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IEEE TRANSACTIONS ON CONTROL SYSTEMS TECHNOLOGY, VOL. 23, NO.

3, MAY 2015 1063

Automated Engine Calibration of Hybrid


Electric Vehicles
Nikolce Murgovski, Markus Grahn, Lars Mårdh Johannesson, Member, IEEE, and Tomas McKelvey

Abstract— We present a method for automated engine power between the ICE and EMs. The problem can be
calibration, by optimizing engine management settings and approached in different ways, but besides heuristic and
power-split control of a hybrid electric vehicle (HEV). The rule-based approaches [6]–[10], the dominating approaches
problem, which concerns minimization of fuel consumption under
a NO x constraint, is formulated as an optimal control problem. contain an optimal control formulation, based on, e.g.,
By applying Pontryagin’s maximum principle, this paper shows dynamic programming (DP), or Pontryagin’s maximum
that the problem is separable in space. In the case where the limits principle [1], [7], [11]–[13]. The problem formulations often
of battery state of charge are not activated, we show that the opti- consider idealized conditions, assuming an exact knowledge
mization problem is also separable in time. The optimal solution of the driving mission. The idealized solutions could then
is obtained by iteratively solving the power-split control problem
using dynamic programming or the equivalent consumption be used as a benchmark for HEV powertrain design, or as
minimization strategy. In addition, we present a computationally a starting point for development of power-split strategies for
efficient suboptimal solution, which aims at reducing the number real-time control. The equivalent consumption minimization
of power-split optimizations required. An example is provided strategy (ECMS) is a well-known real-time control strategy
concerning optimization of engine management settings and that can be regarded as an approximation of an optimal control
power-split control of a parallel HEV.
formulation [2].
Index Terms— Engine calibration, engine management system, Besides energy efficiency, additional performance criteria in
hybrid electric vehicle (HEV), optimal control. vehicles are the levels of harmful emissions, such as nitrogen
I. I NTRODUCTION oxides (NOx ), soot, carbon monoxide, and hydrocarbons,
which are combustion byproducts formed in ICEs. An effective

E LECTRIFICATION of vehicles is a promising


technology that has the potential to improve energy
efficiency of vehicles and thereby reduce carbon dioxide
solution that reduces toxic emissions in gasoline engines is
a three-way catalyst (TWC). The TWC, however, cannot be
used for a diesel ICE. Instead, diesel vehicles are equipped
emissions. An example of electrified vehicles is hybrid electric with oxidation catalyst and particulate filter, which effectively
vehicles (HEVs). HEVs possess most of the features of remove soot, hydrocarbons, and carbon monoxide [14]. Unless
conventional vehicles, but besides the internal combustion additionally equipped with a lean NOx trap or a selective
engine (ICE), they also include an energy buffer, typically a catalytic reduction, diesel vehicles cannot reduce the engine-
battery, and one or more electric machines (EMs). This gives out NOx emissions. Instead, the approach is to operate the
them an additional degree of freedom in choosing engine engine such that NOx emissions are low already when leaving
operating points, which allows more efficient operation [1]. the engine. During combustion, there is a well-known trade-
The energy efficiency of HEVs depends on several fac- off between fuel consumption and NOx emissions; control
tors, from which the most studied are optimal power-split measures that decrease NOx emissions typically increase fuel
control (see [1], [2], and references therein), and optimal consumption and vice versa [15].
dimensioning of powertrain components (see [3]–[5] and Methods that minimize fuel consumption in an HEV while
references therein). The power-split control is a dynamic limiting, or penalizing NOx emissions, have been developed
optimization problem that governs arbitration of demanded and described in [7], [16], and [17]. However, these studies
Manuscript received January 22, 2014; revised May 19, 2014; accepted do not consider the dependence on optimal performance of
September 20, 2014. Date of publication October 15, 2014; date of current engine management system settings, concerning boost pres-
version April 14, 2015. Manuscript received in final form on sure, exhaust gas recirculation rate, fuel rail pressure, multiple
September 24, 2014. This work was supported by the Swedish Energy
Agency. Recommended by Associate Editor U. Christen. injections with controllable timings and durations, and so on.
N. Murgovski and T. McKelvey are with the Department of Signals and Instead, when optimizing power-split control of HEVs, the
Systems, Chalmers University of Technology, Gothenburg 412 58, Sweden ICEs management system is typically set (calibrated) for a
(e-mail: nikolce.murgovski@gmail.com; tomas.mckelvey@chalmers.se).
M. Grahn is with the Department of Signals and Systems, Chalmers Uni- conventional vehicle.
versity of Technology, Gothenburg 412 58, Sweden, and also with Volvo Car A common approach when calibrating engine management
Corporation, Gothenburg 418 78, Sweden (e-mail: markus.grahn@ settings is to first approximate a given driving cycle to steady-
gmail.com).
L. M. Johannesson is with the Department of Signals and Systems, Chalmers state engine operating points. Then, the ICE calibration at
University of Technology, Gothenburg 412 58, Sweden, and also with Viktoria these points is either based on solving the Lagrangian pri-
Swedish ICT, Gothenburg 417 56, Sweden (e-mail: larsjo@chalmers.se). mal [18], or dual problem [19], [20]. In the latter problem,
Color versions of one or more of the figures in this paper are available
online at http://ieeexplore.ieee.org. the objective function is essentially a sum of fuel consumption
Digital Object Identifier 10.1109/TCST.2014.2360920 and weighted emissions, using a constant weighting factor
1063-6536 © 2014 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.

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1064 IEEE TRANSACTIONS ON CONTROL SYSTEMS TECHNOLOGY, VOL. 23, NO. 3, MAY 2015

(the Lagrange multiplier). Early work with the latter approach system, the fuel injection system, and the after-treatment
can be found in applications of conventional vehicles, for both system. These systems have many degrees of freedom, and
gasoline ICE [18], [19] and diesel ICE [20]. Most recent work many settings that can be calibrated. A sophisticated global
with this approach has been performed in [21] and [22], within optimization procedure that accounts for all systems’ settings
the scope of conventional vehicles. is, in practice, not (yet) possible [29], [30]. Instead, some
The ICE operation in conventional vehicles and HEVs is systems’ settings are calibrated manually at an early design
different, and the optimal ICE settings in a conventional stage, and possibly in conjunction with the hardware design,
vehicle are most likely not optimal for the same engine in an such as design of pistons, cylinder head, and physical location
HEV (e.g., in an HEV, ICE operation at low speed and torque of injectors. The early stage calibration is based on limited
is generally avoided [1]). Moreover, an HEV may include input data, typically the operating range of engine speed and
a downsized engine that has been calibrated for a smaller load. Examples of settings calibrated at the early stage are
size conventional vehicle, or an engine that is specifically the number of injection pulses for combustion events, indi-
designed for an HEV. Therefore, the ICE calibration in an vidual dwell time between different injection pulses, fuel rail
HEV should be performed with respect to the optimal engine pressure, and relative injection amounts in different injection
operating points that are obtained by the energy management pulses.
(power-split) controller. In turn, the optimal power-split control Next, the remaining systems’ settings are calibrated
depends on how the ICE is calibrated. These two tasks are with respect to a complete driving cycle. Three settings,
strongly coupled and the optimization should reflect on that. z = [z 1 z 2 z 3 ]T , are typically considered, which have a large
Surprisingly, there are only few published papers on this impact on fuel consumption and emissions. These settings
topic. The published strategies rely on the possibility of are the injection timing z 1 , duty cycle to the exhaust gas
splitting the optimization problem in two parts, one for the recirculation valve z 2 , and duty cycle to the variable geometry
calibration and one for the power-split control. The ICE turbine z 3 .
calibration is performed similarly as mentioned above for
conventional vehicles, while the power-split control is based
either on suboptimal methods [23], or on DP [24], [25]. A. Calibration Under Steady-State Operation
In this paper, we revisit the problem of combined ICE The calibration procedure of z involves two steps at which
calibration and HEV power-split control, and we formulate the optimal set points for z are obtained. First, an engine model is
problem as a constrained, dynamic optimal control problem, generated in a form of 5-D static maps for fuel consumption
where states are NOx mass and battery state of charge (SoC). and emissions. The process involves operating the engine in
This allows the problem to be studied using optimal control a test cell, for discrete grid values of engine speed, torque,
theory [26], where problem separability in space (optimization and z, within the entire operating range of the engine. Fuel
variables) is derived directly from Pontryagin’s maximum consumption and emissions are measured under stationary
principle [27]. We show that for a special case, where battery conditions.
SoC limits are not activated, the optimization problem is also Second, the optimal set points for z are obtained by
separable in time and can be solved efficiently. The optimal minimizing fuel consumption, while fulfilling constraints on
solution is obtained by iteratively solving the power-split con- accumulated emissions. The optimization is performed over
trol problem using DP [28] and the ECMS [2]. We present also a set of representative engine speed/torque operating points,
a computationally efficient suboptimal solution, which aims which are obtained by simulating the vehicle model on a
at reducing the number of power-split optimizations required. certain driving cycle. Note that, although these speed/torque
An example is provided concerning optimization of engine points may not excite the entire operating range of the engine,
management settings and power-split control of a parallel they can still be used to optimize the complete working range
HEV. The computationally efficient solution for the studied of the engine. This is a direct result of the optimal calibration
example managed to achieve the global optimum in <4 min. procedure, which considers a scalar coefficient weighting the
This paper is outlined as follows. Section II provides flow of fuel and emissions for the entire operating range
background on engine calibration in conventional vehicles, of the engine [18]–[20]. Obtaining the optimal weighting
state of the art in engine calibration, and delimitations of coefficient is an iterative procedure, where simulation of the
this paper. The problem formulation and modeling details are vehicle model and optimization of the set points for z is
described in Section III. The optimization method is presented repeated several times. The method will be detailed later, in
in Section IV. Computationally efficient optimization methods Section IV-B, for the case of an HEV. Note that, since the
are provided in Section V. An example of ICE calibration procedure is iterative, the representative operating points are
and power-split control of an HEV is given in Section VI. obtained by simulating a vehicle model, rather than operating
This paper is ended with a discussion and the conclusion in the real vehicle.
Sections VII and VIII, respectively. The resulting engine calibration is optimal only for the
set of speed/torque points that are chosen as representative.
II. E NGINE C ALIBRATION P ROCEDURES FOR How these points are chosen depends mainly on the standard
C ONVENTIONAL V EHICLES procedure for determining the legislative limits for emis-
Common controllable systems that affect fuel consumption sions. In Europe, the new European driving cycle (NEDC) is
and emissions of a modern passenger car are the gas exchange designed to assess emission levels of passenger vehicles [31].

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MURGOVSKI et al.: AUTOMATED ENGINE CALIBRATION OF HEVs 1065

Fig. 2. HEV with a parallel powertrain configuration. The ICE propels the
front wheels, while the EM is mounted on the rear axle.

transient engine operation. The state of the art optimization of


steady-state engine operation is as described in Section II-A.
Fig. 1. Optimization framework for steady-state engine calibration, including The state of the art research on optimization of tran-
compensations for transients. The steady-state calibration is repeated several sient engine operation has been mainly focused on reducing
times, after adjusting (typically manually) the emission limits and the transient
compensation model. emission spikes for a subset of engine transient scenarios,
rather than optimizing fuel consumption on a complete driving
The set of representative points depends also on the pow- cycle [36]–[41]. Several studies have included optimization
ertrain and engine model. The powertrain model translates over a complete driving cycle, considering both steady-
the speed/torque points of the driving cycle from the wheels state and transient engine operation [32], [33], [42], [43].
to the engine. It is relevant that these models approximate The approach in [42] and [43] proposes neural network
reasonably well the net fuel consumption and emissions of the for modeling transient engine behavior, while the approach
real vehicle. The modeling accuracy becomes more important in [32] and [33] is complementing transient compensations,
as the new driving cycle, the World-Harmonized Light-Duty rather than replacing them with an accurate dynamic engine
Vehicle Test Cycle, is being developed. This cycle is likely model. Optimal engine calibration based on a complete
to include a larger portion of engine transient operation, dynamic engine model is yet to be developed.
compared with the NEDC [31]. The study presented in this paper focuses solely on engine
calibration based on a static engine model. The transient
B. Compensations for Transients compensation procedure, which is well established in the
When calibrating the engine based on a static engine literature, is not further discussed in the rest of this paper.
model, the transition between two successive operating points
is assumed immediate. However, dynamics in the engine III. P OWERTRAIN M ODEL AND P ROBLEM F ORMULATION
necessitate a transient engine operation, which leads to higher Depending on the ICE and EM arrangement, HEV pow-
fuel consumption and emissions than fuel consumption and ertrains are commonly divided into series, parallel, and
emissions from the static engine model. To account for the series–parallel configurations [1]. The powertrain studied here
differences, compensations are used that limit emissions dur- is a through-the-road parallel powertrain, in which both the
ing transients [32]–[35]. The compensations involve manual ICE and EM are mechanically connected to the wheels. The
adjustments of the optimal engine set points, typically the powertrain is constructed by augmenting a front-wheel driven
oxygen fraction in the intake manifold and the injection timing. conventional vehicle with a battery and an EM mounted on
In addition, when calibrating the static engine model, the the rear axle, as shown in Fig. 2. The EM can operate in both
emissions’ limits are lowered, such that the real vehicle does motoring and generating mode. This allows recuperation of
not exceed the legislative limits for emissions. braking energy, which in the case of a conventional vehicle is
After the transient compensations are performed, the static lost as heat.
engine model is recalibrated. The whole process is iterated
several times with different limits on accumulated emissions, A. Powertrain Model
until the real vehicle achieves satisfactory fuel consumption
The vehicle is required to fulfill a certain driving mission
and emission levels. The engine calibration process, including
fully described by road altitude, desired vehicle velocity, and
transient compensation, is shown in Fig. 1.
acceleration at each point in time. In the view of the vehicle
powertrain, this can be translated to angular velocity ω and
C. State of the Art in Engine Calibration and torque T demanded at the wheels, for each time instant of the
Delimitations of This Paper driving mission (see Appendix). When delivering the inputs
The research in engine management system optimization is ω and T , we adopt a commonly used backward simulation,
divided into optimization of steady-state engine operation and quasi-static powertrain model [1], which does not necessitate

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1066 IEEE TRANSACTIONS ON CONTROL SYSTEMS TECHNOLOGY, VOL. 23, NO. 3, MAY 2015

Similarly, the EMs dissipative power PMd , includ-


ing the inverter and rear differential losses, is obtained
from speed/torque measurements under stationary conditions.
An example of a static EM model is given in Fig. 3.
To keep the problem simple, it is assumed that no additional
losses are associated with arbitration of the engine ON / OFF
state, gear selection, and clutch engagement. Therefore, when
the engine does not deliver torque, it is turned OFF and
declutched from the wheels. This does not affect the generality
of the solution proposed in Section IV, as the method allows
Fig. 3. Static maps of an ICE, left, and an EM, right. The ICE map shows inclusion of dynamic engine ON / OFF, transmission, and clutch
efficiency for fixed values for injection timing, duty cycle to the exhaust
gas recirculation valve, and duty cycle to the variable geometry turbine.
models. This is further discussed in Section VII-B.
The EM efficiency map also includes the losses from the inverter and rear
differential gear.
B. Problem Formulation
a driver model. In this model, the vehicle follows exactly The optimization objective is formulated to minimize fuel
the reference trajectories, ω and T, yielding the following consumption, by limiting NOx emissions under a certain level
equations:  tf
T = TE r (g)η(g) + TM (1) f NOx (ω E , TE , z)dt ≤ m NOx max (7)
0
PB = TM ω + PMd (TM , ω) (2)
throughout the entire driving mission with duration t f . Then,
ω E = r (g)ω. (3) the optimization problem can be formulated as follows:
The notation above reads as follows: TE and TM are torques  tf
of the ICE and EM, ω E is rotational speed of the ICE, r and η min f f (ω E , TE , z)dt (8a)
g,TE ,z 0
are gear ratio and efficiency of gear g, and PB is power at the
s.t. T = TE r (g)η(g) + TM (8b)
battery terminals. The efficiencies of all gears, including the
two differential gears, are modeled as constant. The efficiency PB = TM ω + PMd (TM , ω) (8c)
and gear ratio of the front differential gear are denoted ω E = r (g)ω (8d)
with η and r , while the losses of the rear differential gear ṁ NOx = f NOx (ω E , TE , z) (8e)
and power inverter are reflected within the EM losses PMd .
m NOx ∈ [0, m NOx max ] (8f)
The dominating inertia of the vehicle is the inertia of the
vehicle itself (chassis, driving axels, wheels, etc.), and we have z ∈ Z(ω E , TE ) (8g)
therefore neglected the rotational inertia of the ICE and EM. ṡ = f s (PB , s) (8h)
Auxiliary load is not considered. s(0) = s(t f ) = s0 (8i)
The battery is modeled as a series connection of a voltage
s ∈ [smin , smax ] (8j)
source u(s) and a resistance R(s), which, in a general case, are
both a function of SoC. Then, the SoC derivative is given as TM ∈ [TMmin (ω), TMmax (ω)] (8k)
i TE ∈ [0, TEmax (ω E )] (8l)
ṡ = − = fs (PB , s) (4)
QB ω E ∈ [ωEidle , ω Emax ] (8m)
with PB ∈ [PBmin , PBmax ] (8n)

u(s) −u 2 (s) − 4R(s)PB g ∈ {0, 1, ..., gmax }. (8o)
f s (PB , s) = − . (5)
2Q B R(s) The NOx constraint (7) has been replaced by equivalent con-
In the equations above, s and Q B denote battery SoC and straints (8e) and (8f). There are five time-dependent variables,
capacity, respectively. Equation (5) is obtained by deriving the g, TE , and z = [z 1 z 2 z 3 ]T , and two states, m NOx and s.
battery current i from The vectors TM , PB , and ω E are removed from the control
signals in (8). These vectors can be directly expressed by
PB = u(s)i − R(s)i 2 . (6)
TE , g, and the reference signals T and ω, by simply back
The ICE is modeled by two static functions, f f (ω E , TE , z) substituting the equalities (8b)–(8d). The constraint (8i) is
and f NOx (ω E , TE , z), describing fuel consumption and NOx introduced to conserve battery energy at the beginning and
emissions in g/s, respectively. The inputs z = [z 1 z 2 z 3 ]T , end of the driving cycle. The set Z(ω E , TE ) in (8g) is a
are control variables denoting injection timing z 1 , duty cycle feasible set for z, expressed as a function of engine speed and
to the exhaust gas recirculation valve z 2 , and duty cycle to torque. The remaining constraints are boxing constraints on the
the variable geometry turbine z 3 (see [15] for background optimization variables, where the EM and ICE torque limits,
on ICEs). An example of the ICEs efficiency map for fixed (8k) and (8l), are functions of speed. All variables have real
values of z is given in Fig. 3. The maps’ generation is further values, except the gear number g, which accepts nonnegative
discussed in Section VII-A. integer values. The constraints are imposed for ∀t ∈ [0, t f ].

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MURGOVSKI et al.: AUTOMATED ENGINE CALIBRATION OF HEVs 1067

IV. O PTIMIZATION M ETHOD


A straightforward way to solve (8) is by directly using
DP. However, a serious limitation of DP is that the computa-
tional time increases exponentially with the number of state
variables [28]. Recall that the optimization problem (8) has
two real-valued states. Solving this problem with a standard
DP implementation will require high computational demands.
To shorten computational time, we propose here an alternative
solution based on Pontryagin’s maximum principle, which will
eliminate at least one state from the problem.
Fig. 4. Illustration of the map f z∗ (ω E , TE ) holding the optimal engine
calibration points for grid values of engine speed and torque.
A. Problem Separability in Space
The Hamiltonian of the optimization problem (also known
as Pontryagin’s H function), reads as follows: This allows the problem (11) to be formulated as a bilevel
program
H(·) = f f (ω E , TE , z) + λs f s (PB , s)
min f f (ω E , TE , z ∗ ) + λs f s (PB , s) + λ∗NOx f NOx (ω E , TE , z ∗ )
+ λNOx f NOx (ω E , TE , z). (9) g,TE

Here, λs and λNOx are costates of the system, for which it s.t. (8b)–(8d), (8h)–(8o), (11b) (12a)

holds z = arg min f f (ω∗E , TE∗ , z) + λ∗NOx f NOx (ω∗E , TE∗ , z)
 ∗  ∗ z
λ̇∗s = − ∂ H(·)
∂s
∂ H(·)
, λ̇∗NOx = − ∂m NO
=0 (10) s.t. z ∈ Z(ω∗E , TE∗ ) (12b)
x

at any optimal solution (marked by ∗ ). This is a necessary that can be separated into two tasks, by obtaining z ∗ for
condition at any local/global optimum [26], where the above any feasible combination of ω E and TE . The upper-level task
mentioned derivatives are defined. Hence, the solution of (8) optimizes the HEV power-split control, while the lower-level
can also be obtained by minimizing the Hamiltonian task optimizes the ICE calibration.
min H(·) (11a)
g,TE ,z
s.t. (8b)–(8o) B. Optimal ICE Calibration
∂H(·) The lower-level task in (12), i.e., the engine calibration
λ̇s = − (11b)
∂s problem, can be solved independently of the upper-level task,
λ̇NOx = 0. (11c) by optimizing z for any feasible combination of values of the
optimization variables in the upper-level task. Furthermore,
The necessary condition (10) reveals that along sections since the engine calibration does not explicitly depend on gear
of the driving mission, where the derivative ∂H(·)/∂m NOx is number, and the gear number is directly related to engine
defined, λ∗NOx is, in fact, a constant value, because H(·) does speed via (3), z can be optimized for feasible combinations
not explicitly depend on m NOx . It is clear that the derivative is of ω E and TE . Then, the engine calibration problem can be
not defined when the constraint (8f) is active. Since m NOx is approached by gridding the feasible sets for z, ω E , and TE ,
monotonically increasing (in time), the constraint (8f) might be and solving
active only at two time segments, one starting at the beginning
of the driving mission, and one ending at the end of the f z∗ (ω E , TE ) = arg min f f (ω E , TE , z)
driving mission. Hence, if there is at least one time instant z
in the remaining time interval (where m NOx does not lie on + λ∗NOx f NOx (ω E , TE , z) (13a)
the bounds), it is possible to obtain a single constant value
for λ∗NOx . (The trivial case where the HEV is operated as a s.t. z ∈ Zd (ω E , TE ) (13b)
pure electric vehicle along the entire mission is not of interest ω E ∈ W E ⊆ [ωEidle , ω Emax ] ⊆ R n
(13c)
in this paper and has been neglected.) Then, obtaining the
optimal value for λNOx is a straightforward procedure, which TE ∈ T E (ω E ) ⊆ Rm (13d)
will be detailed later, in Section IV-D.
where the sets Zd , W E , and T E are discrete. Here,
Now consider the case where the optimal costate λ∗NOx is
f z∗ (ω E , TE ) ∈ Rn×m×3 is a 3-D map, shown in Fig. 4, holding
given. (Naturally, we also consider a feasible optimization
the optimal set points of z for all speed/torque combinations.
problem.) The consequence is that the NOx limit (8f) can
As a consequence, the 5-D fuel and NOx maps can be replaced
be removed from the problem, as the optimal costate must
with the 2-D maps
satisfy this constraint. Without the NOx limits, the NOx
state constraint (8e) is also not needed and can be removed f˜f (ω E , TE ) = f f (ω E , TE , f z∗ (ω E , TE )) (14)
from the problem. Then, the variables z in (11) are present
only in the objective function (9) and in the constraint (8g). f˜NOx (ω E , TE ) = f NOx (ω E , TE , f z∗ (ω E , TE )) (15)

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1068 IEEE TRANSACTIONS ON CONTROL SYSTEMS TECHNOLOGY, VOL. 23, NO. 3, MAY 2015

which are calibrated with the optimal set points for z. The
map (14) is used in the power-split optimization problem, to be
explained in Section IV-C, for obtaining the optimal engine
speed and torque trajectories ω∗E and TE∗ . The optimal engine
settings are here obtained as a function of engine speed and
torque, but, if needed, they can also be obtained as explicit
functions of time, z ∗ = f z∗ (ω∗E , TE∗ ), as originally stated in (8).
For speed/torque points that are not in the discrete sets W E
and T E , z ∗ can be obtained by interpolation in f z∗ .
The maps f˜f (ω E , TE ) and f˜NOx (ω E , TE ) are calibrated
optimally, only when the optimal costate λ∗NOx is given. For
any different value λNOx , the problem (13) will generate
suboptimal maps. The optimization framework for obtaining
λ∗NOx is described in Section IV-D.

C. Optimal Power-Split Control


After the engine is calibrated, the power-split control prob-
lem is solved by minimizing the Hamiltonian (11), or the
primal problem (8), without considering constraints associated Fig. 5. Optimization framework for ICE calibration in an HEV. The ICE cal-
ibration is an iterative procedure, where iterations are needed for obtaining
to z. A problem formulation based on (8) can be written as the optimal costate that weights the tradeoff between fuel consumption and
 tf emissions.
min f˜f (ω E , TE )dt
g,TE 0 several values of λNOx , until the optimal λ∗NOx is attained.
s.t. (8b)–(8d), (8h)–(8o). (16) The set of steps to be performed is shown in Fig. 5 and
line up as follows: for an initial guess of λNOx , the ICE is
Bellman’s principle of optimality can be applied for solving
calibrated by solving (13) and the 2-D maps f˜NOx (ω E , TE )
the problem via backward recursion, in a standard DP for-
∗ (s(t ), t ) the cost matrix and f˜f (ω E , TE ) are obtained. The latter map is used in the DP
mulation [28]. Denoting with JDP k k
problem (17), to obtain the optimal engine speed and torque
holding the optimal cost to go from state s(tk ) at time tk to
trajectories. Then, using the optimal trajectories, the NOx
the desired final state at time t f , the optimization problem, at
emission and fuel consumption are computed. This procedure
a time instance tk , can be formulated as
is repeated for several values of λNOx , and the solution is kept

J D∗ P (s(tk ), tk ) = min f˜f (ω E (tk ), TE (tk ))t that gives the lowest fuel consumption that does not violate the
g(tk ),TE (tk ) NOx limit (8f).


+ JDP (s(tk+1 ), tk+1 ) There are several ways to obtain λ∗NOx . A straightforward
s.t. (8b)–(8d), (8k), (8m)–(8o) at tk way is to grid the set of costate values and evaluate the
s(tk+1 ) − s(tk ) = f s (PB (tk ), s(tk ))t algorithm for each discrete value. The costate is nonnegative,
while an approximate upper bound can be found by mini-
s(tk ) ∈ S ⊆ [smin , smax ] mizing NOx emissions for any feasible z, or by engineering
TE (tk ) ∈ T E (ω E (tk )) intuition. A more efficient way to obtain the optimal costate
tk ∈ T ⊆ [0, t f ]. (17) is to use the contradictive nature of the two objectives; that
is, higher penalty for NOx emissions leads to increased fuel
Discrete values are used for time, battery SoC and ICE consumption. Therefore, a monotonic dependence of fuel con-
torque, and the SoC derivative is replaced with a difference. sumption on λNOx can be expected; this has also been observed
The grid resolution of the discrete sets, T , S, and T E , is in the example in Section VI. The monotonic behavior can be
a tradeoff between computational time and accuracy. The exploited to efficiently obtain λ∗NOx by a root finding algorithm,
sampling interval is denoted by t. e.g., bisection.
The cost at the final time is a penalty for violating the
battery charge sustaining constraint. A typical choice, used V. C OMPUTATIONALLY E FFICIENT S OLUTIONS
later in Section VI, is a linear penalty function
A heavy computational burden in the engine calibration

JDP (s(t f ), t f ) = L · |s(t f ) − s0 | (18) framework is the iterative solutions of the DP problem (17).
In this section, we propose solutions that require fewer power-
where L is a large positive number. split optimizations, or replace the power-split control with a
time efficient alternative.
D. Optimization Framework
Finally, we present an algorithm for obtaining the optimal A. Reversed Bilevel Program
solution of (8). The procedure is based on iteratively calibrat- Consider the bilevel program (12), where the lower-level
ing the ICE and solving the power-split control problem for task is moved to the upper level, and the upper-level task is

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MURGOVSKI et al.: AUTOMATED ENGINE CALIBRATION OF HEVs 1069

B. Problem Separability in Time


The power-split control problem has been widely stud-
ied in the literature, both for assessment of performance
and for real-time model predictive control of HEVs. In this
section, a computationally efficient power-split control is
briefly discussed. In a general case, this solution is subop-
timal, although an optimal result could be achieved in special
cases.
A well-known time-efficient power-split control that
has been observed to give near optimal results is the
ECMS [2], [44], [45]. The basic assumption behind ECMS is
that the optimal battery SoC costate λ∗s does not vary sig-
nificantly from a certain reference value (typically constant),
which could be obtained with connection to the typical daily
usage of the vehicle. Operating with the reference costate may
cause violation of the battery SoC limits, and therefore λs is
allowed to deviate from the reference as the battery SoC gets
close to the limits. Typical approach is to control λs with some
sort of closed loop controller [46]–[48].
A special case of the ECMS is a power-split control of a
Fig. 6. Optimization framework for computationally efficient ICE calibration
in an HEV. The power-split control is taken outside the inner ICE calibration vehicle with a large battery, where the battery SoC limits are
loop. The procedure requires fewer power-split optimizations, but it may not activated at any time instant along the driving cycle. Then,
deliver a local optimum. the obtained solution is indeed optimal, if an initial λ∗s0 can
be found, for which the optimal solution of (11) satisfies the
charge sustaining constraint (8i), without activating the SoC
moved to the lower level. The resulting bilevel program limits (8j). As it turns out, the scenario where SoC limits are
 not activated is a typical case in the energy management of
min f f (ω∗E , TE∗ , z) + λ∗NOx fNOx ω∗E , TE∗ , z (19a) HEVs (see [1], [2], and references therein). Then, the power-
z
s.t. z ∈ Z(ω∗E , TE∗ ) (19b) split control problem
ω∗E = r (g ∗ )ω (19c) [g ∗ TE∗ ] = arg min f˜f (ω E , TE ) + λs f s (PB , s)
∗ ∗ ∗
[g , TE ] = arg min f f (ω E , TE , z ) + λs f s (PB , s) g,TE
g,TE s.t. (8b)–(8d), (8h), (8k)–(8o), (11b)
s.t. (8b)–(8d), (8h)–(8o), (11b) (19d) λs (0) = λ∗s0 (20)

is not easily separable in space, as it would require solving becomes separable in time. This means that the optimal control
the power-split problem for all feasible combinations of z. signals g ∗ (tk ) and TE∗ (tk ), at some time instant tk , can be
Instead, this formulation is used as a starting point for a obtained by instantaneous optimization of (20), considering
computationally efficient locally optimal solution. only the single time instant t = tk . This is a direct conse-
A computationally efficient strategy can be devised by quence from the removal of the SoC limits and the charge
assuming that a map f z0 (ω E , TE ) is given, which is, prefer- sustaining constraint. The optimal solution can be obtained
ably, in the neighborhood of f z∗ (ω E , TE ). Then, the map in a forward simulation manner. First, for the given λ∗s0 , the
f˜f 0 (ω E , TE ) is obtained from (14) and the power-split control optimal controls g ∗ (0) and TE∗ (0) are obtained by solving (20)
in the lower level task in (19) [or equivalently (16)] delivers at t = 0. At the same time, both the battery state and costate
the representative points ω∗E0 and TE0 ∗ . The representative are integrated, thus obtaining s ∗ (t1 ) and λ∗s (t1 ), at the next
points are used for recalibrating the ICE, giving new maps time instant t1 . Then, the optimal control signals g ∗ (t1 ) and
f˜f 1 (ω E , TE ) and f˜NOx 1 (ω E , TE ). The difference from the TE∗ (t1 ) are obtained by solving (20) at t = t1 . The procedure
optimization framework in Fig. 5 is that the power-split repeats until t = t f is reached.
problem is moved outside the loop for obtaining f˜f 1 (ω E , TE ) The challenge in this strategy is obtaining λ∗s0 that satisfies
and f˜NOx 1 (ω E , TE ), where iterations over λNOx are performed. the SoC sustaining constraint (8i). The method is similar to the
The procedure repeats until convergence, or maximum num- one obtaining λ∗NOx . The power-split problem (20) is iteratively
ber of iterations is reached. The advantage of this strategy is solved for different values of λs0 , where in each iteration
that fewer power-split optimizations might be required. The the optimal control is obtained for all time instances. The
disadvantage is that the solution may not converge to the procedure stops when s(t f ) is close to s0 . Bisection can also
global optimum, as there is no easy way to choose f z0 (ω E , TE ) be applied for obtaining a new value for λs0 .
sufficiently close to f z∗ (ω E , TE ). The optimization framework of the power-split control
A flowchart of the optimization framework is shown based on the ECMS is shown in Fig. 7. This power-split con-
in Fig. 6. trol can be used in combination with the global optimization

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Fig. 8. Diesel consumption versus NO x emissions for various deviations


from the desired final SoC. The left plot is a contour plot, while the right
Fig. 7. Optimization framework for computationally efficient power-split plot shows an alternative view, a surface plot, of the influence of NO x and
control of an HEV, based on the ECMS. The optimization is iterative, where SoC costates on deviation from the desired final SoC. The optimal result is
iterations are needed for obtaining the optimal initial value for the battery indicated by the star.
SoC costate.
TABLE I
framework shown in Fig. 5, and in the framework for compu- D IESEL C ONSUMPTION AND NO x E MISSIONS FOR THE C ONVENTIONAL
tationally efficient ICE calibration shown in Fig. 6. V EHICLE , THE HEV W ITH ICE C ALIBRATED FOR THE C ONVENTIONAL
V EHICLE , AND THE HEV W ITH THE O PTIMALLY C ALIBRATED ICE
VI. O PTIMIZATION E XAMPLE
This section provides an optimization example of ICE cali-
bration and power-split control of a through-the-road parallel
HEV. We consider a vehicle with 60-kW diesel ICE and
±50 kW EM, as shown in Fig. 3. The 5-D ICEs fuel and
NOx flow maps are obtained using steady-state measurements.
The lithium-ion battery is modeled by constant open circuit
voltage and resistance. Its available energy is 464 Wh, which The number of investigated costate values depends on the
is half of its total capacity; to mitigate battery wear, the desired accuracy and initial knowledge of the interval in which
battery is operated within 25%–75% SoC. We require the the optimal costates reside. An engineering estimate is that
initial and final SoC of the battery to be 50%. Emission levels not more than 40 × 40 iterations are needed until the optimal
are assessed using both the NEDC and USAs Federal Test solution is obtained with a relative error of <0.01% in both
Procedure1 (FTP75). The vehicle is required to emit not more fuel consumption and SoC sustenance (the measurement and
than 0.18 g/km NOx on the NEDC, which corresponds to discretization errors, e.g., are expected to be larger). The entire
Euro V targets on NOx emissions. For simplicity, the same problem is solved in <100 min, on a standard PC (4-GB RAM
level of 0.18 g/km is kept for FTP75. and 2.67-GHz dual core CPU). The computational time can
be reduced if the optimal battery SoC costate, once obtained,
A. Computational Performance is used as a starting point in succeeding iterations.
The optimization problem is solved using the framework The power-split control problem is also solved using DP. For
shown in Fig. 5, where the power-split control is optimized this, the feasible SoC and ICE torque ranges are gridded with
by the ECMS, using 300 discrete points for the ICE torque. 200 and 300 points, respectively. The required optimization
Without considering discretization error, the ECMS result time of DP is much larger, 8–12 h, while the solution’s accu-
is optimal, since the optimal battery SoC does not activate racy is lower than the accuracy of ECMSs solution, due to the
SoC limits, and the optimal SoC costate can be found that discretization in both SoC and engine torque that DP requires.
satisfies the SoC charge sustaining constraint. The satisfaction Therefore, in the rest of this section, we show results obtained
of the battery SoC constraints can be observed in Fig. 9. using ECMS for the power-split control problem.
Furthermore, since the battery is modeled by a constant open
circuit voltage and resistance, it follows from the necessary B. Optimization Results
condition: Minimization of fuel consumption is carried out in three


∂H(·) ∗ different case studies. First, a conventional vehicle is consid-
λ̇∗s = − =0 (21) ered, and the ICE is calibrated to minimize fuel consumption
∂s
on the driving cycle. Second, the conventional vehicle is
that the optimal SoC costate is a constant scalar value, since
converted to an HEV by mounting the EM on the rear axle.
H(·) does not explicitly depend on s. The dependence of
Fuel consumption is minimized by splitting the power between
SoC costate on NOx costate, i.e., the dependence of diesel
ICE and EM but still using the same ICE calibration as for
consumption on NOx emissions, is shown in Fig. 8, for
the conventional vehicle. Third, the ICE is recalibrated with
different values of the difference s(t f ) − s0 .
representative operating points of the HEV.
1 The driving cycles, NEDC and FTP75, are available online at The optimal fuel consumption and NO x emissions are
http://www.dieselnet.com/standards/cycles. May 2014. shown in Table I, and the optimal states’ evolution is shown

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MURGOVSKI et al.: AUTOMATED ENGINE CALIBRATION OF HEVs 1071

Fig. 9. Subplots, from top to bottom, show demanded velocity of the driving cycle and simulation results, including the optimal cumulated fuel consumption,
NO x emissions, and battery SoC. The optimal fuel consumption and SoC trajectories nearly overlap for the HEV with ICE calibrated for a conventional
vehicle and the HEV with optimally calibrated ICE. (a) NEDC. (b) USAs FTP75.

in Fig. 9. It can be observed that by recalibrating the ICE coefficient λ∗NOx that weights fuel consumption and emissions
using the optimal representative operating points of the HEV, in the entire engine range. However, engine operating points
fuel consumption can be decreased by 0.62% for NEDC and that are not excited by the driving cycle, could be further tuned
0.63% for FTP75, by still keeping the NOx emissions under (perhaps manually), without having any impact on the net fuel
the legislative limit. consumption and emissions for that driving cycle.
The optimal ICE efficiency and NOx maps are shown in The optimization problem is also solved using the computa-
Fig. 10. The figure also shows the optimal operating points tionally efficient strategy described in Section V-A. As initial
of the conventional vehicle and the HEV. It can be observed maps in the algorithm, the maps are used that are calibrated for
that the HEV avoids engine operation at low torque, where the conventional vehicle. The algorithm converged in just two
the engine is less efficient. The percentage of total cycle iterations, requiring only two power-split optimizations. This
time, the engine is in the HEV, is 19.9% on the NEDC and outcome was also revealed in Fig. 9, where it can be observed
19% on the FTP75, for both cases of engine calibration. The that the last two case studies have nearly the same optimal SoC
average engine efficiency, when the engine delivers power on trajectories regardless of whether the ICE is calibrated for a
the NEDC, increased from 37.77% to 38.5%, by recalibrating conventional vehicle or for the HEV. The result is obtained in
the ICE in the HEV. On the FTP75, the engine efficiency <4 min and is exactly the same as the optimal result of the
increased from 38.53% to 38.97%. last case study in Table I.
The complete speed/torque grid used for the calibration of
the fuel and NOx flow maps is shown in the right subplots VII. D ISCUSSION AND F UTURE W ORK
of Fig. 10, with the shaded regions showing the representative
This section discusses the process of ICE data gathering,
grid points of the driving cycles. Coincidentally, the engine
the possibility of powertrain model enhancement, and future
operating points of the HEV, regarding the shaded regions,
studies.
are distributed similarly to engine operating points of the
conventional vehicle. Therefore, the recalibration only slightly
enlarged the high-efficiency area toward greater torque values, A. ICE Data Gathering and Calibration
but besides this, the engine efficiency maps are similar. The generation of the static ICE fuel and NOx flow maps
The engine maps shown in Fig. 10 are calibrated in their may require a large number of measurements due to the many
entire range, although the engine operating points do not combinations of input values. To limit the number of mea-
excite the entire operating range of the engine. The optimal surements, the ICE was operated at 2596 input combinations,
calibration procedure makes this possible, due to the single found according to the D-optimal design methodology [49].

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Fig. 10. Optimal ICE efficiency map and NOx map, at the left and right subplots of each subfigure, respectively. The optimal ICE operating points are shown
by stars. The NO x map also shows the complete grid of speed/torque points used for the engine calibration. The shaded regions indicate the representative
grid points at which the ICE is operated for the selected driving cycle. (a) ICE maps calibrated for the conventional vehicle on the NEDC. (b) ICE maps
calibrated for the conventional vehicle on the FTP75. (c) ICE maps calibrated for the HEV on the NEDC. (d) ICE maps calibrated for the HEV on the FTP75.

The collected data were fitted to models describing boost pres- the computational complexity of DP when optimizing the
sure, oxygen fraction in the intake manifold, engine torque, power-split control, as additional states will be needed for
and NOx emissions, as functions of engine speed, injected the ICE ON / OFF, clutch, and transmission gear [53]. The
fuel, and z (see [50]–[52] for details). The maps were then proposed method may also employ stochastically generated
enlarged to 10 × 17 × 30 × 30 × 30 grid points using linear driving cycles [24], applied to both HEVs and plug-in HEVs.
interpolation, and the torque map was inverted to get torque Constraints on other emissions, such as soot, hydrocar-
as input, rather than fuel flow. bon, carbon monoxide, and combustion noise, may also be
To obtain more informative data for the limited amount of considered. This will necessitate additional costates, which
measurements, ICE operation at high speed and torque was will increase the computational complexity [19], but the opti-
not considered, but the focus was kept on the region where mization method will otherwise be the same. Implementing
the studied driving cycles reside. The performed measurements engine thermal dynamics and transient modeling, e.g., boost
covered only part of the available speed and torque range of a pressure dynamics, is a more challenging task that shall
Volvo 2.4-L passenger car diesel engine (with actual maximum be considered in future studies. Experimental validation of
speed of 4700 r/min). This, however, does not infringe the improvements from the ICE recalibration is a major topic to
generality of the proposed method. Utilization of the entire be also considered in future studies.
available speed and torque range shall be considered in future
studies. VIII. C ONCLUSION
A method is presented for combined optimization of ICE
B. Enhanced Modeling and Future Studies management settings and power-split control of an HEV. It
In this paper, we considered a relatively simple power- is shown that the optimization problem is separable in space,
train model, thus emphasizing the optimization methodology. while in the case where battery SoC limits are not activated,
However, the proposed method can readily be applied to it is also shown that the problem is separable in time. The
more detailed powertrain models, including auxiliary losses, optimal solution is obtained by iteratively solving the power-
rotational inertia of the ICE and EM, and more detailed split control problem using DP or the ECMS. A computa-
transmission and clutch models. Dynamic ICE start/stop, tionally efficient solution is presented, which for the studied
clutch, and gearbox models are also possible when, e.g., example managed to achieve the global optimum 25× faster
changes in discrete states are penalized. This will increase (i.e., 100/4 min) than the time needed for the full optimization,

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MURGOVSKI et al.: AUTOMATED ENGINE CALIBRATION OF HEVs 1073

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Nikolce Murgovski received the M.Sc. degree in
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and systems from the Chalmers University of Tech-
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calibration process for diesel engine electronic control module tables— respectively.
Part 2: Modelling and optimization,” Int. J. Engine Res., vol. 13, no. 2, He is currently a Post-Doctoral Researcher with
pp. 147–168, 2012. the Department of Signals and Systems, Chalmers
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ment system strategy for transient engine operation,” in Proc. 7th IFAC ests include optimal control and dimensioning of
Symp. Adv. Autom. Control, Tokyo, Japan, 2013, pp. 1–6. automotive powertrains.
[35] M. Grahn, K. Johansson, and T. McKelvey, “Model-based diesel engine
management system optimization for transient engine operation,” Con-
trol Eng. Pract., vol. 29, pp. 103–114, Aug. 2014.
[36] D. Alberer and L. del Re, “Optimization of the transient diesel engine
operation,” in Proc. SAE Int. Tech., 2009, paper 2009-24-0113. Markus Grahn received the M.Sc. degree in engi-
[37] D. Alberer and L. del Re, “Fast oxygen based transient diesel engine neering physics, and the Ph.D. degree in signals
operation,” SAE Int. J. Engines, vol. 2, no. 1, pp. 405–413, 2009. and systems from the Chalmers University of Tech-
[38] M. Benz, M. Hehn, C. H. Onder, and L. Guzzella, “Model-based actuator nology, Gothenburg, Sweden, in 2003 and 2013,
trajectories optimization for a diesel engine using a direct method,” respectively.
J. Eng. Gas Turbines Power, vol. 133, no. 3, p. 032806, 2010. He has been with Volvo Car Corporation,
[39] S. Nakayama, T. Fukuma, A. Matsunaga, T. Miyake, and T. Wakimoto, Gothenburg, since 2003, where he is involved in
“A new dynamic combustion control method based on charge combustion engine control and calibration. His cur-
oxygen concentration for diesel engines,” in Proc. SAE Int. Tech., 2003, rent research interests include model-based methods
paper 2003-01-3181. to optimize the performance of combustion engine
systems.
[40] S. Nakayama, T. Ibuki, H. Hosaki, and H. Tominaga, “An application
of model based combustion control to transient cycle-by-cycle diesel
combustion,” SAE Int. J. Engines, vol. 1, no. 1, pp. 850–860, 2008.
[41] S. K. Chen and O. Yanakiev, “Transient NOx emission reduction using
exhaust oxygen concentration based control for a diesel engine,” in Proc. Lars Mårdh Johannesson (M’12) received the
SAE Int. Tech., 2005, paper 2005-01-0372. M.Sc. degree in automation and mechatronics, and
[42] C. Atkinson and G. Mott, “Dynamic model-based calibration optimiza- the Ph.D. degree in automatic control from the
tion: An introduction and application to diesel engines,” in Proc. SAE Chalmers University of Technology, Gothenburg,
Int. Tech., 2005, paper 2005-01-0026. Sweden, in 2004 and 2009, respectively.
[43] C. Atkinson, M. Allain, and H. Zhang, “Using model-based rapid He has been with the Electromobility Group,
transient calibration to reduce fuel consumption and emissions in diesel Viktoria Swedish ICT, Gothenburg, since 2011,
engines,” in Proc. SAE Int. Tech., 2008, paper 2008-01-1365. where he is involved in research on powertrain
[44] G. Paganelli, S. Delprat, T. M. Guerra, J. Rimaux, and J. Santin, “Equiva- control with the Chalmers Energy Initiative. His
lent consumption minimization strategy for parallel hybrid powertrains,” current research interests include optimal control of
in Proc. 55th IEEE Veh. Technol. Conf., May 2002, pp. 2076–2081. hybrid and PHEVs, control of auxiliary systems in
[45] S. Delprat, J. Lauber, T. M. Guerra, and J. Rimaux, “Control of a parallel trucks, active cell balancing, and system studies of hybrid vehicles.
hybrid powertrain: Optimal control,” IEEE Trans. Veh. Technol., vol. 53,
no. 3, pp. 872–881, May 2004.
[46] A. Sciarretta, L. Guzzella, and M. Back, “A real-time optimal control
strategy for parallel hybrid vehicles with on-board estimation of control Tomas McKelvey received the Electrical Engineer-
parameters,” in Proc. IFAC Symp. Adv. Autom. Control, Salerno, Italy, ing degree from Lund University, Lund, Sweden,
2004, pp. 502–507. in 1991, and the Ph.D. degree in automatic control
[47] C. Musardo, G. Rizzoni, and B. Staccia, “A-ECMS: An adaptive from Linköping University, Linköping, Sweden, in
algorithm for hybrid electric vehicle energy management,” in Proc. 44th 1995.
IEEE Conf. Decision Control, Eur. Control Conf., Seville, Spain, 2005, He held research and teaching positions with
pp. 1816–1823. Linköping University from 1995 to 1999, where he
[48] P. Rutquist, C. Breitholtz, and T. Wik, “On the infinite time solution became a Docent in 1999. From 1999 and 2000,
to state-constrained stochastic optimal control problems,” Automatica, he was a Visiting Researcher with the University
vol. 44, no. 7, pp. 1800–1805, 2008. of Newcastle, Newcastle, NSW, Australia. Since
[49] D. C. Montgomery, Design and Analysis of Experiments, 7th ed. 2000, he has been with the Chalmers University of
New York, NY, USA: Wiley, 2009. Technology, Gothenburg, where he has held a Full Professor position and
[50] M. Grahn, K. Johansson, C. Vartia, and T. McKelvey, “A structure has been the Head of the Signal Processing Group since 2006 and 2011,
and calibration method for data-driven modeling of NOx and soot respectively. His current research interests include model-based and statistical
emissions from a diesel engine,” in Proc. SAE Int. Tech., 2012, signal processing, system identification, image processing, and control with
paper 2012-01-0355. applications to biomedical engineering and combustion engines.

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