Automotive Control Systems

Prof. N. J. Thakkar
Department of Mechatronics Engineering
 Automotive Control System
1. Introduction to Control System
Overview of control system
Types of control system
Basic components of control system
Control system terminology
2. Engine Control
Basic engine operation
Speed control, knock control, Fuel injection timing control, ignition
control
3. Transmission / Driveline Control
Transmission modeling
State space formulation of driveline model
Driveline control with LQG/LTR
Driveline control for gear shifting 2
 Automotive Control System
4. Vehicle Parameter and State Estimation
Observers
Kalman filters
Friction coefficient estimators
Body side slip angle estimators
Tire contact patch force estimators
5. Vehicle Dynamic Control
Yaw stability control
Anti-lock brake control
Traction control
6. Advanced Automotive Control Techniques
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Modelling of automotive control systems in MATLAB / SIULINK
Chapter 1 Introduction to Control Engineering
1. Introduction to Control System
2. Applications in Automotive Systems
3. Important Definitions
4. Classification of Control System
5. Components of Control System
6. Open loop and closed loop control system

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 Introduction to Control system
• Automatic Control has played a vital role in the advance of
Engineering and Science.
• It is more important in space-vehicle systems, missile guidance
system, robotic system, automobile industry, modern
manufacturing and industrial processes.
• For example,
 Control of machine tools in the manufacturing industries.
 Design of autopilot systems in the aerospace industries.
 Design of cars and trucks in the automobile industries.
 Speed Governors
• It is also essential in industrial operations such as controlling
pressure, temperature, humidity, viscosity and flow
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 Introduction to Control system
Example of Automatic Control System

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 Introduction to Control system
• An automatic control system is a pre-set closed loop control system that
requires no operator (human) action.

• An automatic control system has two process variable associated with it:
1. a controlled variable
2. a manipulated variable

• A controlled variable is the process variable that is maintained at a

specified value or within a specified range.

• In the previous example, the storage tank level is the controlled variable.

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 Introduction to Control system
• A manipulated variable is the process variable that is acted on by the
control system to maintain the controlled variable at the specified value
or within the specified range.

• For example, the flow rate of the water supplied to the tank is the
manipulated variable.

Functions of Automatic Control System:

• In any automatic control system, the four basic functions that occur are:
a. Measurement
b. Comparison
c. Computation
d. Correction
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 Introduction to Control system
Basic Definitions:

System
• A system is a combination or an arrangement of different physical
components which acts together as a entire unit to achieve certain
objective.

Plant
• The portion of a system which is to be controlled or regulated is called
as the plant.
• A plant may be a piece of equipment , perhaps just a set of machine
parts.
• The purpose is to perform a particular operation.
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 Introduction to Control system
Basic Definitions:

Process
• Any operation to be controlled is called a process
• Examples are chemical, economic and biological process

Controllers
• The elements of the system itself or external to the system which
controls the plant or the process is called the controllers
• For example ON/OFF switch to control bulb

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 Introduction to Control system
Basic Definitions:

Input
• It is an applied signal or n excitation signal applied to control system
from an external energy source in order to produce a specified output
• For each system, there must be excitation and system accepts it as an
input.

Output
• It is the particular signal of interest or the actual response obtained
from a control system when input is applied to it.
• For analyzing the behavior of the system for such input, it is necessary to
define the output of the system.
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 Introduction to Control system
Basic Definitions:

Disturbances
• Is a signal which trends to adversely affect the value of the output of a
system.
• Undesirable and unavoidable effects beyond our control generated from
outside the system or from the system.
• If such a disturbance generated within the system, called internal
disturbance.
• Presence of disturbance is one of the main reasons of using control.

Feedback signal
• A mechanism responsible for measuring output that is obtained from a
system for the purpose of delivering information to the controller so
that the compensation process can be implemented 12
 Introduction to Control system
Classification of Control Systems:

1. Natural control systems

• Universe
• Human Body

2. Manmade control systems

• Vehicles
• Aeroplanes

3. Manual control system

• Room temp. regulation via electric fan
• Water level control

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 Introduction to Control system
Classification of Control Systems:

4. Open-loop control system

• Washing machine
• Toaster

5. Closed-loop control system

• Refrigerator
• Driverless car

6. Linear Vs Nonlinear control system

• Output varies linearly with the input
• Output varies non-linearly with the input

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 Introduction to Control system
Classification of Control Systems:

7. Time invariant Vs Time variant

• The characteristics of the system do not depend upon time itself.
• One or more parameters varies with time.

8. Continuous data Vs Discrete data system

• All system variables are function of continuous time t.
• One or more variables that are known only at discrete time intervals.

9. Deterministic Vs Stochastic control system

• If the output is predictable or repeatable
• If the output is unpredictable

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 Introduction to Control system
Classification of Control Systems:

10. Automatic control system

• Room temp. controller via A.C
• Washing machine

11. SISO and MIMO control system

• Has only one input and one
output
• Have more than one input and
output

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17
 Introduction to Control system
Open-loop Control System:

• Any physical system which does not automatically correct for variation
in its output, is called an open-loop system.

• Here output is dependent on input but controlling action or input is

totally independent of the output or change in output of the system
i.e. output remains constant for a constant input signal
• In the presence of disturbance, the system will not perform the desired
task. 18
 Introduction to Control system
Open-loop Control System:

• Any control system that operates on a time basis is open-loop. For

example traffic signal lights

Advantages
• Simple in construction
• Convenient when output is difficult
to measure
• Simple in design hence economical

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 Introduction to Control system
Disadvantages
• Inaccurate and unreliable because the accuracy is totally dependent on
the accurate calibration
• Give inaccurate results if there are variations in external environment
• Recalibration of the controller is necessary

Examples of open-loop control systems

1. Vehicle speed control
2. Automatic washing machine
3. Bread toaster
4. Automatic tea/coffee maker
5. Traffic light controler

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 Introduction to Control system
Closed-loop Control System:

• A system that maintains a prescribed relationship between the output

and the reference input by comparing them and using difference as a
means of control is called closed-loop or feedback control system.

• The actuating error signal which is the difference between the input
signal and the feedback signal, is fed to the controller so as to reduce
the error and bring the output to a desired value. 21
 Introduction to Control system
Closed-loop Control System:

• The output is fed back to the reference input by feedback element and
the signal which is output of the feedback element is called feedback
signal, b(t).
• It is then compared with the reference input diving error signal e(t) =
r(t)±b(t).
• When feedback sign is positive, the system is called positive feedback
system otherwise called negative feedback system.
• The error signal is then modified by the controller and decides the
proportional manipulated signal for the process to be controlled.
• This manipulation is such that the error will approach zero. This signal
then actuate the system and produces an output called controlled
output c(t) 22
 Introduction to Control system
Closed-loop Control System:

Advantages
1. Accuracy is very high.
2. Senses environmental changes as well as internal disturbance and
accordingly modifies the error.
3. Operating frequency zone is very high.

Disdvantages
4. Systems are complicated and time consuming and hence costlier.
5. Less stable operation.
6. Complicate for maintenance.

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 Introduction to Control system
Closed-loop Control System:

Example of closed-loop system

1. Human Being

2. Home heating / cooling system

3. Manual speed control system
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 Introduction to Control system
Examples of Automotive Closed-loop Control Systems

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 Introduction to Control system
Closed-loop Control System:

Comparison of open-loop and closed-loop system

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Applications
• Example 1: Liquid Level Control System
• This system is aimed at controlling the levels of liquid that flows in a
tank. This is considered a closed-loop system whereby it is controlled
automatically. The controller within the system functions to control
the valve opening of the inflow of the fluid to ensure that the water
levels remain at the suitable level in order to avoid shortages and
overflow in case of excess of supply.

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The operation of the valve at input will always be activated according to
the errors from the difference between the set point and the reading from
the liquid level detection.
The controller will act to ensure the valve is closed if the reading sensor
shows that it is at the maximum level. On the other hand, the valve will be
opened if the sensor is unable to detect the existence of the fluid.

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 Example 2: Room Temperature Control System
• A physical diagram of a temperature control system that functions by
controlling the temperature in a room or space is shown.
• Based on the diagram shown, the controllable variable is the
temperature through the open-close valve which is the definitive
element that can be controlled to produce temperature that it
required by the heater.
• The thermometer functions continuously to measure the temperature
in the room and channel the information to the controller to ensure
the temperature is the same as the input system’s setting.
• If there is a difference between the two, the controller has to ensure
the resulting error can be rectified and hence send the signals to the
solenoid valve with the purpose of rearranging the gas flow into the
said space. 29
30
Example 3

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 Introduction to Control system
Requirements of an Ideal Control Systems

To achieve the required objective, a god control system must satisfy the
following requirement:

1. Accuracy
• A good control system must be highly accurate.
• The open loop systems are less accurate and hence feedback is
introduced to reduce the error in the system.

2. Sensitivity
• Should be very insensitive to environmental changes
• Must sensitive to the input command
• Should not be affected by small changes in the certain parametersof
the system 32
 Introduction to Control system
Requirements of an Ideal Control Systems
3. External disturbance or noise
• All physical systems are subjected to external disturbances and nose
signals.
• Should be able to reduce the effects of external disturbances.

4. Stability
• Output of the system must follow reference input
• Must produce bounded output for bounded input

5. Bandwidth
• Is related to the frequency response of the system.
• For the input frequency range, it should give satisfactory output.
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 Introduction to Control system
Requirements of an Ideal Control Systems
6. Speed
• Output should approach to its desired value as quickly as possible.
• Must produce bounded output for bounded input

7. Oscillations
• Should exhibits suitable damping i.e. the controlled output should
follow the changes in the referenced input without overshoots.

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 Introduction to Control system
Introduction to Controllers
• To sense the deviation of the output from the desired value and
correct it till the desired output is achieved.
• Deviation of the actual output from its desired value is called an error.
The measurement of the error is possible because of feedback.
• The actual output is compared with its desired value to generate the
error.
• The controller accepts the error in some for and decides the proper
corrective action.
• The controlled output is then applied to the process or plant and
brings the output back to its desired value.
• The controller is the heart of a control system. The accuracy of the
entire system depends on how sensitive is the controller to the error
detected and how it is manipulating such an error. 35
 Introduction to Control system
Classification of Controllers
Most industrial controllers may be classified according to their control
action as:
1. Two position or on-off controller
2. Proportional controller
3. Integral controller
4. Proportional-plus-integral controller
5. Proportional-plus-derivative controller
6. Proportional-plus-integral-plus-derivative controller
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 Introduction to Control system
Two Position or ON/OFF Controller
• The most elementary controller mode is the two position or ON_OFF
controller mode.
• It is the simplest and cheapest.
• The most general form can be given by:

P=0% ep < 0
P = 100 % ep > 0
• Exp. ON / OFF switch
• When the measured value is less than the set point (i.e. ep > 0), the
controller output will be full (i.e. 100 %).
• When the measured value is more than the set point (i.e. ep < 0), the
controller output will be zero (i.e. 0 %).
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 Introduction to Control system
Proportional Controller
• The output of the controller is simple proportional to the error e(t).
• The relation between the error e(t) and the controller output p is
determined by constant called proportional gain constant denoted as
Kp.
• The output of the controller is a linear function of the error e(t) i.e.
each value of the error has the unique value of the controller output.
• The range of the error which covers 0% to 100% controller output is
called the proportional band.
• The basic relationship between output of the controller and error
signal is given by,
p(t) = Kp e(t)
Taking Laplace transform, P(s) = Kp E(s)
where Kp = Proportional gain constant 38
 Introduction to Control system
Proportional Controller
• Though there exists linear relation between controller output and the
error, for a zero error the controller output should not be zero,
otherwise the process will come to halt.
• Hence there exists some controller output Po for the zero error. Hence
mathematically the proportional control mode is expressed as,
p(t) = Kp e(t) + Po Kp = Proportional gain constant
Po = Controller output with zero error

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 Introduction to Control system
IntegralController
• In the proportional mode, error reduces but can not go to zero. It
finally produces an offset error and it can not adapt with the changing
load conditions.
• To overcome these problems, another control mode is often used
which is based on history of errors and known as integral or reset
controller.
• The value of the controller output p(t) is changes at a rate which is
proportioned to the actuating error signal e(t).
• Mathematically it is expressed as,
= Ki . e(t)

Ki = integral constant
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 Introduction to Control system
IntegralController
• Taking Laplace transform,
sP(s) = Ki . E(s) or P(s) = (Ki/s) . E(s)

• Integrating the above equation, actual controller output at any time t

can be obtained as,

p(t) = Ki

Where P(0) = controller output when integral action starts

i.e. at t = 0

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 Introduction to Control system
Derivative Controller
• The controller produces a control action that is proportional to the rate
at which the error is changing de(t)/dt

• The mathematical equation for the mode is,

p(t) = Kd

Where Kd = derivative gain constant

• Taking Laplace transform

P(s) = Kd s E(s)
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 Introduction to Control system
Proportional + Integral Controller
• This is composite control mode obtained by combining the
proportional mode and integral mode.
• The mathematical expression is,

p(t) = Kpe(t)+KpKi

• Taking Laplace transform,

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 Introduction to Control system
Proportional + Derivative Controller
• Combination of proportional and derivative control mode.
• The mathematical expression is given by,

p(t) = Kpe(t)+KpKd+p(0)

• Taking Laplace transform,

P(s) = [Kp + KpKds]E(s)

• The derivative mode is never used alone because it is not capable of
maintaining a control signal under steady error conditions.
• Always used with the proportional mode and often additionally with
the integral mode.
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 Introduction to Control system
Proportional + Integral + Derivative Controller
• Combination of the proportional, integral and derivative control mode
is called PID control mode and the controller is called three mode
controller.
• It is very much complex to design but very powerful in action..
• The mathematical expression is given by,

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 Introduction to Control system
Proportional + Integral + Derivative Controller
• This mode has advantages of all the modes.
• The integral mode eliminates the offset error of the proportional mode
and the response is also very fast due to derivative mode.
• It can be used for any process condition.
• There is no offset, no oscillations with least settling time.
Proportional Arrests It arrests the changes of the Measured
Action (P) value but always with an Offset from
the Measured value
Integral Action Restores It removes the Offset
(I)
Derivative Accelerates It speeds up the removal of the offset
Action (D)
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 Introduction to Control system
Major Automobile Subsystems
• The functional systems of an automobile are shown in the figure and
are classified as:
Chassis or Body
• Support many other systems as well as
passengers and loads
• Supported by suspension, which connects it
to the axles and wheels
• The design affects vehicle dynamics, fuel
efficiency and passenger comfort
• The current trend is toward lighter body
structures
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 Introduction to Control system
Major Automobile Subsystems
Engine
• Provides the power for moving a vehicle as
well as operating various subsystems
• Mostly used are piston-type, spark-ignited,
liquid-cooled, IC engine and gasoline fuel
• Engine controls improve engine performance
in various ways
• Many new engine technologies like electric,
hybrid, fuel-cell have been developed

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 Introduction to Control system
Major Automobile Subsystems
Drive Strain and Powerstrain
• Consists of the engine, transmission,
driveshaft, differential and driven wheels
• The transmission is gear system that adjusts
the ratio of wheel speed to engine speed to
achieve near-optimum engine performance
• A driveshaft is used in front-engine, rear-
wheel drive systems to transmit the engine
power to the drive wheels
• The differential provides not only the right-
angle transfer of the driveshaft rotary motion to the wheels but also a
torque increase through the gear ratio, thereby allowing the driven
wheels to turn at different speed 49
 Introduction to Control system
Major Automobile Subsystems
Drive Strain and Powerstrain
• The wheels and pneumatic tires provide
traction between the vehicle and the road
surface
• Traction control systems have been
developed to provide good traction under a
variety of road-surface conditions

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 Introduction to Control system
Major Automobile Subsystems
Steering
• Allows a driver to change the orientation of a
vehicle’s front wheel to control the direction
of forward motion
• A rack and pinion steering system design is
typical in many modern automobiles
• Power-assisted steering is now commonplace
and four-wheel-steering (4WS) vehicles are
emerging

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 Introduction to Control system
Major Automobile Subsystems
Suspension
• To provide a smooth ride inside the
automobiles and maintain contact between
the wheels and the road surface
• Influence vehicle dynamics
• Active and semi-active suspensions, which
use electronic controls, are currently
available on some vehicles
Brakes
• For bringing a vehicle to stop
• Two common designs – drum and disk
• Antilock brakes which use electronics control to limit wheel slip are
now common on many commercial vehicles 52
 Introduction to Control system
Major Automobile Subsystems
Instrumentation
• A modern vehicle includes many electronic
sensors, actuators, and other
instrumentation
• Todays car can have above 70 sensors and
50 microprocessors that monitor and
control various aspects of the vehicle

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 Introduction to Control system
Automotive Control Systems
• Control functions are associated with the engine and transmission, cruise
control, traction control, and active suspension
• The control functions in an automobile can be grouped as follows:
1. Powertrain control
2. Vehicles control
3. Body control

1. Powertrain Control:
• Consists of engine and transmission control systems
• The engine control systems may include fuel-injection control, carburetor
control, ignition or spark-timing control, idle-speed control, antiknock
control and exhaust-gas recirculation (EGR) control
• To ensure that an engine operates at near-optimal conditions at all times
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 Introduction to Control system
Automotive Control Systems
1. Powertrain Control:
• Transmission control systems determine the optimal shift point for the
torque converter and the lockup operation point based on throttle-angle
and vehicle-speed measurements
• Often a single electronic control unit (ECU) handles both engine and
transmission control functions

2. Vehicle Control Systems:

• Include suspension control, steering control, cruise control, braking control
and traction control
• These systems improve various vehicle functions including response,
steering stability, ride and handling
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 Introduction to Control system
Automotive Control Systems
3. Body Control:
• Refers to automatic air conditioning, electronic meters, multi-instrument
display, energy control systems, security systems, communication systems,
door-lock systems, power window and rear obstacle detection
• The intension is to increase driving comfort and convenience and to
improve the value of the automobile

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 Introduction to Control system
Automotive Control Systems

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 Introduction to Control system
Automotive Control Systems
• The systems include the controlled variable, the manipulated variable, the
control logic, the measured variables and the actuator used to generate
the control output
• These vehicle control systems can be compared to the “generic” control-
systems block diagram as shown in fig.

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 Introduction to Control system
Automotive Control Systems
• A typical feedback-control system consists of four basic elements: (1)
controller, (2)actuator, (3) controlled system and (4) sensor
• The controller receives a reference (or set-point) input which define the
desired value of the controlled variable and a feedback signal from the
sensor, which is a measurement of the controlled variable
• The controller then applies a particular control logic to compute a control
signal
• The control signal sent to the actuator, which converts information-type
input signal to the power-type input to the controlled system
• The controlled system responds to the actuator as well as any other
uncontrolled inputs (i.e. disturbances) that can act on it.
• The sensor provides a measurement of the controlled variable for the
purpose of feedback to the controller 59
 Introduction to Control system
Automotive Control Systems
• The above said control system is a simple feedback loop with a single
input/single output (SISO) system which control only one variable
• But in reality, many automotive control systems consist of several such
loops that interact in a complex manner
• For example, en electronic engine-control system includes many controlled
variables, actuators and sensors means they are MIMO control systems

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 Introduction to Control system
Air-Fuel Ratio Control
• The air-fuel ratio is the (AFR) is the mass ratio between the amount of air
and fuel that are mixed together in the combustion chamber of a vehicle
• This ratio needs to correct for the fuel to burn correctly and efficiently
• If the ration is too rich or too lean, the engine will not optimally burn the
air-fuel mixture which can cause performance issue
• The ideal AFR that burns all fuels without excess air is 14.7:1 and is referred
as “stoichiometric” mixture in which you have 14.7 parts of air for every 1
parts of fuel
• But at some condition, not all fuel can be mixed and vaporized with air
• Different type of AFRs are:
1. Rich AFR – There is less air (13:1) than the ideal AFR. This can be good for power but bad for
fuel
economy and emissions
2. Lean AFR – There is more air (16:1) than the ideal AFR. This is can be good for fuel economy
but 61
bad for power
 Introduction to Control system
Air-Fuel Ratio Control
• The AFR can affect the internal combustion process and the best AFRs are
for various conditions:
1. Starting – When starting your car, all engine components such as the
cylinder head, cylinder blocks, and intake manifold are cold. Some
extra fuel is needed to start the engine so a rich fuel mixture (9:1) is
temporarily needed
2. Warming Up (idling) - After starting and the engine is still idling, the
coolant temperature is still low and more fuel than normal is still
needed until the vehicle warms up to operating temperatures so in
case, a rich AFR of about 12:1 is necessary
3. Accelerating – When the accelerator pedal is pressed to gain speed,
more air comes into cylinder to meet the extra power requirement
so naturally more fuel is needed. At full throttle, the AFR can be
around 11:1 while moderate acceleration it can be 13:1 62
 Introduction to Control system
Air-Fuel Ratio Control
4. Cruising (Constant speed) – In this condition, the engine is already
warmed up the AFR is near the stoichiometric ratio which is about
14.7:1 and this allows for the best combination of the fuel economy,
emissions and power
5. Heavy Loads – Under heavy loads such as going uphill or if you are
towing any other vehicle then the engine requires more power. This
means a rich AFR similar to accelerating is needed for the excess
demands when under heavy load. The AFR will be around 12:1
6. Decelerating – Under this condition, the accelerator pedal is released
which means no power output is needed from the engine other than
to keep it running. An AFR of about 17:1 (lean) will exist at this point
as the fuel demands are very low at this point
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 Introduction to Control system
Air-Fuel Ratio Control
Here are some common signs for AFR is either too
rich or too lean:

AFR is too rich

• Engine can produce black smoke blowing out the
exhaust
• High fuel consumption
• Strong smell or unburned fuel

AFR is too lean

• Engine will be jerking
• Poor acceleration
• Rough idling; the car will vibrate
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 Introduction to Control system
Air-Fuel Ratio Control
• The air-fuel equivalence ratio (λ) is the ratio of actual AFR to stoichiometric
for a given mixture. λ = 1.0 at stoichiometric, rich mixtures λ < 1.0 and for
lean mixtures λ > 1.0
• The AFR is the controlled variable and it is controlled by fuel injection at
each cylinder
• A mass airflow sensor is used and the fuel injector is the actuator
• An optimal control is used to maintain the air-fuel mixture at stoichiometry
(i.e AFR = 14.7); this reference is selected because in conjunction with a
catalytic convertor, it provides near-optimal performance in an engine
• Thus accurate air-fuel ratio control is important from the perspective of
reducing emissions as well as other performance measures
• An EGO sensor can be used for air-fuel ratio control
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 Introduction to Control system
Air-Fuel Ratio Control
• Air-fuel ratio control sometimes is referred to as lambda control because
the ratio is defined as follows:

λ = ma/mf
where λ is the normalized air-fuel ratio , ma is the mass airflow into the
engine, mf is the metered-fuel mass flow rate and λst is the air-fuel mass
ratio for a stoichiometric mixture (i.e. air-fuel mass ratio is equal to 14.64)
• The driver regulates the amount of air , ma ,
entering the cylinders, and the correct
quantity of fuel, mf, must be added by
the controller
• Undesirable emission gases (e.g. NO, HC and
CO) are produced by the combustion process
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 Introduction to Control system
Air-Fuel Ratio Control
• A catalytic converter reduces the emissions but operates efficiently only if
the value of λis near 1
• For efficient operation of the converter, the
average lambda offset must be maintained
within 0.1 percent

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