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We present a three-way catalyst (TWC) cold-start model, calibrate the modelbased on experimental data from multiple operating points, and use the model togenerate a Pareto-optimal cold-start controller suitable for implementation instandard engine control unit hardware. The TWC model is an extension of apreviously presented physics-based model that predicts carbon monoxide,hydrocarbon, and nitrogen oxides tailpipe emissions. The model axially andradially resolves the temperatures in the monolith using very few statevariables, thus allowing for use with control-policy based optimal controlmethods. In this paper we extend the model to allow for variable axialdiscretization lengths, include the heat of reaction from hydrogen gasgenerated from the combustion engine, and reformulate the model parameters tobe expressed in conventional units. We experimentally measured the temperatureand emission evolution for cold-starts with ten different engine load points,which was subsequently used to tune the model parameters (e.g.~chemicalreaction rates, specific heats, and thermal resistances). The simulatedcumulative tailpipe emission modeling error was found to be typically -20% to+80% of the measured emissions. We have constructed and simulated theperformance of a Pareto-optimal controller using this model that balances fuelefficiency and the cumulative emissions of each individual species. A benchmarkof the optimal controller with a conventional cold-start strategy shows thepotential for reducing the cold-start emissions.

Cold-Start Modeling and On-Line Optimal Control of the Three-Way Catalyst