Research in the automotive sector is driven by the need to reduce the greenhouse gases emissions, while maintaining the expected vehicle performances. The electrification and hybridization ensure to achieve this goal, anyway, some issues still limit their full development in the international panorama. For this reason, the technological improvement of Internal Combustion Engines (ICEs) plays a crucial role in this transition period, also considering the opportunities related to sustainable fuels. Among the technological solutions allowing to improve ICEs performances, the energy recovery from the exhaust gases through Organic Rankine Cycle (ORC)-based power units are one of the most attractive alternatives, due to the high enthalpic content of the hot source. Despite these benefits, the ICE exhaust gases usually have considerable fluctuation of thermodynamic conditions. For this reason, it is necessary the adoption of a reliable and robust control system to keep the main operating ORC quantities (superheating degree, expander intake pressure and temperature) within a suitable and safe range. ORC control strategies for transportation applications are often based on detailed models that predict the unit behaviour, making use of Proportional-Integrative-Derivative (PID) regulators, whose coefficients are generally tuned through theoretical approaches and dedicated software. In the present work, an innovative control system has been developed, based on the integration of a feedforward (FF) and proportional feedback (FDB) regulating strategies. Despite the simplicity of the proposed approach, it ensures the proper plant operation even under severe fluctuations of the hot source. Particularly, the gain of FDB is based on a constitutive relationship between the expander intake pressure and working fluid mass flow rate. Such gain, indeed, is universally valid, not requiring to be tuned as generally done. The benefits of the proposed strategy are assessed thanks to a comprehensive model of the whole ORC unit, validated through experimental data carried out on a fully instrumented test bench in dynamic working conditions. Results demonstrate the robustness of the feedforward-proportional regulating approach: a superheating degree of 15–20 °C is ensured, keeping the plant power and efficiency close to the design value (1 to2 kW and 4 to6% respectively) even in off-design conditions. Moreover, the safe operating of the expander is guaranteed limiting the maximum temperature excursion under the safety limit of 160 °C.
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