Xin Q. Diesel Engine System Design

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902 Diesel engine system design

of a turbocharged V6 diesel engine operating under steady-state conditions’, SAE

paper 2006-01-0688.

Hirabayashi Y, Sumi Y and Nishiguchi F (1986), ‘Development of Nissan variable

geometry JET turbocharger’, SAE paper 860105.

Hishikawa A, Okazaki Y and Busch P (1988), ‘Development of variable area radial

turbines for small turbochargers’, SAE paper 880120.

Hochegger W, Hrauda G, Prenninger P and Seitz H F (2002), ‘Effect of various EGR

systems on HDT-turbocharging’, IMechE paper C602/040/2002.

Hopmann U and Algrain M C (2003), ‘Diesel engine electric turbo compound technology’,

SAE paper 2003-01-2294.

Hountalas D T, Katsanos C O and Lamaris V T (2007), ‘Recovering energy from the

diesel engine exhaust using mechanical and electrical turbocompounding’, SAE paper

2007-01-1563.

Hribernik A (1997), ‘Advantages and disadvantages of the application of a single entry

turbine for pulse system turbocharging of 4-cylinder engine’, SAE paper 972775.

Hussain M and Bhinder F S (1984), ‘Experimental study of the performance of a nozzle-

less volute casing for turbocharged turbines’, SAE paper 840571.

Inoue K, Kubota O, Kishi N and Yano S (1989), ‘A high power, wide torque range,

efcient engine with a newly developed variable geometry turbocharger’, SAE paper

890457.

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2002-01-2165.

Ito N, Ohta T, Kono R, Arikawa S and Matsumoto T (2007), ‘Development of a 4-cylinder

gasoline engine with a variable ow turbo-charger’, SAE paper 2007-01-0263.

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performance and emissions of a heavy-duty diesel engine’, SAE paper 2003-01-

1068.

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Inc., Wilder, VT.

Japikse D (2000), ‘Decisive factors in advanced centrifugal compressor design and

development’, presented at the International Mechanical Engineering Congress

& Exposition (IMechE), November available at: http://www.conceptsnrec.com/

tech_papers.html

Japikse D (2001), ‘Progress and potential in agile engineering for turbomachinery’, ASME

2001 Fluids Engineering Division Summer Meeting, New Orleans, LA, June 1.

Japikse D (2009), ‘Turbomachinery performance modeling’, SAE paper 2009-01-0307.

Japikse D and Baines N C (1997), Introduction to Turbomachinery, Concepts ETI, Inc.

and Oxford University Press, White River Junction, VT.

Japikse D and Platt M J (2004), ‘Optimization in component design and redesign’,

10th International Symposium on Transport Phenomena and Dynamics of Rotating

Machinery, Honolulu, HI, March 7–11.

Jiao K, Li X, Sun H, Schram T, Krivitzky E and Larosiliere L M (2009), ‘Numerical

investigation of advanced compressor technologies to meet future diesel emission

regulations’, SAE paper 2009-01-1469.

Kawaguchi J, Adachi K, Kono S and Kawakami T (1999), ‘Development of VFT (variable

ow turbocharger)’, SAE paper 1999-01-1242.

Diesel-Xin-13.indd 902 5/5/11 12:04:50 PM

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903Diesel engine air system design

Kawamoto A, Takahashi Y, Koike T and Nakamura F (2001), ‘Variable geometry system

turbocharger for passenger car diesel engine’, SAE paper 2001-01-0273.

Keshavarz A, Chapman K S, Shultz J and Kuiper D G (2003), ‘Effect of turbine blade tip

clearance on turbocharger performance: an experimental investigation’, Proceedings of

2003 Fall Technical Conference of the ASME Internal Combustion Engine Division,

ICEF2003-703, Erie, PA, September 7–10.

Kessel J-A, Schaffnit J and Schmidt M (1998), ‘Modelling and real-time simulation of a

turbocharger with variable turbine geometry (VTG)’, SAE paper 980770.

Kohketsu S, Mori K, Sakai K and Hakozaki T (1997), ‘EGR technologies for a turbocharged

and intercooled heavy-duty diesel engine’, SAE paper 970340.

Kuiper D (2007), ‘Turbocharger design and performance analysis, part 1 of 2 (compressor

analysis)’, Proceedings of the Gas Machinery Research Council’s 2007 Gas Machinery

Conference, Dallas, TX, October 1–3.

Lakshmikantha M and Kec M (2002), ‘Optimization of exhaust systems’, SAE paper

2002-01-0059.

Lam J K-W, Roberts Q D H and McDonnell G T (2002), ‘Flow modelling of a turbocharger

turbine under pulsating ow’, IMechE paper C602/025/2002.

Ludu A, Athenstaedt G and Dexter S G (2001), ‘Turbocharging a medium speed diesel

engine to suit different applications’, ASME Internal Combustion Engine Division

(publication) ICE, 37 (2), 1–7.

Luján J M, Payri F, Vera F and Guardiola C (2001), ‘Modelling, effect and behaviour of

the EGR venturi in a heavy-duty diesel engine’, SAE paper 2001-01-3227.

Luján J M, Serrano J R, Cervello C, Arnau F J and Soltani S (2006), ‘A one-dimensional

model for variable and xed geometry radial turbines for turbochargers’, 8th International

Conference on Turbochargers and Turbocharging, Woodhead Publishing Limited and

CRC Press LLC, pp. 97–117.

Lundqvist U, Smedler G and Stalhammar P (2000), ‘A comparison between different

EGR systems for HD diesel engines and their effect on performance, fuel consumption

and emissions’, SAE 2000-01-0226.

Macek J and Vítek O (2008), ‘Simulation of pulsating ow unsteady operation of a

turbocharger radial turbine’, SAE paper 2008-01-0295.

Macek J, Vávra J and Vítek O (2002), ‘1-D model of radial turbocharger turbine calibrated

by experiments’, SAE paper 2002-01-0377.

Maiboom A, Tauzia X and Hetet J-F (2008), ‘Inuence of high rates of supplemental

cooled EGR on NO

and PM emissions of an automotive HSDI diesel engine using

an LP EGR loop’, International Journal of Energy Research, 32, 1383–1398.

Mattarelli E, Bianchi G M and Ivaldi D (2000), ‘Experimental and numerical investigation

on the EGR system of a new automotive diesel engine’, SAE 2000-01-0224.

McCutcheon A R S (1978), ‘Aerodynamic design and development of a high pressure

ratio turbocharger compressor’, IMechE paper C73/78.

Millo F, Mallamo F and Mego G G (2005), ‘The potential of dual stage turbocharging

and Miller cycle for HD diesel engines’, SAE paper 2005-01-0221.

Millo F, Mallamo F, Pautasso E and Mego G G (2006), ‘The potential of electric exhaust

gas turbocharging for HD diesel engines’, SAE paper 2006-01-0437.

Moroz L, Govoruschenko Y, Pagur P and Romanenko L(2005), ‘Integrated conceptual

design environment for centrifugal compressors ow path design’, Proceedings of 2008

ASME International Mechanical Engineering Congress and Exposition, IMECE2008-

69122, Boston, MA, October 31–November 6.

Diesel-Xin-13.indd 903 5/5/11 12:04:51 PM

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904 Diesel engine system design

Moustapha H, Zelesky M F, Baines N C and Japikse D (2003), Axial and Radial Turbines,

Concepts NREC, White River Junction, VT.

Nasser S H and Playfoot B B (1999), ‘A turbocharger selection computer model’, SAE

paper 1999-01-0559.

Nili-Ahmadabadi M, Hajilouy-Benisi A, Durali M and Ghadak F (2008), ‘Investigation

of a centrifugal compressor and study of the area ratio and tip clearance effects on

performance’, Journal of Thermal Science, 17(4), 314–323.

Ogura M, Umezaki E and Tomita T (1989), ‘Study of variable scroll type turbocharger

(performance test in diesel engine)’, SAE paper 891873.

Ogura M and Shao J (1995), ‘Research development of variable nozzle turbocharger,

part 1: a new axially movable turbocharger’, SAE paper 952102.

Okazaki T, Uchiyama K, Yamada K and Tsubouchi H (1982), ‘Development of high

speed small turbochargers for passenger cars’, IMechE paper C33/82.

Okazaki Y, Matsudaira N and Hishikawa A (1986), ‘A case of variable geometry

turbocharger development’, IMechE paper C111/86.

Osborne R P and Morris T (2002), ‘Aspects of EGR control on turbocharged light-duty

diesel engines’, IMechE paper C602/013/2002.

Pampreen R C (1976), ‘The use of variable inlet guide vanes for automotive gas turbine

engine augmentation and load control’, SAE paper 760285.

Pan D, Whiteld A and Wilson M (1999), ‘Design considerations for the volutes of

centrifugal fans and compressors’, Proc. IMechE, Part C: Journal of Mechanical

Engineering Science, 213, 401–410.

Park S, Matsumoto T and Oda N (2010), ‘Numerical analysis of turbocharger response

delay mechanism’, SAE paper 2010-01-1226.

Partridge W P, Lewis S A, Ruth M J, Muntean G G, Smith R C and Stang J H (2002),

‘Resolving EGR distribution and mixing’, SAE paper 2002-01-2882.

Pfeifer A, Smeets M, Herrmann H-O, Tomazic D, Richert F and Schloßer A (2002),

‘A new approach to boost pressure and EGR rate control development for HD truck

engines with VGT’, SAE paper 2002-01-0964.

Rodgers C (2003), ‘The characteristics of radial turbines for small gas turbines’, GT2003-

38026, Proceedings of the ASME Turbo Expo 2003: Power for Land, Sea, and Air,

June 16–19, Atlanta, Georgia, USA.

Rodgers C and Rochford K (2002), ‘Small turbocharger turbomachinery’, IMechE paper

C602/003/2002.

Ryder O, McKenzie D J A and Johnson S (2002), ‘Turbo matching techniques for highly

cyclic bus applications’, IMechE paper C602/006/2002.

SAE Surface Vehicle Recommended Practice J922 (1995), ‘Turbocharger nomenclature

and terminology’.

SAE Surface Vehicle Standard J1723 (1995), ‘Supercharger testing standard’.

SAE Surface Vehicle Recommended Practice J1826 (1995), ‘Turbocharger gas stand

test code’.

Saulnier S and Guilain S (2004), ‘Computational study of diesel engine downsizing using

two-stage turbocharging’, SAE paper 2004-01-0929.

Schmid W and Sumser S (2007), ‘Exhaust gas turbocharger for an internal combustion

engine’, US patent 7,162,872.

Senoguz M T, Bozkurt H A, Karadeniz C and Adil K N (2008), ‘Modeling and testing

of the throttle body usage in a diesel engine to improve NO

emissions’, SAE paper

2008-01-2646.

Serrano J R, Arnau F J, Dolz V, Tiseira A, Lejeune M and Auffret N (2008), ‘Analysis

Diesel-Xin-13.indd 904 5/5/11 12:04:51 PM

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905Diesel engine air system design

of the capabilities of a two-stage turbocharging system to fulll the US2007 anti-

pollution directive for heavy duty diesel engines’, International Journal of Automotive

Technology, 9(3), 277–288.

Shao J, Ogura M, Liu Y and Yoshino M (1996), ‘Performance development of a new

axially moveable vane turbocharger’, SAE paper 961747.

Sharp C A, Khair M K and Gorel A (1999), ‘The effect of a turbocharger clearance

control coating on the performance and emissions of a 2-stroke diesel engine’, SAE

paper 1999-01-3665.

Shutty J (2009), ‘Control strategy optimization for hybrid EGR engines’, SAE paper

2009-01-1451.

Siewert R M, Krieger R B, Huebler M S, Baruah P C, Khalighi B and Wesslau M (2001),

‘Modifying an intake manifold to improve cylinder-to-cylinder EGR distribution in

a DI diesel engine using combined CFD and engine experiments’, SAE paper 2001-

01-3685.

Spraker W A (1987), ‘Contour clearance losses in radial in-ow turbines for turbochargers’,

ASME paper 87-ICE-53.

Spraker W A (1991), ‘Clearance and Reynolds number effects on the efciency of radial

ow compressors’, SAE paper 910417.

Spraker W A (1992), ‘The aerodynamic design of variable power turbines for turbochargers’,

SAE paper 920041.

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CI engines – a perspective’, SAE paper 2006-01-0662.

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H and Strite M A (1987), ‘Inuence of the Reynolds number on the performance of

centrifugal compressors’, Transactions of the ASME, Journal of Turbomachinery,

109, 541–544.

Sumi Y and Yamane K (1986), ‘Recent development of high-response turbochargers for

passenger cars’, IMechE paper C107/86.

Tabaczynski R J (1982), ‘Effects of inlet and exhaust system design on engine performance’,

SAE paper 821577.

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turbocharger compressor for passenger vehicles’, SAE paper 2003-01-0051.

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paper 890647.

Tufail K (2010), ‘Turbocharging and air-path management for light-duty diesel engines’,

in Zhao H (ed.), Advanced Direct Injection Combustion Engine Technologies and

Development, Volume 2: Diesel Engines, Woodhead Publishing Limited, Cambridge,

UK.

Ubanwa B and Kowalczyk M (1993), ‘Optimization procedure for matching exhaust

waste-gate turbocharger to automotive diesel engine’, SAE paper 931102.

Uchida H, Kashimoto A and Iwakiri Y (2006), ‘Transient performance prediction of the

turbocharging system with the variable geometry turbochargers’, 8th International

Conference on Turbochargers and Turbocharging, Woodhead Publishing Limited

and CRC Press LLC, pp. 341–350.

Umezaki E, Ogura M and Tomita T (1989), ‘Study of variable scroll type turbocharger

(determination of shape of scroll)’, SAE paper 891874.

Wallace F J, Howard D, Roberts E W and Anderson U (1986), ‘Variable geometry

turbocharging of a large truck diesel engine’, SAE paper 860452.

Diesel-Xin-13.indd 905 5/5/11 12:04:51 PM

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906 Diesel engine system design

Wang R (1996), Study on the Flow in VGT Scroll and the Performance of Turbocharger,

doctoral dissertation (in Chinese), Shanghai Jiao-Tong University, Shanghai, China.

Watson N (1978), ‘Turbocharger system options for vehicle engines’, IMechE paper

C61/78.

Watson N (1979), ‘Turbochargers for the 1980s – current trends and future prospects’,

SAE paper 790063.

Watson N (1982), ‘Resonant intake and variable geometry turbocharging systems for a

V8 diesel engine’, IMechE paper C40/82.

Watson N and Banisoleiman L (1986), ‘Performance of a highly rated vehicle diesel

engine with a variable geometry turbocharger’, IMechE paper C103/86.

Watson N (1999), ‘The theory of turbocharging’, in Challen B and Baranescu R (eds),

Diesel Engine Reference Book, 2nd edn, SAE International, Warrendale, PA, pp.

27–72.

Watson N and Janota M S (1982), Turbocharging the Internal Combustion Engine,

Macmillan Publishers Limited, London.

Watson N, Marzouk M and Baazaari Z (1978), ‘An evaluation of two stage turbocharging

for efcient high-output diesel engines’, ASME Energy Technology Conference &

Exhibition, Houston, TX, ASME paper 78-DGP-2.

Westin F and Angstrom H E (2002), ‘A method of investigating the on-engine turbine

efciency combining experiments and modeling’, IMechE paper C602/029/2002.

Wiesner F J (1979), ‘A new appraisal of Reynolds number effects on centrifugal

compressor performance’, Transactions of the ASME, Journal of Engineering for

Power, 101, 384–396.

Wilson D and Korakianitis T (1998), The Design of High-Efciency Turbomachinery

and Gas Turbines, Prentice Hall, New Jersey.

Winkler N, Ångström H-E and Olofsson U (2005), ‘Instantaneous on-engine twin-entry

turbine efciency calculations on a diesel engine’, SAE paper 2005-01-3887.

Winterbone D E and Alexander G I (1985), ‘Efciency of the manifolds of turbocharged

engines’, IMechE Proc Instn Mech Engrs, 199(D2), 137–149.

Winterbone D E and Pearson R J (1999), Design Techniques for Engine Manifolds, SAE

International, Warrendale, PA.

Winterbone D E and Pearson R J (2000), Theory of Engine Manifold Design, Professional

Engineering Publishing, London.

Wu T and McAulay K J (1973), ‘Predicting diesel engine performance at various ambient

conditions’, SAE paper 730148.

Yamaguchi S, Yamaguchi H, Goto S, Nakao H and Nakamura F (2002), ‘The

development of effective casing treatment for turbocharger compressors’, IMechE

paper C602/008/2002.

Yang S, Wang L-S, Gu H, Deng K and Cui Y (2006), ‘MIXPC turbocharging system

for diesel engines’, SAE paper 2006-01-3390.

Yokota K, Hattori H, Shimizu M and Furukawa H (1986), ‘A highly BMEP diesel engine

with variable geometry turbocharger’, IMechE paper C119/86.

Zhang J, Zhuge W, Hu L and Li S (2007), ‘Design of turbocharger variable nozzle’,

GT2007-27562, Proceedings of the ASME Turbo Expo 2007: Power for Land, Sea,

and Air, May 14–17, Montreal, Canada, pp. 1313–1319.

Zhang Z, Deng K, Wang Z and Zhu X (2008a), ‘Experimental study on the three-phase

sequential turbocharging system with two unequal size turbochargers’, SAE paper

2008-01-1698.

Zhang Z, Gu H, Guo Z and Deng K (2008b), ‘Modular multi-purpose pulse converter

Diesel-Xin-13.indd 906 5/5/11 12:04:51 PM

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907Diesel engine air system design

turbocharging system for four-stroke diesel engines’, International Journal of Energy

Research, 32(6), 569–580.

Zhuge W, Zhang Y, Zheng X, Yang M and He Y (2009), ‘Development of an advanced

turbocharger simulation method for cycle simulation of turbocharged internal

combustion engines’, Proc. IMechE, Part D: Journal of Automobile Engineering,

223, 661–672.

13.9.1 References and bibliography on second law of

thermodynamics

Alkidas A C (1988), ‘The application of availability and energy balances to a diesel

engine’, Transactions of the ASME, Journal of Engineering for Gas Turbines and

Power, 110, 462–469.

Alkidas A C (1989), ‘The use of availability and energy balances in diesel engines’,

SAE paper 890822.

Bozza F, Nocera R, Senatore A and Tuccillo R (1991), ‘Second law analysis of turbocharged

engine operation’, SAE paper 910418.

Bueno A V, Velásquez J A and Milanez L F (2004), ‘Exergy based diagnosis of in-

cylinder diesel engine’, SAE paper 2004-01-3258.

Caton J A (2000a), ‘A review of investigations using the second law of thermodynamics

to study internal-combustion engines’, SAE paper 2000-01-1081.

Caton J A (2000b), ‘Operating characteristics of a spark-ignition engine using the second

law of thermodynamics: effects of speed and load’, SAE paper 2000-01-0952.

Caton J A (2002), ‘A cycle simulation including the second law of thermodynamics for

a spark-ignition engine: implications of the use of multiple-zones for combustion’,

SAE paper 2002-01-0007.

Caton J A (2005), ‘Use of a cycle simulation incorporating the second law of

thermodynamics: results for spark-ignition engines using oxygen enriched combustion

air’, SAE paper 2005-01-1130.

Edwards K D, Wagner R M and Graves R L (2008), ‘Identication of potential efciency

opportunities in internal combustion engines using a detailed thermodynamic analysis

of engine simulation results’, SAE paper 2008-01-0293.

Endo T, Kawajiri S, Kojima Y, Takahashi K, Baba T, Ibaraki S, Takahashi T and Shinohara

M (2007), ‘Study on maximizing exergy in automotive engines’, SAE paper 2007-

01-0257.

Fijalkowski S and Nakonieczny K (1997), ‘Operation of exhaust systems of turbocharged

diesel engines identied by means of exergy analysis’, Proc. IMechE, Part D: Journal

of Automobile Engineering, 211, 391–406.

Flynn P F, Hoag K L, Kamel M M and Primus R J (1984), ‘A new perspective on diesel

engine evaluation based on second law analysis’, SAE paper 840032.

Gallo W L R (1992), ‘Thermodynamic evaluation of variable valve timing’, SAE paper

921479.

Gerpen J H V and Shapiro H N (1990), ‘Second-law analysis of diesel engine combustion’,

Transactions of the ASME, Journal of Engineering for Gas Turbines and Power,

112, 129–137.

Giakoumis E G (2007), ‘Cylinder wall insulation effects on the rst- and second-law

balances of a turbocharged diesel engine operating under transient load conditions’,

Energy Conversion and Management, 48(11), 2925–2933.

Diesel-Xin-13.indd 907 5/5/11 12:04:51 PM

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908 Diesel engine system design

Giakoumis E G and Andritsakis E C (2007), ‘Irreversibility production during transient

operation of a turbocharged diesel engine’, International Journal of Vehicle Design,

45(1/2), 128–149.

Kyritsis D C and Rakopoulos C D (2001), ‘Parametric study of the availability balance

in an internal combustion engine cylinder’, SAE paper 2001-01-1263.

Li J, Zhou L, Pan K, Jiang D and Chae J (1995), ‘Evaluation of the thermodynamic process

of indirect injection diesel engines by the rst and second law’, SAE paper 952055.

Lipkea W H and DeJoode A D (1989), ‘A comparison of the performance of two direct

injection diesel engines from a seond law perspective’, SAE 890824.

McKinley T L and Primus R J (1988), ‘An assessment of turbocharging systems for diesel

engines from rst and second law perspectives’, SAE paper 880598.

Nakonieczny K (2002), ‘Entropy generation in a diesel engine turbocharging system’,

Energy, 27(11), 1027–1056.

Naterer G F (2008), Entropy Based Design and Analysis of Fluids Engineering Systems,

CRC Press, Boca Raton, FL.

Primus R J (1984), ‘A second law approach to exhaust system optimization’, SAE paper

840033.

Primus R J and Flynn P F (1985), ‘Diagnosing the real performance impact of diesel engine

design parameter variation (a primer in the use of second law analysis)’, International

Symposium on Diagnostics and Modeling of Combustion in Reciprocating Engines,

Tokyo, Japan, pp. 529–538.

Primus R J, Hoag K L, Flynn P F and Brands M C (1984), ‘An appraisal of advanced

engine concepts using second law analysis techniques’, SAE paper 841287.

Rakopoulos C D and Giakoumis E G (2004a), ‘Availability analysis of a turbocharged

diesel engine operating under transient load conditions’, Energy, 29, 1085–1104.

Rakopoulos C D and Giakoumis E G (2004b), ‘Parametric study of transient turbocharged

diesel engine operation from the second-law perspective’, SAE paper 2004-01-

1679.

Rakopoulos C D and Giakoumis E G (2005), ‘Second-law analysis of indirect injection

turbocharged diesel engine operation under steady-state and transient conditions’,

SAE paper 2005-01-1131.

Rakopoulos C D and Giakoumis E G (2006), ‘Second-law analyses applied to internal

combustion engines operation’, Progress in Energy and Combustion Science, 32,

2–47.

Rakopoulos C D and Giakoumis E G (1997), ‘Speed and load effects on the availability

balances and irreversibilities production in a multi-cylinder turbocharged diesel engine’,

Applied Thermal Engineering, 17(3), 299–313.

Rakopoulos C D and Giakoumis E G (2009), Diesel Engine Transient Operation – Principles

of Operation and Simulation Analysis, Springer Verlag London Limited, London.

Shapiro H N and Gerpen J H V (1989), ‘Two zone combustion models for second law

analysis of internal combustion engines’, SAE paper 890823.

Teh K-Y, Miller S L and Edwards C F (2008), ‘Thermodynamic requirements for

maximum internal combustion engine cycle efciency. Part 1: optimal combustion

strategy’, International Journal of Engine Research, 9, 449–465.

Teh K-Y, Miller S L and Edwards C F (2008), ‘Thermodynamic requirements for maximum

internal combustion engine cycle efciency. Part 2: work extraction and reactant

preparation strategies’, International Journal of Engine Research, 9, 467–481.

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SAE paper 940673.

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909

Diesel engine system dynamics, transient

performance, and electronic controls

Abstract: This chapter forms the foundation of dynamic engine system

design based on transient performance and engine controls. The system

dynamics approach adopted shares a common ground with the engine

controls community. The chapter begins with discussions on the differences

between steady-state and transient performance and the effects of hardware

design and software control strategy on transient turbocharged engine

performance. It further covers mean-value models, crank-angle-resolution

high-delity real-time models, air path model-based controls, and fuel path

controls. It also illustrates virtual sensor modeling with an example of the

exhaust manifold gas temperature sensor. Furthermore, it is pointed out that

analytical controller design is an important area where engine system design

can make signicant contributions.

Key words: system dynamics, transient performance, engine controls,

mean-value model, real-time model, model-based controls, sensor, controller

design.

14.1 Overview of diesel engine transient

performance and controls

14.1.1 The roles of engine hardware design and software

controls

Engine controls fulll the requirements derived from performance, emissions,

and durability. Moreover, electronic controls enable exible hardware

designs in modern engines, such as variable valve actuation (VVA) and

high-bandwidth-controlled variable combustion systems. Over the years,

electronic controls, consisting of software and calibration, have become a

core part of engine fundamental architecture. When engine hardware design

and electronic controls are integrated, two challenges are faced: (1) What

hardware should be controlled (i.e., which sensors and controllers should be

able to achieve the settings quickly and reliably)? (2) How should the hardware

be controlled (i.e., how to create the optimum algorithm and seamlessly

integrate it in the hierarchical structure of the system design with the best

trade-offs to minimize transient emission spikes and pumping loss)?

Engine air system hardware needs to be designed to have acceptable

transient capability to minimize turbocharger lag, transient pumping loss,

Diesel-Xin-14.indd 909 5/5/11 12:05:47 PM

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910 Diesel engine system design

fuel consumption and emissions, and to ensure fast warm-up. Transient

simulation plays a critical role in the development process, from predicting

vehicle transients to evaluating electronic control strategies. The commonly

encountered vehicle transients include load response, vehicle launch,

acceleration, and driving cycles. Moreover, predicting the transients can help

to analyze both performance and durability issues, and hence reveal their

parametric dependency. For example, compressor wheel fatigue life can be

evaluated from the transient load calculations for a turbocharger, and the

impact of gear shifting during driving cycles on component durability life

can be accessed as well.

14.1.2 The difference between steady-state and transient

performance

The transient acceleration or deceleration process of naturally aspirated

diesel engines can be approximated by a continuous series of steady-state

operating conditions. However, in turbocharged diesel engines, during

transients the turbine power is not equal to the compressor power, and the

turbocharger speed is affected by turbocharger inertia and turbocharger

power imbalance. There is a turbocharger lag during which the compressor

boost pressure gradually changes to reach a new steady state. The EGR

circuit has a certain volume and there is a transient dynamic response of

an EGR purging and lling process in the intake manifold. The transient

response is usually in the order of several engine cycles. There is also

an air–fuel ratio smoke limit for the maximum fueling, depending on the

available air ow. During transients, air–fuel ratio, EGR rate and in-cylinder

metal wall temperature (due to thermal inertia) are all different from those

in the steady state. The resulting deteriorated combustion efciency and

pumping loss cause differences in emissions and fuel economy between

steady-state and transient. Valve overlap also has a large impact on transient

acceleration performance. With a large overlap, at the beginning of fast

acceleration, the exhaust manifold pressure can be much higher than the

intake manifold pressure for various reasons (e.g., EGR valve closed).

The high engine delta P results in a large reverse ow of residue gases

from the exhaust manifold into the cylinder and the intake manifold. The

increased residue gas fraction reduces the air–fuel ratio and retards the

vehicle acceleration. In contrast, a small valve overlap helps transient

acceleration for the same reason.

14.1.3 Controlling engine transient performance

Steady-state emissions testing establishes appropriate NO

, PM, HC, and CO

throughout the engine speed–load domain by setting the engine calibration

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911Diesel engine transient performance and electronic controls

parameters including fuel injection timing and pressure, VGT vane opening,

EGR valve opening, and intake throttle valve opening. Coordinated controls

of the EGR valve and the VGT and coordinated controls of the EGR valve

and the intake throttle valve have been studied extensively (Nieuwstadt,

2003). Boost pressure (or air–fuel ratio) and EGR rate are mapped in the

speed–load domain during engine steady-state calibration. But the combined

control of the EGR valve and the VGT for transient EGR rate and air–fuel

ratio is challenging. Steady-state engine calibration may set the VGT vane

and the EGR valve opening positions to establish an air–fuel ratio and EGR

rate, but those steady-state air–fuel ratios and EGR rates are not achievable

during fast transients due to turbocharger lag, even if the transient gains are

applied to the steady-state set points of the positions in the lookup table of

the calibration maps.

Compared to steady-state emissions levels, there are three strategies for

designing the transient emission proles in engine controls: (1) overshoot spike

vs. time; (2) undershoot or slow approach vs. time; and (3) a compromise

to closely match a predetermined target without excessive overshoot or

undershoot. These strategies depend on the transient fueling rate changes.

Each strategy has different transient trade-offs between NO

and soot and

different characteristics of transient engine delta P and pumping loss. For

example, a transient NO

spike is normally caused by shutting off EGR during

fast acceleration. Design of each transient emissions prole with proper

combination of hardware and electronic controls is important. The difference

on emissions margin between steady-state and transient can be predicted

at the early stage of engine development. In addition, the requirements of

transient emissions and driving cycle fuel economy can be met through

proper designs.

Meeting a composite emissions target in the US supplemental emissions

test (SET) 13-mode steady-state does not mean the engine can meet the

same emissions target during an FTP transient cycle. In fact, as the NO

emission regulation becomes more stringent, the relative difference between

the FTP transient emissions and the steady-state emissions becomes

larger. It would translate to an unreasonably low steady-state emissions

development target in order to meet the FTP transient emissions target.

Therefore, a dynamic high EGR rate and adjustments of fuel injection

timing and injection pressure during transients must be used to reduce

the transient emissions. During transient operation, the purpose of engine

air system controls is to calculate and regulate the EGR valve and the

turbocharger actuator settings to achieve minimum emissions and maintain

drivability. The settings may be obtained from the position lookup tables

or may be calculated by model-based control algorithms. Various engine

control approaches can be used with different effects on engine transients.

The conventional approach uses various gain-based transient controllers

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