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Energy
EnergyProcedia 126
Procedia 00(201709) 899–906
(2017) 000–000
www.elsevier.com/locate/procedia
72nd Conference of the Italian Thermal Machines Engineering Association, ATI2017, 6-8
72nd Conference of the ItalianSeptember
Thermal Machines Engineering
2017, Lecce, Italy Association, ATI2017, 6-8
September 2017, Lecce, Italy
Model Based Control of Intake Air Temperature and Humidity on
Model Based Control
The 15th of Intake
International Symposium Air on Temperature
District Heating and Humidity on
and Cooling
the Test Bench
the Test Bench
Assessing
a* the feasibility a of using the heat demand-outdoor
Enrico Cortia*, Michele Tacciolia, Luca Marognaaa, Nicolò Cavinaaa, Vittorio Ravaglioliaa
temperature
Enrico function
Corti , Michele for, aLuca
Taccioli long-term
Marogna ,districtNicolò Cavina heat demand
DIN - University of Bologna, viale Risorgimento, 2, 40136, Italy
forecast
, Vittorio Ravaglioli
DIN - University of Bologna, viale Risorgimento, 2, 40136, Italy
I. Andrića,b,c*, A. Pinaa, P. Ferrãoa, J. Fournierb., B. Lacarrièrec, O. Le Correc
a
IN+ Center for Innovation, Technology and Policy Research - Instituto Superior Técnico, Av. Rovisco Pais 1, 1049-001 Lisbon, Portugal
Abstract b
Veolia Recherche & Innovation, 291 Avenue Dreyfous Daniel, 78520 Limay, France
Abstract c
Département Systèmes Énergétiques et Environnement - IMT Atlantique, 4 rue Alfred Kastler, 44300 Nantes, France
Engine test benches are crucial instruments to perform tests on internal combustion engines. Possible purposes of these tests are to
Engine
detect thetestengine
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performance, to performoftests
check the reliability the on internal combustion
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emissions and of engine control
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Abstract
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is to assess the feasibility
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methodology, demand – outdoor temperature function for (humidifier,
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pre-heating and post-heating resistors, chiller and fan) is managedwhere component
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forecast. The
pre-heating and district of Alvalade,
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managed was usedopen-loop
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the control model is composed of two parts, the first one to evaluate the target for the given HVAC component, based on the system
buildings
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onetypology. Three weather scenarios (low, medium, high) andonthree district
physical model, the oneofistwoa PIDparts,
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set-point component,
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estimate the theset-point
error, obtained heat demand values were
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engineon thebench
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methodology from a
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validated demand model,
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system by the authors.
has been developed concerning
on an open
software Real-Time compatible platform, allowing the integration the HVAC control with all other functionalities
The results
software showed compatible
Real-Time that when only weather changethe is integration
considered,ofthe margin ofcontrol
error could be
all acceptable for some applications
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shows the allowing
plant layout, details the the HVAC
control strategy with
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analyzes experimentalconcerning
results
(thetest
the error in annual demand
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The highlighting
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for all details
weather scenarios considered). However, after introducing renovation
obtained on the test bench, the benefits of the proposedtheHVAC control strategy and
management finally analyzes
approach. experimental results
scenarios,
obtained onthethe error value highlighting
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benefits(depending
of the proposed on theHVACweather and renovation
management scenarios combination considered).
approach.
The value of slope coefficient increased on average within the range of 3.8% up to 8% per decade, that corresponds to the
© 2017 The Authors. Published by Elsevier Ltd.
©© 2017
2017 The
decrease TheinAuthors.
the number
Authors. Published
of heating
Published by
by Elsevier
hours of Ltd.
22-139h during the heating season (depending on the combination of weather and
Peer-review under responsibility of Elsevier Ltd.
the scientific committee of the 72ndnd Conference of the Italian Thermal Machines Engineering
Peer-review
renovation under
scenariosresponsibility
considered). of the
On scientific
the other committee
hand, function of theintercept
72 Conference
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Peer-review under responsibility of the scientific committee
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the Italian Thermal (depending
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coupled scenarios). The values suggested could be used to modify the function parameters for the scenarios considered, and
Association.
improve the accuracy
Keywords: HVAC; air conditioning of heat demand estimations.
Keywords: HVAC; air conditioning
© 2017 The Authors. Published by Elsevier Ltd.
Peer-review under
*Corresponding responsibility
author. of the Scientific
Tel.: +39-051-2093307; Committee of The 15th International Symposium on District Heating and
fax: +39-051-2093313.
Cooling.
*Corresponding author. Tel.: +39-051-2093307; fax: +39-051-2093313.
E-mail address: [email protected]
E-mail address: [email protected]
Keywords: Heat demand; Forecast; Climate change
1876-6102 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review underThe
1876-6102 © 2017 responsibility of theby
Authors. Published scientific
Elsevier committee
Ltd. of the 72nd Conference of the Italian Thermal Machines Engineering
Peer-review under responsibility of the scientific committee of the 72nd Conference of the Italian Thermal Machines Engineering
Association.
Association.
1876-6102 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review under responsibility of the Scientific Committee of The 15th International Symposium on District Heating and Cooling.
1876-6102 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review under responsibility of the scientific committee of the 72nd Conference of the Italian Thermal Machines Engineering Association
10.1016/j.egypro.2017.08.156
900 Enrico Corti et al. / Energy Procedia 126 (201709) 899–906
2 Corti et al./ Energy Procedia 00 (2017) 000–000

1. Introduction

Nowadays in the automotive sector, complex solutions are studied and adopted to meet the need for high
performance engines offering good reliability and, due to increasingly stringent anti-pollution standards, low
emissions. A meticulous study is devoted to the development of mechanical components and innovative technical
solutions. Moreover, engineers extensively use electronics to make ‘intelligent’ engines, capable of adapting to the
requirements of the driver to offer the best performance in any condition.
A key part of development is the test activity [1] that is carried out to validate the adopted solutions, and a tool playing
a key role during this process is the engine test bench. In fact, it allows performing different types of tests, producing
large amounts of data in a very short time, thus contributing to the optimal setup, the approval or the rejection of the
considered solutions [2].
The behavior of an engine can be influenced by many factors, and some of them can dramatically change the
outcome of a test in terms of performance, emissions, and reliability. Therefore, it is necessary to monitor and
accurately control, through appropriate systems, each of these parameters in order to carry out focused and repeatable
tests. Fuel and air conditions obviously affect the combustion process: in particular, the conditions of the intake air
can deeply affect the way the combustion develops, leading the engine to generate different performance according to
air pressure, temperature and humidity [3].
Usually, engine test benches are equipped with an HVAC system to control the thermal conditions of the air introduced
into the engine. It is a set of various components that need to be simultaneously controlled with the aim of conditioning
air temperature and humidity (pressure conditioning is usually carried out with dedicated systems).
While in the literature there are many examples of works focusing on engine thermal management [4, 5, 6], model-
based control of HVAC systems has not been previously addressed.
This paper introduces a model based control methodology of the HVAC system. To manage individual components
of this plant, an algorithm putting together the outcomes of open loop and closed loop contributions has been designed.
The open loop control is based on a physical heat exchange model between the intake air and the specific HVAC
element to be controlled, while the closed loop part is based on the difference between target and measured air
conditions.
The developed control model has been integrated into the test bench management software implementing the test
bench automation system, running on a Real-Time platform. In this way, it has been possible to validate the HVAC
system control methodology by performing air conditioning tests, feeding the model inputs with the test bench sensors
outputs.
The paper is subdivided into sections. The first one describes the HVAC system component by component and
briefly shows the hardware set-up of the test bench automation system where tests have been performed. In the second
section, after a brief introduction to the test management software, the algorithm structure is presented, highlighting
its components, leading from the inputs to the actuations commands driving the air conditioning system hardware.
Finally, the last section reports the results of the HVAC system control assessment tests.

Nomenclature

 [°C] target air temperature at the engine intake

 [°C] target air relative humidity at the engine intake
 [g/kg] target air absolute humidity at the engine intake
 [°C] temperature of the air introduced in the HVAC system
 [%] relative humidity of the air introduced in the HVAC system
 [g/kg] absolute humidity of the air introduced in the HVAC system
 [°C] temperature of the air at the engine intake
 [%] relative humidity of the air at the engine intake
 [g/kg] absolute humidity of the air at the engine intake
 [Pa] barometric pressure
 [kg/s] air mass flow rate
 [°C] dew point temperature
 [W] heat to transfer to the air calculated by the open loop control
 Enrico Corti et al. / Energy Procedia 126 (201709) 899–906 901
Corti et al./ Energy Procedia 00 (2017) 000–000 3

 [W] heat to transfer to the air calculated by the closed loop control
 [W] heat to subtract to the air to dehumidify
 [J/kgK] air specific heat
∆ [°C] temperature difference
 [W] chiller cooling capacity
 [%] steam generator open loop control output
 [%] steam generator closed loop control output
 [%] duty cycle of the steam generator
1 % [%] chiller open loop control output produced by the humidity control
 % [%] chiller closed loop control output produced by the humidity control
1% [%] duty cycle of the chiller produced by the humidity control
2% [%] duty cycle of the chiller produced by the temperature control
% [%] duty cycle of the chiller, the maximum between 1% and 2%
 [W] post-heating resistance wattage
 [W] pre-heating resistance wattage
ostH% [%] duty cycle post-heating resistance
reH% [%] duty cycle pre-heating resistance

2. HVAC system and hardware setup

The work presented in this paper has been developed and validated performing air conditioning tests on an engine
test bench. In the following, the structures of the air conditioning system and the control hardware setup are presented.

2.1 HVAC plant layout

The HVAC system that has been tested is located in a technical room near the test bench room.

Fig. 1. Scheme of the HVAC system and sensors layout

As shown in Figure 1, starting from the air intake of the HVAC, a shutter permits to regulate the intake section
establishing the air flow rate processed by the system; next, a filter avoids impurities from being introduced inside.
Then a 12 kW pre-heating resistor allows increasing the air temperature. A maximum temperature thermostat
switches the resistor off when a selectable threshold is exceeded.
902 Enrico Corti et al. / Energy Procedia 126 (201709) 899–906
4 Corti et al./ Energy Procedia 00 (2017) 000–000

The resistor is followed by a heat exchanger, where air is cooled by the liquid refrigerated by a dedicated chiller. If
processed air exceeds the dew point temperature, airborne water vapor condenses, reducing the air absolute humidity.
The producer of the chiller provides a table to estimate the cooling capacity, based on the treated air temperature and
the coolant fluid temperature.
The air cooler is followed by a humidifier, a steam generator whose function is to increase air humidity introducing
water vapour in the conditioned air through a nebulizer. This component can produce up to 26.4 kg/h of steam.
Condensed water is collected in a tank and evacuated outside the technical room.
A 18 kW post-heating resistor performs the last heating process and finally a fan pushes the conditioned air towards
the engine intake.
As regards the model outputs for the management of the HVAC components, the humidifier needs an analogue
signal proportional to the steam flow and a digital enable command. Resistors and chiller are controlled by means of
PWM signals, managing the percentage of the control period spent by the systems in ON or OFF states.
The HVAC control algorithm uses as input variables physical quantities available to the test bench automation
system, specifically the HVAC and engine input air conditions, in terms of humidity and temperature, together with
the atmospheric pressure and the air mass flow rate.
As shown in figure 1, two air humidity and temperature sensors are used, the first one outside of the HVAC system,
the second one placed inside the settling chamber attached to the engine intake. The barometric pressure sensor is
installed in the test bench room while the flow meter is installed downstream of the air conditioning system (before
the settling chamber).

2.2 Hardware Setup

The engine test bench control system managing the HVAC and all other devices, is based on a Real-Time
compatible hardware platform, whose scheme is shown in Figure 2. The hardware setup consists of a Real-Time
controller, a high-performance desktop PC running Labview Real-Time OS, connected via MXI Express BUS
interface with an NI MXI Chassis containing the I/O Modules. Finally, the Host PC, connected via Ethernet with the
Real-Time controller, offers a user interface, allowing the operator to manage and monitor the tests.

Fig. 2. Control system structure

3. The HVAC managing algorithm

The engine test bench control software has been developed in NI Veristand, a software environment for developing
Real-Time testing applications that can run on Real-Time hardware. NI Veristand offers the possibility to include
models, such as the HVAC control logic, developed in NI Labview and running on the Real-Time controller. The NI
Veristand Project incorporates the hardware I/O functionalities, the control models, the user interface and automation
sequences. HVAC systems are usually managed by means of PID controllers implemented on PLCs that manage
single components, such as the steam generator, or the chiller: the proposed control methodology benefits of an open
loop model-based contribution, managing the HVAC system components with a global approach.
Figure 3 shows a schematic representation of the HVAC control model, highlighting the components I/O.
 Enrico Corti et al. / Energy Procedia 126 (201709) 899–906 903
Corti et al./ Energy Procedia 00 (2017) 000–000 5

Fig. 3. Inputs and outputs of the HVAC control model

As previously remarked, each output of the HVAC control model presented in this paper is composed of 2 terms, an
open loop and a closed loop component. The parameters of the PID controllers have been set according to the slowness
of the controlled phenomena. A step variation of the demands could quickly lead PIDs to saturation. For this reason,
the derivative of the targets is saturated with an appropriate rate limiter.
The open loop calculus is based on the estimation of the heat and water vapor that the air conditioning system has
to transfer to (or from) the air processed by the plant. To do this, the model uses the formulation of the heat transfer,
shown in Eq.(1), where ∆ depends on the specific case.
 =  ∗  ∗ ∆ (1)
In order to assess the quantity of water vapor to introduce or remove from the inlet air, the absolute humidity of the
air introduced in the plant is compared with the target, evaluated from target air temperature and relative humidity
required by the operator. The absolute humidity, expressed in terms of grams of water per kg of dry air, is derived
from relative humidity, temperature and barometric pressure through the psychrometric diagram.
The humidity management logic provides two possible paths:
• If absolute air humidity has to be increased, the steam generator is activated. Using Eq.(2), the model
calculates the amount of steam to produce in terms of percentage of the humidifier’s nominal capacity, that
is 26.4 kg/h of steam flow, corresponding to an output signal of 10 V.
 ∗)∗(  )
(
 = ∗.
∗ 0.1 (2)

This open loop contribution is added to the output of the humidifier PID controller that compares the absolute
humidity target with the absolute humidity of the engine intake (based on the relative humidity and
temperature inputs).
The sum result, conveniently saturated between specific limits is the Voltage output managing the humidifier.
 =  +  (3)
904 Enrico Corti et al. / Energy Procedia 126 (201709) 899–906
6 Corti et al./ Energy Procedia 00 (2017) 000–000

It has to be noticed that the desaturation of the integral term in the PID controller has to take into account the
effect of the open loop contribution [7, 8]. Therefore, the output of the PID controller will be as follows,
being SAT the PID authority (i.e., the maximum allowed contribution of the closed loop controller). The
parameter SAT has an important impact on the wind-up behavior of the PID controller.
−; 10 −     ≥ 10 − 
−;   10 −  ≥  ≥  (4)
− ;    < 
• If absolute air humidity has to be decreased, the chiller is activated to decrease air temperature until it reaches
the dew point and the airborne water vapor condenses decreasing air humidity. First of all it is necessary to
determine the dew point through the psychrometric diagram, considering the absolute humidity target and a
relative humidity of 100 %. Then, Eq.(1) is applied, where in this case ∆ is the difference between 
and  : this allows determining the heat  to subtract from the airflow in order to reach the target
absolute humidity. Finally, once determined the chiller cooling capacity for the measured  , the model
output managing the chiller is calculated through Eq.(5).

1 % = ∗ 100 (5)


This term is added to the output of the chiller PID controller that compares the relative humidity target with
the relative humidity of the engine intake. The result, saturated between proper limits is the duty cycle of the
chiller PWM for the humidity control. As stated previously, saturation limits must take into account the
presence of the open loop contribution.
1% = 1 % +  % (6)
As regards the temperature management logic, the closed loop control consists of a PID controller that compares
 with  and produce a contribution, in terms of heat, named . This term is added to the heat 
calculated in open loop. Three are the possible cases that may occur:
• Air temperature must be reduced. This case involves the activation of the chiller, while both the resistors
remain deactivated. 2%, that is the PWM duty cycle to manage the Chiller in the temperature control, can
be estimated through Eq.(7), where  is calculated through Eq.(1) with a ∆ that is the difference between
 and  .
Both humidity and temperature control produce a duty cycle for the chiller PWM, the higher among these is
used to manage the device.
 
2% = ∗ 100 (7)


• Air temperature must be increased, while humidity must be reduced. In this case, the humidity control
activates the chiller and the temperature control switches on the post-heating resistance. In fact, as previously
explained, to decrease the amount of water in the air, it is essential to bring the air at a temperature below the
dew point. So, the best way to increase the air temperature at the same time the chiller is working is to turn
on the post-heating resistance which is placed downstream of the chiller [9]. For this reason, in this specific
case, the amount of heat to transfer to the air is calculated in open loop through Eq.(1) where ∆ is the
difference between  and  . Eq.(8) shows how to calculate the duty cycle of the resistor PWM for this
case.
 +
ostH% =

∗ 100 (8)

• Air temperature must be increased, and humidity must be increased. In this case, since there is a need to
increase the presence of water vapor in the air, the model activates the steam generator and the pre-heating
resistance. The amount of heat to transfer to the air is calculated in open loop through Eq.(1) where ∆ is the
difference between  and  . Eq.(9) shows how to calculate the duty cycle for the resistance PWM in
this case.
 Enrico Corti et al. / Energy Procedia 126 (201709) 899–906 905
Corti et al./ Energy Procedia 00 (2017) 000–000 7

 +
RreH% = 
∗ 100 (9)

If the heat quantity is so high that it exceeds the pre-heating resistor wattage, also the post-heating resistor is
switched on, with a duty cycle established with Eq.(10)
 + 
ostH% =

∗ 100 (10)

4. Tests Results

Two different types of test have been carried out. First of all, the HVAC has been tested without engine on the
bench and at fixed air flow, generating sudden variations of target temperature or humidity.
The HVAC system reaction to a sudden change of the target temperature (from 25°C to 30°C), at a fixed demand of
humidity of 50%, is shown in Figure 4 a): although the reaction is slow, the temperature variation is obtained without
critical oscillations in relative humidity, which is in the range 50±2%. The reason of the slow response is to be ascribed
to several factors: on one hand, the target derivative is saturated, and the actual target is reached after more than 330
seconds. On the other hand, the resistors switching period is very long (1 minute). Finally, temperature changes are
damped out by the presence of the settling chamber, which means that the plant reactions are very slow. This is a
disadvantage when air conditions must be changed abruptly, but it is useful to maintain air conditions during engine
speed and load transients. It has to be remarked that typically, once target air conditions are reached, they are
maintained through the test duration.
Intake Temperature [°C]

Intake Temperature [°C]

Relative Humidity [%]

Relative Humidity [%]

Fig. 4. a) change of target temperature at fixed humidity and air flow rate; b) change of target humidity at fixed temperature and air flow rate

Figure 4 b) shows the reaction to the variation of target humidity (from 50% to 60%), at a requested temperature of
25 °C: similar considerations can be applied. It can be noticed that air temperature oscillates in the range ±1°C, due
to the PID constant calibration. This setting, obtained with a fine tuning following the application of Ziegler-Nichols
approach, could be considered improvable in steady flow conditions, but it has been considered the best-compromise
solution taking into consideration also unsteady flow operation, typical of engine testing. The overall controller
stability has been proved against the most extreme working conditions (maximum difference of target Temperature
and Humidity with respect to feedback values).
Figure 5 shows that even in tests with highly variable flow rate and high target temperature humidity remains near the
target, with a maximum variation of 3.5% and a standard deviation of 1.45%. The test has been performed running an
engine on the test bench, alternating full throttle steps at different engine speeds to low throttle conditions at low
engine speed.
906 Enrico Corti et al. / Energy Procedia 126 (201709) 899–906
8 Corti et al./ Energy Procedia 00 (2017) 000–000

Intake Temperature [°C]

Relative Humidity [%]
Air Flow Percentage [%]

Fig. 5. Intake air humidity and temperature during a test with highly variable flow rate

5. Conclusions

The paper describes the implementation of an HVAC system control: each component control setting is determined
according to the combination of an open loop model-based contribution, and a closed loop PID contribution. The
control system has been implemented in the real-time test automation system controller, and tested with and without
the engine. Even though the control of the HVAC system could take advantage of some hardware modifications, such
as the possibility of controlling the chiller fluid temperature, or the increase in the resistors switching frequency, the
approach demonstrated a good control capability, allowing engine testing in different steady temperature and humidity
intake air conditions, even with very unsteady air flow.

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