Novel virtual sensors development based on machine learning combined with convolutional neural-network image processing-translation for feedback control systems of internal combustion engines

Physical sensors are commonly used to record performance data of internal combustion engines (ICEs) for online feedback control and calibration, but they are prone to diagnostic and increased development costs. Lookup tables are commonly used in conventional calibration and feedback control; however, the table parameters increase with the advancement of ICE technologies under transient operations. Consequently, the calibration and control systems are time-consuming. This work proposes novel virtual sensors to address these issues by predicting the combustion, performance, and emission of ICEs using neural networks and image processing/translation. The novel sensors are targeted for onboard feedback control systems under transient driving. Firstly, a virtual diesel engine (VDE) was developed and calibrated against experimental data taken from a production 2.2 L turbocharged diesel engine. The VDE was calibrated under WLTC, JC08, and NEDC transient operations and was used to generate teaching data. Next, the virtual sensors are developed using five machine learning (ML) regressors. The result shows that the coefficient of determination R2 from all ML regressors exceeded 0.94, and the XG-Boost outperforms other ML techniques with R2 > 0.977. XG-Boost parameter estimations were 8 times faster than that on a desktop simulation. Then, an image classification model using a deep convolutional neural network (D-CNN) is constructed, and the dependency of performance parameters and exhaust emissions with the rate of heat release (R.H.R) and in-cylinder pressure profile is confirmed. The performance parameters and emissions dependency was compared individually with R.H.R. and the in-cylinder pressure profile. As a result, a strong correlation between the performance and R.H.R. was observed. Finally, a generative adversarial network (GAN) model was constructed to translate the in-cylinder pressure profile to R.H.R. profile. A novel method to develop virtual sensors for advanced feedback control of any type of ICEs is proposed for the first time.