Combustion Engine Diagnosis

During the last decades internal combustion engines have developed to rather com

plex systems through an increasing number of components and variabilitie There-

fore, more actuators, sensors and many more electronic control functions were im-

plemented. This resulted together with constructive and thermodynamic designs in

a considerable improvement of performance and reduction of fuel consumption and

emissions. However, because of the increased complexity improved monitoring and

troubleshooting is a well-known challenge.

The increasing requirements on the coverage and precision of fault detection and

diagnosis for internal combustion engines and powertrains therefore need system-

atic procedures for the development. Compared to the classical on-board diagnosis

(OBD) for emission-related faults advanced methods with signal models and process

models allow a considerable expansion of the detection and localization performance

for engine component faults.

Advanced engine diagnostic methods support also the workshop-based diagnosis

(off-board) to find the root causes of faults more quickly and to reduce vehicle down-

time. It also opens remote access to be used by service stations and manufacturers.

Hence, these methods enable to improve the engines reliability, maintenance and

lifetime.

After an introduction to current developments for powertrains, on-board and off-

board diagnosis systems and some failure statistics the book gives in Part I a brief

survey on advanced supervision, fault detection and diagnosis methods. Part II first

describes structures for combustion engine control and diagnosis. Then, model-based

diagnosis methods for gasoline and diesel engines are treated for the main compo-

nents, like the intake system, fuel supply, fuel injection, combustion process, tur-

bocharger, exhaust system and exhaust gas aftertreatment. In general, series produc-

tion sensors are used.

The fault diagnosis of electrical DC, AC and PMSM motors, electrical, pneu-

matic and hydraulic actuators is compiled in Part III. Theoretical as well as experi-

mental results from test benches are shown and many experimental studies display

the applicability and the diagnosis quality for implemented faults. In the last part IV

on fault-tolerant systems, fault-tolerant sensors and actuators are considered.

The book is dedicated to graduate students of mechanical, electrical and mecha-

tronic engineering and computer science and is especially focused for automotive

engineers in practice.

The author is grateful to his research associates, who have performed many the-

oretical and experimental research projects on the subjects of this book, among them

S. Leonhardt, C. Ludwig, M. Willimowski, F. Kimmich, A. Schwarte, E. Hartman-

shenn, M. Leykauf, S. Clever, C. Eck, A. Sidorow and P. Kessler.

Without their continuous work on new methods and building up and maintaining

the combustion-engine test bench, measurement and computer equipment many re-

sults of this book would not have been obtained. Great appreciation goes also to our

precision mechanics workshop guided by A. Stark.

We also would like to thank the research organization Forschungsgemeinschaft

Verbrennungskraftmaschinen (FVV), within the Arbeitsgemeinschaft industrieller

Forschungsvereinigungen (AiF) who supported many projects. Several results were

obtained in cooperation projects with industrial companies. Among them are Adam

Opel AG, GM Europe, and Volkswagen AG. We appreciate these cooperations

strongly as they contributed positively to our own research.

Finally, I would like to thank Kerstin Keller, Moritz Neeb, Lisa Hesse and es-

pecially Brigitte Hoppe for the laborious and precise text setting, Sandra Schutz for ¨

drawing many figures and Springer Verlag for the excellent cooperation.