much less costly vehicle tests and optimizations. The paper’s novel approach and developed digital twins model were able to predict both instantaneous and accumulated fuel consumption with good accuracy, and also for tests cycles different to the one used to train the model.

Optimasi konsumsi bahan bakar pada mesin bensin menggunakan artificial neural network

The engine control unit (ECU) is the primary component of the current injection technique used in spark ignition (SI) engines. The combustion system, which includes injection timing and ignition timing, is controlled by the engine map recorded in the ECU. To maximize an engine's performance, ECU remapping can be used. Remapping is currently not efficient because the data is typically employed in a trial-and-error fashion. To solve these issues, artificial neural network (ANN) techniques are being developed. In this study, engine remapping for fuel economy optimization is predicted using an artificial neural network (ANN). The purpose of this study is to use ANN to compare motorbike performance between before and after engine remapping (Artificial Neural Network). A set of dynamometers is used in this study approach to assess the performance of the 4 stroke, 160 CC spark plug ignition engine in terms of fuel consumption, power, and torque. A current (standard) engine map that contains a number of data from the electronic control unit (ECU) is used to start the optimization process. Pertalite and Pertamax, which are purchased from the closest gas station, are the fuels used in this study. In addition, optimization utilizing ANN is carried out with the goal of 10% increases in torque and power while maintaining a consistent fuel consumption. Following re-implementation into the ECU, the outcomes of the ANN training will be tested again on the dynamometer. The study's finding is that by using the training function, it is possible to improve machine performance using the regression value of R = 0.98993 and the ANN prediction outcomes. Comparing the optimized engine performance to the factory default engine performance, torque increased 10.9% and power rose 9.5%.

Numerical Evaluation of Fuel Consumption and Transient Emissions of Different Hybrid Topologies for Two-Wheeler Application

<div>In Asian countries, small two-wheelers form a major share of the automobile segment and contribute significantly to carbon dioxide (CO<sub>2</sub>) emissions. Hybrid drives, though not widely applied in two-wheelers, can reduce fuel consumption and CO<sub>2</sub> emissions. In this work three hybrid topologies, viz., P2 (electric motor placed between engine and transmission), P3 (electric motor placed between transmission and final drive), and power-split concepts (with planetary gear-train) have been modeled in Simulink, and their fuel consumption and emissions under the World Motorcycle Test Cycle (WMTC) have been evaluated. A physics-based model for the Continuously Variable Transmission (CVT) was used which is capable of predicting its transient characteristics. A map-based fuel consumption model and a Neural Network (NN)-based transient emission model were used for the engine. The NN-based transient emission model avoids the need to model the air path and fuel path in transient conditions, which is time consuming. The fueling characteristics of the Engine Control Unit (ECU) in transients need not be known if an NN model is built and tuned with sufficient experimental data. Several transient experiments were performed with speed-load profiles similar to the WMTC for tuning the NN emission models. Simulation results show that the P2 hybrid, P3 hybrid, and power-split drives have fuel economy benefits of about 27%, 37%, and 49%, respectively, compared to the conventional powertrain. However, nitrogen oxides (NOx) emissions are much higher for the hybrid powertrains due to the operation of the engine at higher load ranges for efficiency but are still within the prevailing BS6 Indian emission limits. A significant portion of the wheel energy input can be recovered through efficient regenerative braking in the WMTC. This will be even more significant under peak traffic city driving conditions. The belt losses in the CVT significantly reduce the potential benefits of the hybrid powertrain, and hence, an efficient transmission to replace it will be beneficial.</div>

Combustion and Exhaust Emission Improvement in a 3-Cylinder Mpfi Engine Through Downsizing

This research aims to compare the potential and existing conditions of a small-sized spark ignition (SI) engine with a 1.0-liter capacity suitable for cylinder deactivation. The cylinder deactivation strategy is used to solve the issues of inefficient combustion and increased exhaust emission under part loading. Consequently, the possibility of implementing cylinder deactivation in terms of decreased exhaust pollution has been assessed. A computerized, 1.0-liter, 4-stroke, water-cooled, spark-ignition engine with an open engine control unit (ECU) and multi-point fuel injection (MPFI) was used for the trials. Both modes were tested at 2500 revolutions per minute (RPM) under loads of 15, 30, and 45 N-m. The spark plug and fuel injector deactivate the cylinder. The results show that when the highest possible load is used, the peak cylinder pressure is 55.78% higher, and the maximum heat release rate is 53.96% more in the deactivation mode than in the traditional mode. In deactivation mode, the mass fraction consumed is larger at each crank angle point, suggesting a faster rate of combustion and increased combustion efficiency. The increased mean gas temperature permits the catalytic converter to perform more efficiently after downsizing. When compared to the conventional mode, carbon monoxide (CO) emission is almost non-existent at full load, unburned hydrocarbon (UHC) is reduced by 92.89%, and oxides of nitrogen (NOx) are reduced by 35% in the deactivation mode. Furthermore, the experiment indicated that, when employed at part load, the deactivation mode is more beneficial than the standard mode in terms of better combustion stability and lesser emissions.

Advanced model-based closed-loop combustion control strategies with combustion rate shaping

Combustion rate shaping (CRS) is an advanced closed-loop concept which controls the crank-angle resolved combustion trace by adapting the fuel injection profile. The thermodynamic potential of this concept to enable real-time combustion control independent of fuel property variations, injector drift, cylinder tolerances, or changing air-path boundary conditions has already been demonstrated. The highest benefit of this control concept is achieved when it is directly applied on the engine control unit (ECU) in combination with an in-cylinder pressure measurement. This enables online optimization and adaption of the fuel- and air-path settings to the fuel used during vehicle operation. Therefore, the development of a CRS concept with real-time capability has been the main focus so far. To ensure a robust online real-time combustion control, a key development step was the identification of control variables that describe the entire combustion process and only minimally influence each other. For this purpose, the combustion phasing, the combustion gradient and the indicated mean effective pressure have been determined as parameters for the feedback control. However, the stringent requirements for higher efficiencies, emission robustness and combustion noise necessitate the extension of the CRS control concept. Therefore, in this work, the CRS control concept is extended with the aim of realizing a combustion with constant volume pressure increase to the peak firing pressure limit to achieve highest efficiency. In addition, intelligent control of the fuel injection profile is to be used to achieve a combustion temperature for lowest possible NOx raw emissions and a robust combustion noise excitation limitation. The optimized control strategy is implemented on a heavy-duty single cylinder engine test bench using a Rapid Control Prototyping (RCP) system, and the control performance is demonstrated.

Adaptive system on engine misfire and knocking features for IC engine

Most countries in the world still rely on internal combustion engines as their daily means of transportation. The issue with internal combustion engines is irregularities in the combustion process that impact the environment, including misfiring and knocking. Numerous engineers and researchers have conducted studies to find solutions to this important engine problem to improve engine efficiency and achieve quality characteristics and customer satisfaction. The research aims to identify a workable integrated solution for the misfire and knocking features of an internal combustion engine. The RedLeo Pro V8 version 8.033 software was used to simulate the input data monitoring and control engine system. The engine condition was controlled by the Engine Control Unit (ECU). Data was collected using a vibration sensor and a wideband oxygen sensor. Low Processing program was used to represent data in two or three-dimensional graphs to determine the decision method. These signals were synthesized as adaptive system design signals to reduce noise and improve accuracy, enabling modification between normal and abnormal signals. As a result, the proposed method proves to be an effective method for engine fault diagnosis performed on the methodological paradigm of feature extraction and feature selection.

An Offline Closed-Form Optimal Predictive Power Management Strategy for Plug-In Hybrid Electric Vehicles

This article develops an optimal predictive power management strategy (OP-PMS) for plug-in hybrid electric vehicles (PHEVs) to manage the remaining battery level throughout a defined journey. Apart from using the battery before charging it again at the destination, this approach also supports transit through an Ultra Low Emission Zone (ULEZ), where a PHEV needs to operate in pure electric mode to avoid emissions. This type of PHEV power management strategy (PMS) design problem is a noncausal control problem, where the power demand of the remaining driving cycle and the final battery energy level targets influence the current power management action. Rather than solving the whole optimization problem online, this article presents a simplification that leads to a closed-form analytic solution with parameters that can be computed offline. This article makes three key contributions. First, a novel input-linearization method is developed, which converts the OP-PMS into a convex quadratic programming (QP) problem that captures the essential model nonlinearities using an input transformation and a quadratic cost function. Second, the influence of future power demands and final targets on current energy management policy is explicitly quantified from a dynamic optimal control perspective. Third, the noncausal convex QP is approximated with a closed-form analytic solution that is calculated offline. This leads to a real-time implementable OP-PMS with coefficients that can be precalculated and stored in the engine control unit. To demonstrate the viability of this approach, numerical examples are provided based on a generic PHEV model to verify the efficacy of the proposed OP-PMS.

The diagnostics of windings of vehicle alternator units

INTRODUCTION: An alternator unit is a necessary unit in a vehicle, as it provides all the consumers with electricity. Therefore, the operation capability of the whole vehicle depends on the alternator units operational state. The issue of the diagnostics of a vehicle alternator unit by means of determination of alternator phases windings active resistance is addressed.
 AIM: Improvement of diagnostics informativity by means of voltage controllers with a self-diagnostic function.
 METHODS: It is proposed to perform the alternator unit diagnostics without dismantling or disassembly by means of plugging to the diagnostic points.
 RESULTS: The existing and known methods of vehicle alternator unit diagnostics with embedded diagnostic tools and with use of external diagnostic tools were analyzed. The method of diagnostics of phase winding active resistance with use of reference resistance was proposed. The algorithm of implementation of the proposed method was suggested. The recommendations for use of the proposed method were given.
 CONCLUSIONS: The proposed diagnostics method can be used in engine control units or by technicians of maintenance stations during the alternator unit maintenance without dismantling or disassembly.

Validation of relationships between tractor performance indicators, engine control unit data and field dimensions during tillage

In order to improve the efficiency of tillage and reduce the impact of the tractor on the environment, it is important to scientifically understand the relationship between the dimensions of the cultivated field and the operational indicators of the tractor. The purpose of this study is to find a numerical relationship between tractor tillage performance indicators (tractor working time efficiency, work efficiency, fuel consumption, engine power utilization), engine control unit data and field dimensions. A numerical relationship between field dimensions, tractor performance and engine control unit data were obtained by combining two methods to calculate tractor time efficiency. The first method was to calculate the time efficiency value of the tractor using the “load profile” data from the engine control unit. In the second method, the time efficiency value of the tractor was calculated from the average working speed, the working width of the implement, the field area, its average length and width at the widest point. It was found that the performance of the tractor when working in the soil correlates quite well with the time efficiency according to the linear dependence and with the average length of the field according to the exponential dependence.

Comparative Study of Gasoline Fuel Mixture to Reduce Emissions in the Metropolitan District

In the present investigation, the behavior of fuel consumption was studied due to the high cost of gasoline and its price increase in Ecuador in recent years, for which reason the different mixtures have been studied to obtain lower consumption. The optimum fuel mixture rate for a T18SED e-tec II engine, Multiport Electronic Fuel Injection System (MPFI) between extra gasoline, super gasoline, and ethanol was obtained on two urban roads in the city of Quito (Ecuador). For the first test, mixtures of 10% super gasoline and 90% extra gasoline were made, and so on, for the following tests: (20–80), (30–70), (40–60), (50–50), (60–40), (70–30), (80–20), and (90–10) % super and extra gasoline. Then, mixtures between super gasoline and ethanol and extra gasoline and ethanol with concentrations of 5% and 10% were made. The results showed a low consumption on Maldonado Avenue with the 20% extra and 80% super mixtures obtaining a value of 2.9 L, while the mixture that presented a higher consumption was 100% extra of 3.4 L. At the end of each test, the fuel tank was completely drained, and the engine control unit (ECU) was reset for each test. The data acquisition was carried out through an OBD II (on-board diagnostic system) installed in each of the tests.

New approach of model based detection of early stages of fuel injector failures

The aim of the work was to develop a method of real time diagnosing electromagnetic fuel injectors using the observation of electric current parameters available in the engine control unit. Performing this task required finding a precise criterion for assessing the correct operation of an electromagnetic injector. For this purpose, a mathematical model describing the individual phases of the injector's operation was used, allowing the simulation of the occurrence of typical failures. On its basis, symptoms of particular failures were determined based on the observation of electric current parameters in the control circuit. Observation of voltage and current waveforms allows to locate both electrical and mechanical damages to the injectors and to assess the correctness of the power system components. The presented diagnostic method allows the detection of the described damages in the early stages of their development, which prevents damage to the catalytic converter and other engine systems (valves, piston rings or cylinder surfaces), i.e. damages resulting from an incorrect fuel mixture.

Enhancement of Heavy-Duty Engines Performance and Reliability Using Cylinder Pressure Information

Sustainability issues are becoming increasingly prominent in applications requiring the use of heavy-duty engines. Therefore, it is important to cut the emissions and costs of such engines to reduce the carbon footprint and keep the operating expenses under control. Even if for some applications a battery electric equipment is introduced, the diesel-equipped machinery is still popular thanks to the longer operating range. In this field, the open pit mines are a good example. In fact, the Total Cost of Ownership (TCO) of the mining equipment is highly impacted by fuel consumption (engine efficiency) and reliability (service interval and engine life). The present work is focused on efficiency enhancements achievable through the application of a combustion control strategy based on the in-cylinder pressure information. The benefits are mainly due to two factors. First, the negative effects of injectors aging can be compensated. Second, cylindrical online calibration of the control parameters enables the combustion system optimization. The article is divided into two parts. The first part describes the toolchain that is designed for the real-time application of the combustion control system, while the second part concerns the algorithm that would be implemented on the Engine Control Unit (ECU) to leverage the in-cylinder pressure information. The assessment of the potential benefits and feasibility of the combustion control algorithm is carried out in a Software in the Loop (SiL) environment, simulating both the developed control strategy and the engine behavior (Liebherr D98). Our goal is to validate the control algorithm through SiL simulations. The results of the validation process demonstrate the effectiveness of the control strategy: firstly, cylinder disparity on IMEP (+/−2.5% in reference conditions) is virtually canceled. Secondly, MFB50 is individually optimized, equalizing Pmax among the cylinders (+/−4% for the standard calibration) without exceeding the reliability threshold. In addition to this, BSFC is reduced by 1% thanks to the accurate cylinder-by-cylinder calibration. Finally, aging effects or fuel variations can be implicitly compensated, keeping optimal performance thorough the engine life.

BIOETHANOL AS AN ALTERNATIVE FUEL

The production of biofuels is like the development of a new, promising economic sector in Latvia. The production and introduction of biofuels is a factor promoting the development of Latvia's rural areas, which allows the acquisition of abandoned agricultural land, improves soil fertility, creates additional income and new jobs for farmers, promotes investment in rural development and the establishment of new production companies. Biofuels are one way of reducing environmental pollution from road transport. To rebuild the car to run on bioethanol fuel E85, it is necessary to reprogram the engine control unit. Specifically, overwriting the information on the EPROM chip. In five years (2016–2020), the consumption of biofuels in transport has increased 4.4 times more due to changes in legislation - an increase in the minimum blend of biofuels.