Development of a Model Predictive Airpath Controller for a Diesel Engine on a High-Fidelity Engine Model with Transient Thermal Dynamics

Abstract: This paper presents the results of a model predictive controller (MPC) development for diesel engine air-path regulation. The control objective is to track the intake manifold pressure and exhaust gas recirculation (EGR) rate targets by manipulating the EGR valve and variable geometry turbine (VGT) while satisfying state and control constraints. The MPC controller is designed and verified using a high-fidelity engine model in GT-Power. The controller exploits a low-order rate-based linear parameter-varying (LPV) model for prediction which is identified from transient response data generated by the GT-Power model. It is shown that transient engine thermal dynamics influence the airpath dynamics, specifically the intake manifold pressure response, however, MPC demonstrates robustness against inaccuracies in modeling these thermal dynamics. In particular, we show that MPC can be successfully implemented using a rate-based prediction model with two inputs (EGR and VGT positions) identified from data with steady-state wall temperature dynamics, however, closed-loop performance can be improved if a prediction model (i) is identified from data with transient thermal dynamics, and (ii) has the fuel injection rate as extra model input. Further, the MPC calibration process across the engine operating range to achieve improved performance is addressed. As the MPC calibration is shown to be sensitive to the operating conditions, a fast calibration process is proposed.