System for turbocharger performance monitoring and adaptation

A method of operating a physical plant and an associated configurable controller, the physical plant having a plurality of actuators for controlling operation of the physical plant and a plurality of sensors for observing a plurality of characteristics of the physical plant operations, with the plurality of actuators and plurality of sensors operably linked to the configurable controller, the method comprising:

• capturing a current state of the physical plant by communication with the plurality of sensors;
• controlling behavior of the physical plant using at least one of the plurality of actuators;
• using one or more models for the physical plant, and the current state of the physical plant, estimating an operating value of a first parameter in the physical plant;
• using one of the plurality of sensors, measuring an operating value of the first parameter in the physical plant;
• comparing the estimated value to the measured value for the first parameter to calculate a difference in the first parameter;
• calculating a state of health (SOH) of the physical plant using the difference in the first parameter;
• and
• storing the SOH using the configurable controller.

A vehicle comprising:

• an internal combustion engine having associated therewith a plurality of actuators for controlling operation of the physical plant and a plurality of sensors for observing a plurality of characteristics of the physical plant operations, the internal combustion engine comprising a charge air cooler (CAC) and a turbocharger having a compressor for compressing engine intake air using power derived from a turbine receiving exhaust air from the engine, the CAC positioned having an inlet to receive charged air from the compressor and an outlet to issue cooled charged air to the engine intake, the engine including a CAC outlet temperature sensor;
• a configurable controller for controlling the physical plant, operably coupled to the actuators and the sensors, the configurable controller including a state observer configured to capture a current state of the physical plant by communication with the plurality of sensors, a low level controller configured to control behavior of the physical plant using at least the actuators, an engine control unit (ECU) coupled to the low level controller, the ECU configured for analyzing the state of health (SOH) of the engine by:
• using one or more models for the engine, and the current state of the physical plant, determining an estimated CAC outlet temperature;
• using the CAC outlet temperature sensor, determining a measured CAC outlet temperature;
• comparing the estimated CAC outlet temperature value to the measured CAC outlet temperature a parameter difference;
• and
• calculating SOH of the engine using the parameter difference.