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Nitrogen oxide (NOx) sensing is required both for on-board diagnosis and optimal selective catalytic reduction (SCR)-catalyst control in heavy duty diesel engines. This can be accomplished either by physical solid-state sensors, or by so-called virtual sensors, which estimate the value of the target quantity using other states by means of a model. Both approaches have advantages and disadvantages. This paper resumes the derivation and the identification of a virtual sensor based on a polynomial structure and optimal experimental design methods and compares its performance to the one of a production physical solid state sensor. The virtual sensor is compared with a commercially available solid-state sensor in terms of accuracy (stationary as well as dynamic) and operation limits.

Although the application of cylinder pressure sensors to gain insight into the combustion process is not a novel topic itself, the recent availability of inexpensive in-cylinder pressure sensors has again prompted an upcoming interest for the utilization of the cylinder pressure signal within engine control and monitoring. Besides the use of the in-cylinder pressure signal for combustion analysis and control the information can also be used to determine related quantities in the exhaust or intake manifold. Within this work two different methods to estimate the pressure inside the exhaust manifold are proposed and compared. In contrary to first principle based approaches, which may require time extensive parameterization, alternative data driven approaches were pursued. In the first method a Principle Component Analysis (PCA) is applied to extract the cylinder pressure information and combined with a polynomial model approach.

At the moment, no equipment is available for fast measurements of particulate matter (PM) from production CI engines, especially during transients. Against this background, virtual sensors may be an option, provided their precision can be validated. This paper presents a new approach to estimate PM emission based only on in-cylinder pressure data. To this end, an in-cylinder pressure trace is measured with a high resolution (0.5 CAD) and every trace is divided into 8 segments according to critical cylinder events (e.g. opening of the valves or the beginning of injection). A piecewise principle component analysis (PCA) is used to compress the information. This information is then used for PM estimation via a second order polynomial model structure. The key element is the separate use of pressure trace information before and during the early stages of combustion. The model is parameterized by steady points and transient experiments which include parts of the FTP and the NEDC.

Abatement and control of emissions from passenger car combustion engines have been in the focus for a long time. Nevertheless, to address upcoming real-world driving emission targets, knowledge of current engine emissions is crucial. Still, adequate sensors for transient emissions are seldom available in production engines. One way to target this issue is by applying virtual sensors which utilize available sensor information in an engine control unit (ECU) and provide estimates of the not measured emissions. For real-world application it is important that the virtual sensor has low complexity and works under varying conditions. Naturally, the choice of suitable inputs from all available candidates will have a strong impact on these factors. In this work a method to set up virtual sensors by means of design of experiments (DOE) and iterative identification of polynomial models is augmented with a novel input candidate selection strategy.

Due to the advancements in passenger car Diesel engine design, the contribution of transient emission spikes has become an important fraction of the total emissions during the standardized test cycles, hence the interest of this work on dynamical engine operation, in particular on the improvement of NOX and PM emissions. This paper proposes to use a UEGO sensor (universal exhaust gas oxygen sensor) in the upstream of the turbine in combination with a Kalman filter to estimate the target quantities, namely in-cylinder oxygen concentration before and after combustion. This information is used to define the fuel injection as well as the values of the air path actuators. Test bench measurements with a production Diesel engine are presented, where the oxygen based approach is compared to the standard calibration during a fast load increase. It is shown that the torque response could be maintained while NOX as well as PM emission peaks were reduced significantly.

NOx and PM are the critical emissions to meet the legislation limits for diesel engines. Often a value for these emissions is needed online for on-board diagnostics, engine control, exhaust aftertreatment control, model-based controller design or model-in-the-loop simulations. Besides the obvious method of measuring these emissions, a sensible alternative is to estimate them with virtual sensors. A lot of literature can be found presenting different modeling approaches for NOx emissions. Some are very close to the physics and the chemical reactions taking place inside the combustion chamber, others are only given by adapting general functions to measurement data. Hence, generally speaking, there is not a certain method which is seen as the solution for modeling emissions. Finding the best model approach is not straightforward and depends on the model application, the available measurement channels and the available data set for calibration.

The trend to reduced development times represents a strong motivation for an extended use of dynamical engine test benches, which are used to reproduce driving conditions typically measured in the vehicle. To reproduce the engine load conditions a complex control system is used, which has an inherently different nature in comparison with the vehicle driving conditions and consequently also limitations. As a consequence, the set of possible transients is limited by the actuator limitations and the bandwidth of the control loops. Outside the admissible transients it is necessary to do a trade-off between goals, mainly between the precision of the reproduction of the engine speed and the precision of the load torque tracking. In this paper we discuss how to calculate the admissible set and how to do a trade off. Based on these cognitions we present a feedforward control algorithm which allows best performance transients simulation along the performance limits.

Emission abatement is one of the main targets in engine development and design today. Modern turbocharged CRDI Diesel engines with variable turbine geometry (VTG) and exhaust gas recirculation (EGR) provide new degrees of freedom for air path control with enormous effects on emissions. Exploiting these degrees of freedom usually involves a huge calibration work, as sensors are available only for few quantities and dynamical models are mostly not available, so feedback or model based optimization is hardly possible. This paper presents a time efficient data based strategy to obtain such models yielding an accurate as well as robust emission model for nitrogen oxides (NOx) and particulate matter (PM) by means of design of experiment. The model output is generated by smoothly switching between local models, representing different engine operating points. An adapted D-optimal design of experiments strategy provides optimal data for model identification.

Transient emission peaks have become an important fraction of the total emissions during the standardized test cycles for passenger car Diesel engines. This paper is concerned with their reduction, in particular of nitric oxides (NOx) and particulate matter (PM) emissions, by online receding horizon optimal control. It is based on former works in which alternative target quantities for engine control were proposed, namely in-cylinder oxygen concentrations before (O2,BC) and after combustion (O2,AC). The actual work is concerned with testing an in-cylinder oxygen concentrations based control in simulation as well as by a real-time implementation on a turbocharged common rail passenger car production Diesel engine. The promising results confirm the choice of these concentrations as sensible control references and the feasibility of a real-time use in a model predictive control implementation.

Torque control is a basic element of engine control systems, in particular since it has become a standard interface for different functionalities. Torque control is also a critical requirement emission test cycle simulation on test benches. This torque control is usually reached by extensive, physical based modeling of the vehicle. This paper presents an approach to avoid this effort and to obtain a dramatic reduction of the parametrization work, by first determining an approximated model and then updating it online during operation. This model is than used for a stable inverse control. To handle model uncertainties and perturbation a correction feedback, with robustifying effect, is added to the control structure. This approach is detailed using data and measurements on a BMW M47D production diesel engine on a dynamic test bench.

During transients, engines tend to produce substantially higher peak emissions like soot - the main fraction of particular matter (PM) - which are the longer the more important as the steady state emissions are better controlled. While Diesel particulate filters are normally able to block them, preventing their occurrence would of course be more important. In order to achieve this goal, however, they must be measurable. While for most emissions commercial sensors of sufficient speed and performance are available, the same is not true for PMs, especially for production engines. Against this background, in the last years the possible use of a full stream 50Hz sensor based on Laser Induced Incandescence (LII) was investigated, and the results were very encouraging, showing that the sensor could recognize transient changes undetected by conventional measurement systems (like the AVL Opacimeter) but confirmed by the analysis of combustion.

Modeling the soot emissions of a Diesel engine is a challenge. Although it was part of many works before, it is still not a solved issue and has a substantial potential for improvement. A major problem is the presence of two competing effects during combustion, soot formation and soot oxidation, whereas only the cumulative difference of these effects can be measured in the exhaust. There is a wide consensus that it is sensible to design crank angle resolved models for both effects. Indeed, many authors propose crank angle based soot models which are mostly based on detailed first principles based structures, e.g. spray models, engine process calculations etc. Although these models are appealing from a theoretical point of view, they are all lacking of the required measurement information to validate all the complex model parts. Finally, most parts of the model remain at their assumed values and only a few parameters are used for calibration.

Transient emission peaks have become an important fraction of the total emissions during the standardized test cycles for passenger car Diesel engines. To this end this paper is concerned with the challenge of measuring emissions during transients. The importance of this topic is increasing due to strict regulation on pollutant emissions. Hence, suitably accurate and fast measurement devices for PM emission detection are required. Thus, we present a comparison between different measurement techniques for Particulate matter (PM) emissions from a Diesel engine, in particular during transients. The compared equipments include AVL Micro soot sensor, AVL Opacimeter, Differential mobility spectrometer and Laser induced incandescence. The goal of this paper is to reveal the most accurate device in the sense of sensitivity and dynamics for fast measurements of PM from a Diesel engine.

Modern Diesel engines have become complex systems with a high number of available sensor information and degrees of freedom in control. Due to recent developments in production type in-cylinder pressure sensors, there is again an upcoming interest for in-cylinder pressure based applications. Besides the standard approaches, like to use it for closed loop combustion control, also estimation and on-board diagnostics have become important topics. Not surprising in general the trend is to utilize those sensors for as many tasks as possible. Consequently this work focuses on the estimation of the injection parameters based on the indicated pressure signal information which can be seen as first step of a combustion control based on desirable indicated pressure characteristics which may be utilized for e.g. the minimization of NOx emissions. Currently the acquisition of the cylinder pressure traces can be done in real-time by fast FPGA (Field Programmable Gate Array) based systems.

The Laser Induced Incandescence technique (LII) is a sensitive optical method for reliable spatially and temporally resolved measurement of particulate matter (PM) concentration. This technique appears to be suitable for measurement of fast transient PM emissions, from diesel engines, which forms the main fraction of total emissions during standardized test cycles. However, the existing commercial LII devices require modifications in the exhaust gas flow, dilution, sampling cell, or it measure only in a partial stream. This article presents the development of a laser based optical setup - LII for rapid in-situ measurement of PM concentrations during the combustion process of a diesel production engine. The presented LII setup is suitable for direct in-situ, full stream, measurements of soot emissions without needs of dilution or a sampling cell.

In a typical diesel engine exhaust aftertreatment system consisting of a diesel oxidation catalyst (DOC), a diesel particulate filter (DPF) and a selective catalytic reduction (SCR) system the main purpose of the DOC, besides the oxidation of CO to CO₂, is the oxidation of NO to NO₂. The NO to NO₂ conversion is an essential contribution for the downstream SCR system because the fast SCR reaction which provides the highest conversion rates of NOx to H₂O and N₂ works well only under roughly equal concentrations of NO and NO₂. The typical amount of NO to NOx ratio produced by the engine is about 0.95, hence the DOC is necessary to decrease this coefficient close to 0.50. Due to the temperature dependency of the DOC reaction mechanism the oxidation of NO to NO₂ takes only place sufficiently if the temperature of the DOC is higher than 200°C, which, however, cannot be reached during low engine speed and low load situations.

Although SCR is a well established technology for many applications, it is still a field in which several new approaches and components are being tested. Control is a critical issue, as the conflicting requirements of NOx abatement and very small NH3 slip need to be met. Besides empirical solutions, model based controls have been proposed and are probably the technology of choice, also in view of the combination with monitoring functions. However, SCR models are typically based on First Principles (FP), i.e. on global chemical equations and reaction rate equations, and require precise calibration. Still, their performance for the control of dynamic processes is limited, or a high detail, much a priori information, e.g. on the actual SCR reaction rates, are needed. Frequently, this information is not available or reliable, and this is particularly true when components are changed or modified during the development process, so that typically a re-design is needed.

This paper shows the potential of a multicalibration approach for reducing fuel consumption while keeping pollutant immissions. The paper demonstrates that the current engine control approach with a single fixed calibration involves important fuel penalties in areas with low vehicle densities where local pollution is not an issue, while the NOx emissions in urban areas are usually too high to fulfill air quality standards. The proposed strategy is based on using information about the vehicle location and the NOx concentrations in the ambient to choose a suitable calibration amongst a set of possibilities. To assess the potential of such a strategy experimental tests have been done with a state-of-art turbocharged Diesel engine. First, a design of experiments is used to obtain three different calibrations.

The plausibility of measurements is a key question for many kinds of large complex systems. In this paper we present a method of automatic measurement data plausibility assessment. Even the focus here was put on an automotive engine test bench application, the presented method can cope also with other complex systems with a large number of measurement devices included. The presented method is still in the development phase, thus its performance still did not reach the optimum. But as for the time being the obtained experimental results seams to be quite acceptable.

Drag torque compensation is a part of the control units of modern gasoline and diesel engines. To achieve it, a characteristic drag torque curve as a function of the engine speed is usually saved in the ECU. Since the drag torque will not be constant during an engine's lifetime, this curve must be adapted. This paper proposes an approach to adapt the drag torque curve. The goal is achieved using a high gain observer known as a Kalman filter. The proposed method combines detection of drag torque curve errors and adaptation of the drag torque curve in one step. The effects of variable geometry turbochargers are included in the overall curve by an extension of the basic algorithm. The performance of the method is shown using data and measurements on a BMW M47D engine. As the measurements confirm, the proposed method works consistently and correctly.