Safe Reinforcement Learning for Real-World Engine Control

This work introduces a toolchain for applying Reinforcement Learning (RL), specifically the Deep Deterministic Policy Gradient (DDPG) algorithm, in safety-critical real-world environments. As an exemplary application, transient load control is demonstrated on a single-cylinder internal combustion engine testbench in Homogeneous Charge Compression Ignition (HCCI) mode, that offers high thermal efficiency and low emissions. However, HCCI poses challenges for traditional control methods due to its nonlinear, autoregressive, and stochastic nature. RL provides a viable solution, however, safety concerns, such as excessive pressure rise rates, must be addressed when applying to HCCI. A single unsuitable control input can severely damage the engine or cause misfiring and shut down. Additionally, operating limits are not known a priori and must be determined experimentally. To mitigate these risks, real-time safety monitoring based on the k-nearest neighbor algorithm is implemented, enabling safe interaction with the testbench. The feasibility of this approach is demonstrated as the RL agent learns a control policy through interaction with the testbench. A root mean square error of 0.1374 bar is achieved for the indicated mean effective pressure, comparable to neural network-based controllers from the literature. The toolchain's flexibility is further demonstrated by adapting the agent's policy to increase ethanol energy shares, promoting renewable fuel use while maintaining safety. This RL approach addresses the longstanding challenge of applying RL to safety-critical real-world environments. The developed toolchain, with its adaptability and safety mechanisms, paves the way for future applicability of RL in engine testbenches and other safety-critical settings.

Introducing a Deep Neural Network-based Model Predictive Control Framework for Rapid Controller Implementation

Model Predictive Control (MPC) provides an optimal control solution based on a cost function while allowing for the implementation of process constraints. As a model-based optimal control technique, the performance of MPC strongly depends on the model used where a trade-off between model computation time and prediction performance exists. One solution is the integration of MPC with a machine learning (ML) based process model which are quick to evaluate online. This work presents the experimental implementation of a deep neural network (DNN) based nonlinear MPC for Homogeneous Charge Compression Ignition (HCCI) combustion control. The DNN model consists of a Long Short-Term Memory (LSTM) network surrounded by fully connected layers which was trained using experimental engine data and showed acceptable prediction performance with under 5% error for all outputs. Using this model, the MPC is designed to track the Indicated Mean Effective Pressure (IMEP) and combustion phasing trajectories, while minimizing several parameters. Using the acados software package to enable the real-time implementation of the MPC on an ARM Cortex A72, the optimization calculations are completed within 1.4 ms. The external A72 processor is integrated with the prototyping engine controller using a UDP connection allowing for rapid experimental deployment of the NMPC. The IMEP trajectory following of the developed controller was excellent, with a root-mean-square error of 0.133 bar, in addition to observing process constraints.