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GMU – GM PROJECT

GMU – GM PROJECT. Model-Based On-Board Fault Diagnosis of Emission Control Components in Automotive Engines “FaultFinder” 1990-1996. The emission control problem. Main pollutants in automotive tailpipe emissions: Hydrocarbons (un-burnt fuel) Carbon monoxide (partially burnt fuel)

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GMU – GM PROJECT

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  1. GMU – GM PROJECT Model-Based On-Board Fault Diagnosis of Emission Control Components in Automotive Engines “FaultFinder” 1990-1996

  2. The emission control problem Main pollutants in automotive tailpipe emissions: • Hydrocarbons (un-burnt fuel) • Carbon monoxide (partially burnt fuel) • Nitrous oxides (compounds arising from high-pressure combustion) Single catalytic converter for the three pollutants

  3. Catalyst efficiency for three pollutants

  4. Basic fuel-control system driver air exhaust THROTTLE ENGINE fuel FUEL INJECTOR POSITION SENSOR OXYGEN SENSOR CONTROLLER feed-forward feedback

  5. Exhaust gas recirculation (EGR) driver air exhaust THROTTLE ENGINE EGR VALVE MAP SENSOR RPM SENSOR CONTROLLER

  6. On-Board Diagnosis (OBD) – II Regulation(Mid-nineties) Any fault of an emission control component causing any of the three main pollutants to exceed its legal limit by 50% must be detected/diagnosed within three driving cycles. Warning light must illuminate. Driving cycle: 25 min highway/city

  7. Car engine model Thr Egr Fuel Load MANIFOLD SUBSYSTEM INERTIAL SUBSYTEM AIR-FUEL SUBSYSTEM Map Oxygen Rpm Thr: throttle Egr: exhaust gas recirculation Map: Manifold absolute pressure Rpm: Revolutions per minute

  8. Car engine model Car engine model Thr Egr Fuel Load MANIFOLD SUBSYSTEM INERTIAL SUBSYTEM AIR-FUEL SUBSYSTEM Map Oxygen Rpm

  9. Car engine model Car engine model Car engine model Thr Egr Fuel MANIFOLD SUBSYSTEM AIR-FUEL SUBSYSTEM Rpm Map Oxygen

  10. Work-plan • Data-collection from vehicle (idle, city, highway, hill) • Model identification (direct identification of each equation) • Algorithm design • Coding (HC11; assembly code, memory-limited system) • Building fault-emulators (hardware on vehicle) • Road testing (fault free/faulty)

  11. Six-variable system Thr Thr Egr Fuel Map Rpm VO2 0 1 1 1 1 1 1 0 1 1 1 1 1 1 0 1 1 1 1 1 1 0 1 1 1 1 1 1 0 1 1 1 1 1 1 0 VO2: Oxygen sensor voltage Map Egr Fuel VO2 Rpm

  12. Four-variable system Thr Map Thr/Iac Egr Map Maf 0 1 1 1 1 0 1 1 1 1 0 1 1 1 1 0 Iac: Idle air control Maf: Mass air flow MANIFOLD SUBSYSTEM Iac Egr Maf

  13. The four subsystems Thr/Iac Egr THROTTLE BODY INTAKE MANIFOLD Map Maf Map Maf

  14. Residual generation Thr Iac Egr Map MODEL - + Map^ EXCEPTIONS Thr Rpm raw residual

  15. A “typical” equation Map^(t) = 13.72 constant + 0.78*Thr(t) + 0.049*Iac(t) + 0.22*Egr(t) + 0.66*Map(t-1) autoregressive term – 0.0085*Thr2(t) – 0.001*Iac(t)*Egr(t) linear terms nonlinear terms

  16. Residual processing raw residual LOW-PASS FILTER filtered residual THRESHOLD TESTING 0/+1/-1 UP/DOWN COUNTER count (periodically reset) THRESHOLD TESTING one bit of the fault-code

  17. Residual and counter – no fault

  18. Residual and counter – high noise

  19. Residual and counter – with fault

  20. System report – no fault

  21. System report – MAF fault

  22. System report – EGR or MAP fault

  23. 25-car fleet experiment Fleet of “identical” vehicles (Chevy Blazer) available at GM • Collect data from 25 vehicles • Identify models from combined data from 5 vehicles • Test on data from 25 vehicles Residual means and variances vary  increase thresholds (sacrifice sensitivity) Only a 50% increase is necessary

  24. Fault sensitivities Critical fault sizes for detection and diagnosis (fleet experiment) Thr Iac Egr Map Maf detection 2% 10% 12% 5% 2% diagnosis 6% 20% 17% 7% 8%

  25. Contributors At GMU At GM Ron Hira Man-Feng Chang Xiaowen Fang Mark Costin Qiang Luo Derong Liu Moid Kunwer Tom Ting Ramin Monajemy John Van Gilder Zdzislaw Kowalczuk Jim Heron Bill Hunter Yong Li Jason Peng

  26. Epilogue • May 26, 2004 DETROIT, Michigan - General Motors honors its top innovators of 2003 at the 28th annual "Boss" Kettering Awards ceremony today. The "Boss" Kettering Award is GM’s highest award for recognizing GM technical inventions and innovations.

  27. FaultFinder: Model-Based Approach for Advanced Engine Diagnostics This model-based approach for advanced engine diagnostics … requires no additional sensors or other hardware, reduces false-alarm rates, improves vehicle repair rates and dealership effectiveness.

  28. This innovation has beenimplemented in the2004 Chevrolet Malibufeaturing ECOTEC 2.2-LITER 4- cylinder engines;Cadillacsfeaturing the Northstar 4.6-liter V-8 engines; andChevrolet Colorado and GMC Canyon mid-size trucks. The FaultFinder team includes Thomas Ting and Dr. Man-Feng Chang of GM R&D; John Van Gilder and Dr. Mark Costin of GM Powertrain Division.

  29. Janos, While celebrating this recognition, we would like to acknowledge your invaluable contributions as a Principal Investigator of a five-year joint project between GM and George Mason University.   The project resulted in the first General Motors experimental demonstration of model-based diagnostics for the detection of faults in an engine emission system.  This is an important step and set the stage for further research in this area. Thank you again.  Man-Feng

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