Combustion Engine Diagnosis: Model-based Condition Monitoring of Gasoline and Diesel Engines and their Components (ATZ/MTZ-Fachbuch)

This book offers first a short introduction to advanced supervision, fault detection and diagnosis methods. It then describes model-based methods of fault detection and diagnosis for the main components of gasoline and diesel engines, such as the intake system, fuel supply, fuel injection, combustion process, turbocharger, exhaust system and exhaust gas aftertreatment. Additionally, model-based fault diagnosis of electrical motors, electric, pneumatic and hydraulic actuators and fault-tolerant systems is treated. In general series production sensors are used. It includes abundant experimental results showing the detection and diagnosis quality of implemented faults. Written for automotive engineers in practice, it is also of interest to graduate students of mechanical and electrical engineering and computer science. The Content Introduction.- I SUPERVISION, FAULT DETECTION AND DIAGNOSIS METHODS.- Supervision, Fault-Detection and Fault-Diagnosis Methods - a short Introduction.- II DIAGNOSIS OF INTERNAL COMBUSTION ENGINES.- On the Control and Diagnosis of Combustion Engines.- Gasoline Engine Diagnosis.- Diesel Engine Diagnosis.- III DIAGNOSIS OF ELECTRICAL DRIVES, MOTORS AND ACTUATORS.- Electrical Motors, Actuators.- IV FAULT-TOLERANT SYSTEMS.- Fault-tolerant sensors and actuators.- V APPENDIX.- Terminology for Fault Diagnosis. The Target Group Written for automotive engineers in practice, it is also of interest to graduate students of mechanical and electrical engineering and computer science. The Author Rolf Isermann studied Mechanical Engineering and obtained the Dr.-Ing. degree in 1965 from the University of Stuttgart, Germany. In 1972 he became Professor in Control Engineering at the University of Stuttgart. From 1977-2006 he was Professor for Control Systems and Process Automation at the Institute of Automatic Control of the Darmstadt University of Technology. Since 2006 he is Professor emeritus and is head of the Research Group for Control Systems and Process Automation in the same institution. R. Isermann received the Dr. h.c. (honoris causa) from L'Université Libre de Bruxelles and from the Polytechnic University in Bucharest. In 1996 he was awarded by the "VDE-Ehrenring", and in 2007 by "VDI-Ehrenmitglied". The MIT Technology Review Magazine awarded him in 2003 to the Top Ten of Emerging Technologies in Mechatronics. In 2010 he received the Rufus Oldenburger Medal from the American Society of Mechanical Engineers (ASME: highest scientific award for lifetime achievements), and in 2016 the IFAC lifetime achievement award for mechatronics Preface 6 Contents 8 List of Symbols 13 1 Introduction 22 1.1 Combustion engine control and diagnosis developments 22 1.1.1 On the historical development of gasoline engines control 24 1.1.2 On the historical development of diesel engines control 24 1.2 Current engine developments 26 1.2.1 Gasoline engines 26 1.2.2 Diesel engines 28 1.2.3 Alternative drives 31 1.3 On-board and off-board diagnosis 31 1.4 Failure statistics 35 1.5 On the contents of this book 39 References 41 I Supervision, Fault Detection and Diagnosis Methods 43 2 Supervision, fault-detection and fault-diagnosis methods – a short introduction 44 2.1 Basic tasks of supervision 44 2.2 Knowledge-based fault detection and diagnosis 45 2.2.1 Analytic symptom generation 46 2.2.2 Heuristic symptom generation 47 2.2.3 Fault diagnosis 47 2.3 Signal-based fault-detection methods 48 2.3.1 Limit checking of absolute values 48 2.3.2 Trend checking 48 2.3.3 Plausibility checks 49 2.3.4 Signal-analysis methods 50 2.4 Process-model-based fault-detection methods 51 2.4.1 Process models and fault modeling 51 2.4.2 Fault detection with parameter estimation 54 2.4.3 Fault detection with state observers and state estimation 55 a) State observers 55 b) Output observers 57 c) State estimation 57 2.4.4 Fault detection with parity equations 57 2.4.5 Direct reconstruction of non-measurable variables 59 2.5 Fault-diagnosis methods 61 2.5.1 Classification methods 61 2.5.2 Inference methods 61 2.6 Fault detection and diagnosis in closed loop 62 Concluding remarks 64 References 64 II Diagnosis of Internal Combustion Engines 67 3 On the control and diagnosis of internal combustion engines 68 3.1 Electronic engine control 68 3.1.1 On the control of gasoline engines 70 3.1.2 On the control of diesel engines 73 3.2 On-board and off-board diagnosis of engines 76 3.3 Control- and diagnosis-oriented subdivision of combustion engines 81 3.4 Model-based fault detection of combustion engines 84 References 86 4 Diagnosis of gasoline engines 91 4.1 Intake system (air path manifold) 91 4.1.1 Fault diagnosis of the intake system with physical models 91 4.1.2 Fault diagnosis of the intake system with experimentally identified models 96 a) Case 1: fuel stratified direct injection gasoline engine 96 b) Case 2: homogeneous combustion gasoline engine 104 4.2 Misfire detection 107 4.2.1 Engine speed analysis 108 4.2.2 Ion-current analysis 113 4.2.3 Exhaust gas pressure analysis 114 4.3 Fuel supply and injection system 117 4.3.1 Low-pressure supply system 118 4.3.2 High-pressure fuel supply and injection system 120 a) Wavelet analysis of the rail pressure signal 122 b) Analysis of the engine speed signal 123 c) Fault detection and diagnosis in the rail pressure system 124 4.3.3 Tank leak diagnosis 125 4.4 Ignition system 127 4.5 Combustion pressure analysis 129 4.6 Exhaust system 130 4.6.1 Leaks and congestions 130 4.6.2 Catalyst diagnosis 130 4.7 Cooling system 132 4.7.1 Fault detectionof the cooling system with mechanical driven pumps 132 4.7.2 Fault detection with electrical driven coolant pumps 133 4.8 Lubrication system 135 4.8.1 Models of a lubrication circuit 137 4.8.2 Model-based fault detection of a lubrication circuit 141 4.9 Overall gasoline engine fault diagnosis 142 References 143 5 Diagnosis of diesel engines 149 5.1 Intake system 151 5.1.1 Modeling of the intake system with semi-physical nonlinear models 152 5.1.2 Fault detection with nonlinear parity equations and diagnosis 158 5.2 Direct injection system with distributor pump and combustion 163 5.2.1 Fault detection with combustion features and speed measurement 165 5.2.2 Fault detection with combustion features and excess air measurement 169 5.2.3 Combined diagnosis for injection and combustion 172 5.2.4 Combustion pressure measurement analysis 174 5.3 Common-rail injection system 177 5.3.1 Analysis of the rail pressure signal 178 5.3.2 Model-based fault diagnosis 183 a) Mean common-rail pressure 183 b) Uniformity 185 c) Fuel delivery 185 d) Experimental results 186 5.4 Turbochargers with wastegate and variable geometry 189 5.4.1 Models of VGT turbochargers 190 5.4.2 Model-based symptom generation 196 5.4.3 Wastegate turbocharger 197 5.5 Exhaust system 200 5.5.1 Analytical redundancies for air mass flow 200 a) Dynamically corrected HFM air mass flow 200 b) Charged air mass flow 200 c) Air mass flow based on exhaust oxygen content 201 5.5.2 Combined fault detection for wastegate turbocharger and air mass flow 201 5.5.3 Particulate filter and catalyst 201 5.6 Overall diesel engine fault diagnosis 203 References 203 III Diagnosis of Electric Drives, Motors and Actuators 207 6 Diagnosis of electric motors 208 6.1 Direct-current motor (DC) 210 6.1.1 Models of a DC motor with brushes 210 6.1.2 Fault detection with parity equations 212 6.1.3 Fault detection with parameter estimation 213 6.1.4 Experimental results for fault detection 214 6.1.5 Conclusions 217 6.2 Alternating-current motor (AC) 217 6.2.1 Models of induction motors (asynchronous motors) 218 a) Electrical subsystem 218 b) Mechanical subsystem 220 c) Thermal subsystem 220 6.2.2 Signal-based fault detection of the power electronics 221 6.2.3 Model-based fault detection of the AC motor 223 a) Electrical part of the AC motor 224 b) Mechanical subsystem of the AC motor 225 c) Thermal subsystem 226 d) AC motor at standstill 228 6.2.4 Conclusions 229 6.3 Alternating-current synchronous motors (SM) 229 6.3.1 Types of three-phase synchronous motors 229 6.3.2 Models and control of permanent magnet synchronous motors (PMSM) 232 6.3.3 Model-based fault detection of a PMSM motor 234 References 237 7 Diagnosis of actuators 239 7.1 Electric actuators 239 7.1.1 Electromagnetic actuator 239 a) Position control 241 b) Fault detection with parameter estimation 244 c) Reconstruction of the armature position of a proportional magnet with voltage and current measurement 247 7.1.2 Electrical automotive throttle valve actuator 248 a) Structure and models of the actuator 248 b) Input test cycle 250 Fault detection with parameter estimation 251 c) Parameter estimation for the dynamic behavior 251 Parameter estimation for the static behavior 252 c) Fault detection with parity equations 254 d) Fault diagnosis 255 e) Conclusions 256 7.1.3 Brushless DC motor 257 a) Structure and models 257 b) Fault detection with parameter estimation 259 c) Fault detection with parity equations 260 d) Conclusions 262 7.2 Pneumatic actuators 262 7.2.1 Design of pneumatic actuators 262 7.2.2 Models of pneumatic actuators 264 7.2.3 Fault detection of pneumatic actuators 270 7.3 Hydraulic actuators 271 7.3.1 Camshaft phasing 271 7.3.2 Models of a hydraulic camshaft phasing system 272 7.3.3 Fault detection 277 References 278 IV Fault-Tolerant Systems 281 8 Fault-tolerant components 282 8.1 Safety-related systems 282 8.2 Basic fault-tolerant structures 283 8.3 Fault tolerance for control systems 286 8.4 Fault management 287 8.5 Fault-tolerant sensors 287 8.5.1 Hardware sensor redundancy 288 8.5.2 Analytical sensor redundancy 288 8.5.3 Fault-tolerant position sensor for an electrical throttle 290 8.5.4 Fault-tolerant air intake sensor system 291 8.6 Fault-tolerant actuators and drive systems 294 8.6.1 Fault-tolerant hydraulic systems 295 a) Fault-tolerant hydraulic brake 295 b) Fault-tolerant fuel injection pump 295 c) Fault-tolerant hydraulic actuators 295 8.6.2 Fault-tolerant electrical actuators and drives 296 a) Electrical duplex actuator system 297 b) Fault-tolerant electrical drives 298 References 300 V Appendix 305 9 Terminology in fault detection and diagnosis 306 States and signals 306 Functions 306 Models 307 System properties 307 References 308 Index 309 This book offers first a short introduction to advanced supervision, fault detection and diagnosis methods. It then describes model-based methods of fault detection and diagnosis for the main components of gasoline and diesel engines, such as the intake system, fuel supply, fuel injection, combustion process, turbocharger, exhaust system and exhaust gas aftertreatment. Additionally, model-based fault diagnosis of electrical motors, electric, pneumatic and hydraulic actuators and fault-tolerant systems is treated. In general series production sensors are used. It includes abundant experimental results showing the detection and diagnosis quality of implemented faults. Written for automotive engineers in practice, it is also of interest to graduate students of mechanical and electrical engineering and computer science. The Content Introduction.- I SUPERVISION, FAULT DETECTION AND DIAGNOSIS METHODS.- Supervision, Fault-Detection and Fault-Diagnosis Methods - a short Introduction.- II DIAGNOSIS OF INTERNAL COMBUSTION ENGINES.- On the Control and Diagnosis of Combustion Engines.- Gasoline Engine Diagnosis.- Diesel Engine Diagnosis.- III DIAGNOSIS OF ELECTRICAL DRIVES, MOTORS AND ACTUATORS.- Electrical Motors, Actuators.- IV FAULT-TOLERANT SYSTEMS.- Fault-tolerant sensors and actuators.- V APPENDIX.- Terminology for Fault Diagnosis. The Target Group Written for automotive engineers in practice, it is also of interest to graduate students of mechanical and electrical engineering and computer science. The Author Rolf Isermann studied Mechanical Engineering and obtained the Dr.-Ing. degree in 1965 from the University of Stuttgart, Germany. In 1972 he became Professor in Control Engineering at the University of Stuttgart. From 1977-2006 he was Professor for Control Systems and Process Automation at the Institute of Automatic Control of the Darmstadt University of Technology. Since 2006 he is Professor emeritus and is head of the Research Group for Control Systems and Process Automation in the same institution. R. Isermann received the Dr. h.c. (honoris causa) from L'Université Libre de Bruxelles and from the Polytechnic University in Bucharest. In 1996 he was awarded by the "VDE-Ehrenring", and in 2007 by "VDI-Ehrenmitglied". The MIT Technology Review Magazine awarded him in 2003 to the Top Ten of Emerging Technologies in Mechatronics. In 2010 he received the Rufus Oldenburger Medal from the American Society of Mechanical Engineers (ASME: highest scientific award for lifetime achievements), and in 2016 the IFAC lifetime achievement award for mechatronics Front Matter....Pages I-XXI Introduction....Pages 1-21 Front Matter....Pages 23-23 Supervision, fault-detection and fault-diagnosis methods – a short introduction....Pages 25-47 Front Matter....Pages 49-49 On the control and diagnosis of internal combustion engines....Pages 51-73 Diagnosis of gasoline engines....Pages 75-132 Diagnosis of diesel engines....Pages 133-190 Front Matter....Pages 191-191 Diagnosis of electric motors....Pages 193-223 Diagnosis of actuators....Pages 225-266 Front Matter....Pages 267-267 Fault-tolerant components....Pages 269-291 Front Matter....Pages 293-293 Terminology in fault detection and diagnosis....Pages 295-297 Back Matter....Pages 299-303