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generalized gain scheduling control mechanism based on the design of engine control systems a very difficult task. Fur-
A 0 ff-line optimization techniques has been developed for a
2-cylinder, water cooled diesel engine. First, a set of linearized
thermore, diesel engines are inherently open-loop and marginally
stable in the sense that the engine speed will drift in the absence
models is obtained for the engine operating at three different of feedback control actions, or the engine may stall when the
speeds and a total of 15 load conditions. From the experimental operating speed is below a certain level (1 500 rev/min for the
data analysis, it is concluded that the behavior of the engine can current engine at no load).
best be characterized by a set of fifth order difference equations It is also interesting to note that diesel engines are inherently
with appropriate time delays. Optimal controllers with a PID time-varying discrete-time systems in the sense that the engine
structure are then synthesized by off-line numerical optimization speed is a function of the fuel injection timing, compression, and
using these mathematical models to minimize the integral combustion processes which depend again on the instantaneous
squared error (ISE) of the engine speed deviation subject to a step engine speed. It will be shown later that there is a pure time delay
speed change command. The designed control system has been between the movement of the throttle position and the engine
implemented and tested on a Petter diesel engine (Model PH2W). speed response. This time-delay decreases as the engine speed
Experimental results have indicated that the designed optimal increases. These undesirable characteristics make the design of
control strategy has tremendously improved the performance of optimal engine control systems even more challenging.
the original engine in terms of both speed regulation and distur- Despite these difficulties, several attempts have been made to
bance rejection. Attempts have also been made to evaluate the synthesize optimal controllers for diesel engines. Optimal control
fuel efficiency of the engine with respect to controller parameter for a diesel engine speed goveming loop has been formulated in
variations. It is concluded that there exists a strong correlation [l]. Both 4-cylinder and 6-cylinder engines have been consid-
between controller parameter settings and the engine fuel con- ered. A sample data model of the engine is first constructed in the
sumption rate. state-space form. The cost function is then defined as a quadratic
function of the error in engine speed variables, control effort, and
Improving Diesel Engine Efficiency the air-fuel-ratio. This optimal control problem is then solved by
Diesel engines have been widely used as power sources in both dynamic programming and the discrete minimum principle.
practice. Diesel engine driven systems include automobiles, However, this article is theoretical in nature, and no attempt has
ships, and backup power generating units, to mention a few. been made to implement the developed control scheme on an
However, most of the existing engines still use simple mechani- actual engine.
cal fly-wheel type govemors to regulate speed. The performance A novel smoke sensor has been used in conjunction with a
of these engines is often limited by inflexibilities of their gover- tacho-generator to control the transient response of a diesel
nors. With advances in computer technology and the growing engine [2]. The engine fuel rack is controlled by a servo-motor
shortage of world energy resources, it is highly desirable to drive. The control algorithm is of proportional and integral (PI)
develop new control strategies to improve the performance of type. The controller parameters are chosen such that the engine
existing engines in terms of speed regulation, robustness to load overshoot and the amount of engine exhaust smoke are mini-
disturbance, and more importantly, fuel efficiency. The main mized. The control scheme has been evaluated on an actual
objective of this article is to demonstrate how computer technol- engine under four operating speeds and three load conditions. A
ogy and modem control theory can be used to develop optimal second order transfer function is assumed for the system from
control strategies for diesel engines, to experimentally verify the the fuel rack to the engine speed. However, the transfer function
developed scheme on an existing diesel engine, and to study the from the fuel rack to engine smoke is found to be highly non-
effect of controller parameters on the engine fuel efficiency. linear. Therefore, a set of models has to be used in the control
As is well known, diesel engines are highly nonlinear devices, system design for the engine at different load conditions.
and their characteristics vary as a function of power output, Since almost all farm tractors are driven by diesel engines,
speed, ambient temperature, etc. Such nonlinear behavior makes some research work has been done to design fuel efficient control
systems for tractors. Among other things, optimal control of
Based on a paper presenfed at The Second IEEE Conference on diesel engines used in tractors has drawn a great deal of attention,
Control Applications, Vancouver, British Columbia, Canada, Sep- [3]-[5].In these publications, an optimal engine speed control
tember 13-16,1993.The author is with the Department of Electrical system has been developed. The engine model from the fuel rack
Engineering, University of Western Ontario, London, Ontario, N6A to the shaft speed is identified first for various engine operating
5B9 Canada. This work was supported by the DepartmentofEnergy, conditions. This model is a fifth-order auto-regressive moving
Mines, and Resources of Canada. average (ARMA) type. Lead-lag compensators are then de-
August 1994 43
Because of the nonlinear characteristics of the engine, the
coefficients in (I ) and (2) are nonlinear functions of the engine
speed and power output. Their respective values are obtained by
the least squares parameter estimation procedure, and tabulated
in Table I.
Table I
Parameters of the En
44 I E E E Control Systems
Fig. 2 . Three controller-parameters for the engine at different operating conditions.
> 7.1 -
7 -
6.9
0 5 10 15 20 25 30 35 40
Time (sec)
August 1994 45
ever, there is a significant variation in the integral controller gain
5 Kl. The general changing pattem for KI is that it decreases as
--
c
4.5 ......
;*<,,;
, , . . : :
.. . . .~ ..
.!
j
..
... . .. . ...
j
..
j
!.
I.
.
..
:.
.
..
.j
. engine load increases. The general pattem for the derivative gain
P i : ; : ... : ... : ... : ... , ... : ... KD is opposite from that of Kz, i.e., as load increases, KD de-
$ 4
I .. ..
...........................
.... ... ...
..
- ...
..
................. _.
...
. . .
...............................
... ... .. creases.
. . . . .
g 3.5 ..........j ..........................................
j i j j
(.
j j i
46 I E E E Control Systems
tracking error even with this ramp command input. However, this
is not true in general for large loads.
The performance of the engine under step load changes is
shown in Fig. 7 where the initial engine speed is 1000 rev/min
when an extra 1.05 kW load is being added. As can be seen, the
effects of such load disturbance on the engine speed is negligible.
The performance of the engine under ramp load disturbances has
5 10 15 20 25 also been studied. The load disturbance pattem and the corre-
Time (sec) sponding engine speed response for the engine operating at a
A C;.
7.d
nominal speed of 1000 rev/min are shown in Fig. 8. The mini-
.......;. ..................(.. ............. mum and maximum load variations are 0.075 kW and 1.62 kW,
respectively. Under such a wide range of load variations, the
.......+ ..................i ............. maximum speed deviation is only 43 rev/min.
2.5 .................. .................j..................... .................... ! The third group of tests deals with situations where the engine
2 speed and the torque output are varied simultaneously in the same
0 5 10 15 20 25 pattern. Fig. 9 shows the torque and speed change pattems and
Time (sec)
the corresponding speed response of the engine operating at a
nominal speed of 1000 rev/min. In this case, the speed variation
Fig. 8. The engine speed deiiation with a rump load disturbance ut is 1 .O V, which corresponds to 168 rev/min, and the range of total
nominal speed of 1000 revlmin. power output is from 0.02 kW to 2.46 kW. The graph clearly
indicates that the engine can maintain reasonably good transient
fa) Toraue & SDeed Chanae Pattern and steady-state responses.
n
setpoint. The magnitude of the step change is 1.0 V, which rev/min. A 0.05-Hz square wave of 0- 1.O V has been applied at
corresponds to 168 rev/min (from (4)). The results are shown in
Fig. 5 where the engine was originally operating around 1000 I - 7 FY;Y
rev/min when a speed change signal has been issued. As a result,
the engine accelerates quickly and settles at the new speed. -
-
An example of the engine speed response to a ramp input 20
command is shown in Fig. 6. The ramp signal is approximated
by a triangular waveform. The figure shows engine speed re- '-1 mil I
10
sponses at two load conditions, at the nominal speed of 1000
5
rev/min. The upper graph has been obtained when the engine 0 I - KWatts
carries no extemal load, while the lower one represents the same No exterinal load 1.9
except that the initial engine power output is about 2 kW. Com- Output Power
parison of these two graphs indicates that faster tracking can be
obtained with lighter load. It appears that there is no steady-state Fig. I O . Fuel efficiency tests subject to step engine speed changes.
August 1994 47
I I
Table I1
Fuel Efficiency Tests Subject to Step-Like Engine Load Variations
the engine speed setpoint. The performance of the three sets of concluded that the damping of the closed-loop system has the
controller parameters has been evaluated; one for optimal con- most significant effect on the fuel efficiency of the engine. In
trollers, and the other two for nonoptimal ones. Tests have been fact, the optimal controller designed to minimize the overshoot
conducted under three different engine power output levels by and settling time of the transient response also provides better
appropriate setting of output torques. The experimental results fuel efficiency.
and the test conditions are illustrated in Fig. 10.
As we can see from this figure,the controllerparametersdo affect Acknowledgment
the fuel efficiency of the engine. In fact, the optimal controller Permission to use the diesel engine located at the Lakehead
designed to minimize the overshoot and settlingtime of the transient University was highly appreciated.
response also provides better fuel efficiency.The parameters of the
nonoptimal controllers are chosen arbitrarily. The experimental References
results have indicated that both nonoptimal controllers have rela- [ I ] J.O. Flower and R K GUptd, “Optimal control considerations of diesel
tively small damping which degrades the engine efficiency. engine discrete modela,”It7t J Control, vol 19, no 6, pp 1057-1068, 1974.
The effect of load variations on the engine fuel efficiency have [2] G Hong and N Collings, “Design of diesel smoke feedback control using
also been studied for the optimal controllers under three different a combination of PI control algorithm and performance optimization,” SAE
nominal speed settings. In addition, the fuel efficiency of the Tech paper, no 890387, 1989
engine controlled by the mechanical govemor has also been [3] N Zhdng, J.V Perumpral, R K Byler, and S D Shaffer, “Diesel engine
investigated. The engine load is varied periodically by applying control based on an ARMA model,” Ttans ASAE, vol. 32, no 4, pp.
a square wave of 0.05 Hz to the load pattem generator (see Fig. 1112-1120. 1989
1). The experimental results are presented in Table 11.
[4]N Zhang, J V Perumpral, and R.K. Byler, “Automatic control system for
One of the interesting observations in this set of tests is that
optimizing diesel engine performance,” Comp Electron Agriculture, vol. 2,
the mechanical govemor appears to have better fuel economy. pp 31-46, 1987
However, such an observation is not completely true unless we
also examine the speed characteristics of the engine under me- [5] N. Zhang, “Microprocessor-based digtal controllerlmprovlng tractor operatmg
efficiency,”Ph.D dissertahon,V u p a Polytechnic Inshtute and State Umv., 1987.
chanical govemors. Due to the integral action of the PID control-
ler, the steady-state engine speed will be at the preset speed even [6] S.P. Boyd and C H Barratt, Linear Controller Design Limits ofPerform-
in the presence of a constant load disturbance. However, in the ante. Englewood Cliffs, NJ Prentice Hall, 1991.
case of a mechanical govemor, the engine speed deviates from (71 B.D.O. Anderson and J.B. Moore, Optimal Control Linear Quadratic
the original set speed (steady-state error). Because of such a Methods Englewood Cliffs, NJ: Prentice Hall, 1990.
reduction in speed, it appears that the engine equipped with the
[8] G C Newton, Jr ,L.A Gould, and J F Kaiser, AnalvticalDesign ofLinear
mechanical govemor is more fuel efficient. However, results
Feedhac k Controls New York: Wiley, 1957
become meaningless under this situation.
Jin Jiang completed the Ph D. degree in 1988 at the
Summary Department of Electrical Engmeenng, The University
of New Brunswick, Fredencton, New Brunswick,
A generalized gain scheduling control scheme using optimi-
Canada. He was on the faculty of the Manne Institute,
zation techniques has been developed for a diesel engine. The
St. John’s, Newfoundland, and Lakehead University,
designed scheme has been implemented using a microcomputer Thunder Bay, Ontano, before j o m g The University
and evaluated on a real engine. The results indicate that the of Western Ontario, where he is an Associate Professor
performance of the engine with the designed control scheme is in the Department of Electncal Engmeermg. His re-
much superior to that with the existing speed govemor. In addi- search interests are mainly m the areas of control
tion, the relationship between the controller parameters and the fuel systems, fault detection and diagnom, power sys-
efficiency of the engine has also been explored experimentally.It is tem dynamics, and controls