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The paper focuses on a system and an appropriate controller concept for advanced air management of a turbo-charged passenger car diesel engine. The proposed air management system consists of a VTG turbocharger and two separate Exhaust Gas Recirculation (EGR) loops, a cooled or non-cooled high-pressure EGR (HP EGR) and a cooled low-pressure EGR (LP EGR) loop. In the LP EGR loop, the exhaust gas leaving the particulate filter is mixed with fresh air just in front of the compressor inlet. A main model (MM) was created in Simulink to design a Nonlinear Model-based Predictive Controller (NMPC). This model is mainly founded on physical equations, allowing easy adaptation to various systems. MM is a detailed model which was developed first and which is also used for software-in-the-loop (SIL) tests of the controller with the simulated engine.

The present paper focuses on a system and an appropriate controller concept for an advanced air management system of a turbocharged passenger car diesel engine. The proposed air management system consists of a VTG turbocharger, two separate EGR loops, a non-cooled high-pressure EGR and a cooled low-pressure EGR loop. In the low pressure EGR loop, the exhaust gas leaving the particulate filter is mixed with fresh air just in front of the compressor inlet. The first step consisted of developing a sensor and actuator concept. Prior to conducting engine tests on this system, GT power simulations were performed. Additionally, a MATLAB/Simulink model was created to design a model-based predictive controller. This model is mainly founded on physical equations, allowing for easy adaptation to various systems. At the beginning of the engine test stage, stationary measurements were conducted to examine the influence of variations of the EGR rate, boost pressure, fresh air mass, etc.

Ultra-Downsizing (UD) was introduced as an even higher level of downsizing for Internal Combustion Engines ICEs, see [2] SAE 2015-01-1252. The introduction of Ultra Downsizing (UD) aims to enhance the power, efficiency, and sustainability of ICEs while maintaining the thermal and mechanical strain within acceptable limits. The following approaches are utilized: 1 True Atkinson Cycles are implemented utilizing an asymmetrical crank mechanism called Variable Compression and Stroke Ratios (VCSR). This mechanism allows for extended expansion stroke and continuous adjustment of the Volumetric Compression Ratio (VCR). 2 Unrestricted two or more stage high-pressure turbocharging and intensive intercooling: This setup enables more complete filling of the cylinder and reduces the compression work on the piston, resulting in higher specific power and efficiency. 3 The new Load Control (LC) approach is based to continuous VCR adjustment.