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© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 1
GT Conference 2017:Simulation Tool for Predictive Control Strategies for an ORC-System in Heavy Duty Vehicles
October 09-10, 2017
Dipl.-Ing. Jörg Kreyer M.Sc. FH Aachen
Prof. Dr.-Ing. Thomas Esch FH Aachen
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 2
• Scientific questions and solution methods
• Model intention and model features
• Data acquisition for heavy duty truck
• GT-Model presentation
• Longitudinal vehicle model incl. ORC-model
• 1-D engine model
• Predictive control strategies for ORC-system
• Summery and outlook
Content
GT Conference 2017
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 3
Scientific questions
• How can a non-stationary heat offering in the commercial vehicle be used to reduce fuel consumption?
• Which potentials offer route and environmental information among with predicted speed and load trajectories to increase the efficiency of a ORC-System?
Methods
• Desktop bound holistic simulation model for a heavy duty truck incl. an ORC System
• Prediction of massflows, temperatures and mixture quality (AFR) of exhaust gas
GT Conference 2017Scientific questions and solution methods
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 4
Radiator 1D-fuid components and control parameters
• Engine
• Injection and combustion
• EGR and TC
• Cooling circuit
• Pump and thermostat control
• Coupled Retarder
• ORC-System
• Working fluid: Ethanol
• Using of EGR and EAT Heat
• Electrical regeneration
• Actuators:
• ORC Fluid pump
• Split- and Bypassvalves
GT Conference 2017Model intention / Model features
Heat exchanger after EAT
T
G
M
Condenser
Massflow split valve
Bypass valve
Compen-sation tank
ORC pump
Generator/Expander
M
C
Retarder
Batterie
CAC
Recuperator
ORC cooling pump
CAC: Charge Air coolerEGR: Exhaust gas recirculationEAT: Exhaust aftertreatment
Heat exchanger after EGR
cooling pump
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 5
Vehicle configuration
• Actros 1845 LS / OM 471
• 330 kW @ 1800 RPM
• 2200 (2400 Top Torque) Nm @ 1100 RPM
• Displacement: 12,81 ltr. / 6 cylinder in-line
• Maximum Efficiency: ηeff = 46%
• EURO 6
• Gearbox: 12 gears
• 3 axes tarpaulin trailer
• Overall vehicle mass: 31700 kg
GT Conference 2017Data acquisition for heavy duty truck
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 6
GT Conference 2017Data acquisition for heavy duty truck
TV
ሶ𝐕 𝐩 𝐓
ሶ𝐕 𝐩 𝐓𝐩 𝐓 𝐓
𝐩 𝐓
𝐓𝐓
λ 𝐩 𝐓 𝐓
𝐩 𝐓
Fleet-
board
𝐩 𝐓
λ 𝐩 𝐓
𝐩 𝐓
ሶ𝐦𝑳
RadiatorRetarder
CAC
EAT
EGR
FPI
CAC: Charge Air coolerEGR: Exhaust recirculation coolerFPI: Fuel post injectionEAT: Exhaust aftertreatment
distance radar
𝐩
Measuring scope:
• Temperature, pressure, AFR
• Analysation of video data
• Mass- and volume flow
• Bosch HFM 7-25.0
• Volumeflow radiator and retarder
• Venturi nozzle for AGR
J1939 Protocol / OBD II:
• diver load demand
• indicated engine load
• engine speed
• Friction torque
• Injection amount
• Injection begin
Volume flow radiator
Airflow before intake filter Venturi nozzle for EGR
Dashboard information
OBD II
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 7
Autobahn cycle: Aachen (AC)
Characterized by:
• High density of construction side
• High speed restrictions
• Less road gradient
Autobahn cycle: Aachen-Frankfurt-Aachen (AC-F-AC)
Characterized by:
• Traffic congestion
• Less speed restrictions
• High road gradient
Aldenhoven Testing Center (ATC) and Rural Road (RR)
• Stationary load points
• Cast down curves
• Breaking tests
GT Conference 2017Data acquisition for heavy duty truck
0
160
320
480
640
800
0
20
40
60
80
100
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5
Gra
die
nt of
road [
m]
Vehic
le s
peed
[km
/h]
Driving time [h]
ATC
AC-F-AC
RR
0
500
1000
1500
2000
2500
400 800 1200 1600 2000
Teff
[Nm
]
Engine speed [RPM]
Full load curve
Top Torque
Load points ATC
Load Points CR
0160320480640800
020406080
100
0 0,5 1 1,5 2
Gra
die
nt of ro
ad
[m]
Vehic
le s
peed
[km
/h]
Driving time [h] Vehicle speed [km/h]Gradient of road [m]
AC
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 8
Status of the model development
• Vehicle dynamics, transmission and clutch controller
• Forward simulation done by driver model
• Fuel Consumption and heat release done by engine state model
• Operating characteristics of fluid systems: ORC and cooling circuit via Feed-forward controller
GT Conference 2017Longitudinal vehicle model incl. ORC-model
Model overview
ORC circuit model with single heat
input and recuperator
0
1
2
3
4
5
6
0 2000 4000 6000
ORC P
ow
er
outp
ut
[kW
]
Driving duration [s]
Transient Turbine Power Output
for Autobahncycle Aachen (AC)
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 9
GT-POWER Engine Modell OM 471
• Manifold desigen
• Valve timing
• Combustion
• EGR and Turbocharger performace control
GT Conference 2017Modelling: 1D GT-POWER engine model / OM 471
4321 5 6
CAC EGR
C TEGR
valve
EGR
throttle
1
1,5
2
2,5
3
3,5
4
4,5
5
0 0,2 0,4 0,6 0,8
Pre
ssure
Rato
[-]
Massflow [kg/s]
0,15
0,2
0,25
0,3
0,35
0,4
1,5 2,5 3,5 4,5M
assflow
[kg/s
]
Pressure Ratio Turbine [-]
ηmin=0,602ηmax=0,692
Turbocharger Maps
Source: Daimler AG,
2017 www.roadstars.mercedes-benz.com
0
500
1000
1500
2000
2500
Teff
[Nm
]
600 800 1000
Engine Speed [RPM]
400 1200 1400 1600 1800 2000
EGR Throttle position
nmin= 120000 1/minnmax= 30000 1/min
ηmin=0,61ηmax=0,78
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 10
GT Conference 2017Modelling: 1D GT-POWER engine model / OM 471
Simulated Exh. massflow [g/s]
0
600 800 1000 1200 1400 1600 1800 2000400
500
1000
1500
2000
2500Measured exh. massflow [g/s]
0
600 800 1000 1200 1400 1600 1800 2000400
500
1000
1500
2000
2500
2,5
1,5
3,5
3
2
1
0,5
0
500
1000
1500
2000
2500
26
24
22
20
26
28
3432
30
2424
26
26
28
Simulated EGR Rate [%]
0
600 800 1000 1200 1400 1600 1800 2000400
500
1000
1500
2000
2500
600 800 1000 1200 1400 1600 1800 2000
Engine Speed [RPM]
400
Measured EGR Rate [%]
Teff
[Nm
]
0
10
20
30
40
50
60
1 2 3 4 5 6 7 8 9 10
EG
R R
ate
[%
]
Load Point [#]
EGR Rate (MEASUREMENT)
EGR Rate (SIMULATION)
0
50
100
150
200
250
300
350
1 2 3 4 5 6 7 8 9 10
m_Ex [
g/s
]
Load Point [#]
m_Ex (MEASUREMENT)
m_Ex (SIMULATION)
Engine Speed [RPM]
Teff
[Nm
]
Engine Speed [RPM]
Teff
[Nm
]
Engine Speed [RPM]
Teff
[Nm
]
Increasing Peff
Increasing Peff
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 11
0
100
200
300
400
500
600
700
1 2 3 4 5 6 7 8 9 10
T_AT [
°C]
Load Point [#]
T_AT (MEASUREMENT)
T_AT (SIMULATION)
0
100
200
300
400
500
600
700
1 2 3 4 5 6 7 8 9 10
T_BT [°
C]
Load Point [#]
T_BT (MEASUREMENT)
T_BT (SIMULATION)
Simulated Temp. after turbine [°C]
0
600 800 1000 1200 1400 1600 1800 2000400
500
1000
1500
2000
2500
GT Conference 2017Modelling: 1D GT-POWER engine model / OM 471
Simulated Temp. before turbine [°C]
0
600 800 1000 1200 1400 1600 1800 2000400
500
1000
1500
2000
2500
Measured Temp. after turbine [°C]
0
600 800 1000 1200 1400 1600 1800 2000400
500
1000
1500
2000
2500
400
Measured Temp. bevor turbine [°C]
0
600 800 1000 1200 1400 1600 1800 2000400
500
1000
1500
2000
2500
550
500
450
400
350
300
350
300
250
200
Teff
[Nm
]
Increasing Peff
Increasing Peff
Engine Speed [RPM]
Teff
[Nm
]
Engine Speed [RPM]
Teff
[Nm
]
Engine Speed [RPM]
Teff
[Nm
]
Engine Speed [RPM]
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 12
Description of predictive control strategy:
• Multi-physical model vehicle (GT-SUITE)
• Restriction for the system behavior
• Energy prediction for the ORC system
• Basic controller and model predictive control (MPC) of ORC system
GT Conference 2017Predictive control strategies for ORC-system
Map based longitudinal vehicle
predictor model
GT model conventional
vehicle
GT model vehicle incl. ORC System
Load
𝛼, 𝑓𝑅, 𝑇𝑢,𝑝𝑢
Natural
Environment
Designed
Environment
𝑣𝑟𝑒𝑠
𝒙𝟏
𝒙𝟐n
Teff
TA
Prediciton of exhaust-enthalpy
ሶ𝒎A
n
Teff
Sim
ula
ted
Maps
Contr
olli
ng o
f
actu
ato
rs
Engine speed
Constraint optimization problem
T(t)
ሶ𝑚𝐴 tλ(t)
Restrictions:
• max. ORC fluid temperatures
• EGR temperature
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 13
Map based longitudinal vehicle predictor model:
• Designed Environment
• Legal speed restrictions
• Speed restrictions by traffic
• Natural Environment
• Road gradient:
• Roll resistance:
• Ambient conditions:
• Temperatur caclulation Map-based with first order delay element PT1:
Predictive control strategies for ORC-system
GT Conference 2017
DriverBalance of forces
Engine
Veh. Drivetrain
Load
n
𝑓𝑅𝑇𝑢𝑝𝑢
α
𝑖𝑔𝑒𝑠
Natural
Environment
Designed
Environment
𝑣𝑟𝑒𝑠
𝑣(𝑡)𝑎(𝑡) 1
𝑠
GT Power based lookup tables
𝑡𝑜𝑟𝑞𝑢𝑒
n
𝑑𝑈
𝑑𝑡=
𝑑
𝑑𝑡𝑐 ∙ 𝑚𝑤∙ Δ𝑇
ሶ𝑄𝑑𝑖𝑠𝑠
ሶ𝑚𝐸𝑥 ∙ 𝑐𝑝 ∙ 𝑇𝑖𝑛
ሶ𝑚𝐸𝐺𝑅 ሶ𝑚𝐸𝑥
𝑇𝐸𝑥𝑇𝐸𝐺𝑅
𝐿𝑜𝑎𝑑
PT1 PT1
ሶ𝐻𝑖𝑛 =
ሶ𝑚𝐸𝑥 ∙ 𝑐𝑝 ∙ 𝑇𝑜𝑢𝑡
ሶ𝐻𝑜𝑢𝑡 =
𝑓𝑅
𝑇𝑢, 𝑝𝑢
α
Engine
Torque
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 14
GT Conference 2017Predictive control strategies for ORC-system
100
200
300
400
500
600
Tem
pera
ture
befo
r tu
rbin
e[°
C]
-40
-20
0
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Absolu
te
devia
tion [
%]
Driving Time [s]
100
150
200
250
300
350
400
Tem
pera
tur
aft
er
EAT [
°C]
0
40
80
120
160
200
0
20
40
60
80
100
Gra
die
nt of
road [
m]
Vehic
le s
peed
[km
/h]
Driving profile: Autobahn Cycle AC Vehicle speed [km/h]Gradient of road [m]
-80
-40
0
40
Absolu
te
devia
tion
[%]
Measured
Simulated
Measured
Simulated
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017 | 15
GT Conference 2017Summary and outlook
Summery
• A simulation tool for ORC performance analyzation in heavy duty trucks is created
• A strategy for energy prediction to ORC system was presented
• A data base of real driving data has been brought up
Next Steps
• Combining of 1-D engine model with driveline, coolant and ORC sub-systems
• Development of feed-backward controller for ORC system
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 09. October 2017
FH Aachen
Dipl.-Ing. (FH) Jörg Kreyer M.Sc.
European Centre for Sustainable Mobility
Aachener-und-Münchener Allee 1
52064 Aachen
T +49. 241. 6009 52827
F +49. 241. 6009 52489
FH Aachen
Prof. Dr.-Ing. Thomas Esch
European Centre for Sustainable Mobility
Hohenstaufenallee 6
52064 Aachen
T +49. 241. 6009 52369
F +49. 241. 6009 52680