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Control Strategy for a Dual Loop EGR

System to Meet Euro 6 and Beyond

2009 Directions in Engine-Efficiency and Emissions Reduction


Research (DEER) Conference
August 3-6, 2009, Dearborn, Michigan.

John Shutty and Robert Czarnowski

Contents
Background
System Description
Thermodynamic Analysis

Control System Overview


Structure
Features
Control Optimization

NEDC Results
On Engine Application

Conclusions
2

DEER Conference 2009

Motivation
1.0
0.8
0.6

Eu Kor
Eu ro II ea
ro I 20
IV
0
20 5
10

0.4

s
ate 7
St 200
d
ite n 5
Un II Bi
r
Tie

Japan
Japan 2005
Japan 2009

Reduce the cost and


lower emissions of
diesel engines in an
ever tightening
regulatory world
Focus on EGR and
Boost Systems

India
Bharat II 200
5
Bharat III 20
10

NOx Emissions Regulation (g/km)

ina 07
Ch 3 20 0
1
20
ro
Eu r o 4
Eu

Eu Euro
Eu r o 3 p e
Eu ro 4 2000
ro
2
5 2 005
00
9

DEER Conference 2009

EGR & Turbo Charging System Architecture


Base Dual Loop EGR system Layout

I4 diesel engine, common rail

Exhaust
Throttle

VTG
DPF

HP-EGR
Valve
HPEGR
Cooler

LPEGR
Cooler
LP-EGR Valve

Base engine HW:


2L Inline 4 EURO4
Adjusted Parameters:
EGR-rate, Boost pressure
Combustion system:
standard Diesel (diffusive)

Intake
throttle

EGR Mixer

Charge Air Cooler

EGR-system:
cooled HP-EGR, cooled LPEGR
Boosting system:
1-stage VTG

DEER Conference 2009

Last year conclusions


A Dual Loop EGR System offers significant
advantages to reduce emissions and fuel consumption
and can meet future emission requirements

Mostly due to improved turbocharger operating


efficiency

Charge Air Temperature Reduced


Up to 4% improvement in BSFC in steady state
More EGR can be driven without performance
sacrifice

Dynamic engine performance can be improved with a


dual loop EGR system

Transient controls need to be developed and improved


(focus of today's presentation)

DEER Conference 2009

Thermodynamic Analysis HP&LP Loop


Specific fuel consumption at different HP/LP-EGR-splits
n = 2500 1/min VTG Closed
BMEP = 12 bar
EGR = 30%
100%
HP

100%
LP

75%
55%

VTG
Open

Low fuel consumption


Better use of the
exhaust energy and
higher efficiencies of
38%
the compressor and
turbine
6

DEER Conference 2009

Development Process
Modeling of Production Baseline
Full GT-Power Model
Real time capable mean value model (MVM)

Development of controller in Simulink


Controller Verification and calibration
with GT-Power MVM in Simulink
Dynamometer testing and final
calibration using same Simulink code
Verification on Dyno simulating NEDC
Cycle
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DEER Conference 2009

Previous Controller Options


Separate EGR and Boost Controllers
Stability achieved by maintaining open loop or slow
dynamic controls

Decoupled EGR and Boost Controllers


Loop interference reduced but slow response and
overshoots still an issue

In both cases, NOx and PM control


compromised during transients
8

DEER Conference 2009

Air Controller System Architecture


Load

HP EGR set point

Speed

EGR-Boost
optimization

Temperature

HP EGR
Control
Map

High
Pressure
LowFeed
Pressure
Forward
Loop
Controls
Loop
Controls
Loops
HP EGR Valve

HPL
Split

Engine
State

Intake Throttle
EGR TOTAL
set-point

Feedback
Controller

LP EGR set point


LPL
Split

LP EGR
Control
Map

Engine
State
Total EGR
frac
estimator

Boost Pressure
Set Point

LP EGR &
Exhaust Throttle Module

Sensor(s)

Boost
Controller

Turbo VTG
Sensor(s)

Turbo
Controls
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DEER Conference 2009

BW Coordinated Controller Features

Negative coupling is eliminated and positive coordination is added


to improve response and control
Dual Loops and VTG help each other to achieve higher
efficiency
Static EGR Estimation Improvement
Achieves requested EGR rate more accurately
EGR Boost Optimization Block
Determines EGR loop split
Calculated dynamically for best efficiency
Utilization of EGR path which is most capable and efficient of
achieving the set-point
statically (actuator saturation (virtual or actual))
dynamically (slower loop dynamics)
Improved Dynamic Control
Coordinated EGR and boost system to adjust on the fly with
closed loop control

10

DEER Conference 2009

Coordinated Controller Results


Static EGR Estimation Improvement
Better fuel economy achieved at same NOx level

EGR Boost Optimization Block


Fuel economy improved by higher Turbo Efficiency and lower
NOx achieved by increasing EGR

Dynamic feedback control of EGR mass flow, both


EGR loops and VTG
Improved Dynamic Control
Decoupling of VTG and EGR allows control of each during
transients
Less NOx and PM spikes

Easy to implement in production ECU


Low memory and CPU usage
No extra I/O
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DEER Conference 2009

HPL/LPL Split Strategy


Maximize Efficiency of Turbocharger
Minimize pumping losses
Improve dynamic Performance
Control Charge air temperature
Minimize Condensation in LPL

12

DEER Conference 2009

Torque

LP / HP EGR Split Strategy Steady State Map


%HP EGR / %LP EGR
Increase oxygen
content

40/60
High pumping
loss with LP
20/80 EGR

0/100
Fast
reaction
time
40/60
75/25

40/60
75/25
100/0
Combustion temperature

Optimizing
VTG
position

Engine speed
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DEER Conference 2009

Static and Dynamic Improvements Relative to Baseline


EGR Rate above
requested rate

50
EGR rate setpoint
EGR rate actual

EGR Rate (%)

40
30

Production ECU
Control

20
10
0

200

230

290

320

350

380

410

Maintains
requested rate
during cycle

50
40
EGR Rate (%)

260

440

470

500

EGR valve shutoff to decouple

EGR rate setpoint


EGR rate actual

BorgWarner
Control

30
20
10
0

200

230

260

290

320

350

380

410

440

470

500
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DEER Conference 2009

120
80
40
250

0
Base HP EGR calibration / Daimler ECU controller
HP+LPHP
EGREGR
V0 calibration
/ BWES
controller
V0 / ECU
Control
HP+LP EGR V5 calibration / BWES controller

NOx concentration [ppm]

200

Vehicle speed [km/h]

EUD Cycle - On Engine NOx Control

Production ECU HPL 25%

HP/LP EGR V0 / BW Controller


HP/LP EGR V5 / BW Controller

NOx Peaks
reduced

150

BW Dual Loop 20%

100

50

Significant NOx
reduction
0
780

880

980

BW Dual Loop 35%

1080

1180

Cycle time [s]

15

DEER Conference 2009

Charge temperatures reduced with dual Loop EGR


Temp
reduced
over 30C
HPL & LPL
have same
size coolers
25% Prod ECU HP EGR
35% Dual Loop EGR
25% Dual Loop EGR
Km/hr

16

DEER Conference 2009

Cumulative NOx and CO2 on NEDC Test


Production ECU Control HPL vs. BW Control Dual Loop EGR
24% Reduction
in NOx
Constant PM
6% less fuel
consumption
BWDualLoopEGR20%
ProdECUHPEGR25%

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DEER Conference 2009

Increased EGR rate to Maximize NOx Reduction


Production ECU vs BorgWarner Coordinated Controls

Km/hr

NOxmg/km

ProdECUHPEGR25%

72%
Reduction in
NOx

-72% Increased
EGR to
Obtain
Equivalent
BWDualLoopEGR35%
Fuel
Consumption
Seconds
& PM

18

DEER Conference 2009

System Summary
System

EGR System

Fuel
Consumption
reduction (%)

NOx
Reduction (%)

Baseline

High Pressure
loop w/ cooler
25%

NA

NA

BorgWarner
coordinated
controls

High Pressure
loop w/ cooler
20%

BorgWarner
coordinated
controls

Dual Loop EGR


w/ coolers
20%

24

BorgWarner
coordinated
controls w/
increased EGR

Dual Loop EGR


w/ coolers
35%

72
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DEER Conference 2009

Summary Map: CO2 vs NOx


Relative Contributions to Emissions Reduction
NOx Reduction Contributions

175

+ 15
EGR

+15% EGR
Actual
CO2 g/km

Theoretical
Line +15% EGR

+15% EGR
Actual

180

ECU Control
HP EGR

170

165

+ 15%
EGR

+
BW
+BorgWarner
Air
Controls
Path Controls

160

+ LP
EGR
155
0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

NOx g/km

20

DEER Conference 2009

Conclusions
Dual Loop EGR offers significant advantages to
reduce emissions and fuel consumption to meet future
emission requirements

A coordinated control system has been developed to


optimize the EGR and air boost system

Significantly reduces fuel consumption and / or NOx


Improves dynamic performance of turbocharger
Potential for NOx aftertreatment system cost reduction
Future work includes two stage boosting systems
together with dual loop EGR allows further enhanced
performance while utilizing down speeding to achieve
CO2 targets.
DEER Conference 2009

21

Thank You For Your Attention

For Further Information


Contact:
Bob Czarnowski
22

rczarnowski@borgwarner.com

DEER Conference 2009

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