Enhancement of Heavy-Duty Engines Performance and Reliability Using Cylinder Pressure Information

Sustainability issues are becoming increasingly prominent in applications requiring the use of heavy-duty engines. Therefore, it is important to cut emissions and costs of such engines to re-duce the carbon footprint and keep the operating expenses under control. Even if for some applications a battery electric equipment is introduced, the diesel-equipped machinery is still popular, thanks to the longer operating range. In this field, the open pit mines are a good example. In fact, the Total Cost of Ownership (TCO) of the mining equipment is highly impacted by fuel consumption (engine efficiency) and reliability (service interval and en-gine life). The present work is focused on efficiency enhancements achievable through the ap-plication of a combustion control strategy based on the in-cylinder pressure information. The benefits are mainly due to two factors. First, the negative effects of injectors ageing can be com-pensated. Second, cylindrical online calibration of the control parameters enables the combus-tion system optimization. The article is divided into two parts. The first part describes the tool-chain that is designed for the real time application of the combustion control system, while the second part concerns the algorithm that would be implemented on the Engine Control Unit (ECU) to leverage the in-cylinder pressure information. The assessment of the potential benefits and feasibility of the combustion control algorithm is carried out in a Software in the Loop (SiL) environment, simulating both the developed control strategy and the engine behavior (Liebherr D98). Our goal is to validate the control algorithm through SiL simulations. The results of the validation process demonstrate the effectiveness of the control strategy: firstly, cylinder dispari-ty on IMEP (+/-2.5% in reference conditions) is virtually canceled. Secondly, MFB50 is individual-ly optimized, equalizing Pmax among the cylinders (+/-4% for the standard calibration), without exceeding the reliability threshold. In addition to this, BSFC is reduced by 1%, thanks to the ac-curate cylinder-by-cylinder calibration. Finally, ageing effects or fuel variations can be implicitly compensated, keeping optimal performance thorough engine life.