MoBEO: Model based Engine Development and Calibration · 2016-09-28 · MoBEO: Model based Engine...

125 Feb 2015 |FPC 2015

MoBEO: Model based Engine Development and CalibrationInnovative ways to increase calibration quality within the limits of acceptable development effort!

Dr. Prakash Gnanam, AVL Powertrain UK Ltd

2P.GNANAM | PTE | 25 Feb 2015 |FPC 2015

Outline

• Challenges

• AVL Approach

• MoBEO: Model Overview

• Model Accuracy

• Application Environment

• Use Cases


Powertrain Development Challenges

CO2 / Fuel Consumption

Real Driving Emissions

Broad Vehicle Portfolio

Reduction of

development costs€

Reduction of

development time

Keep quality standards1

Increased system

complexity (EAS, OBD, Hybridization)


AVL APPROACH


Test Environments

Vehicle Data

Extension to the Virtual

EnvironmentsMOBEO

Methodology

Actual effortPlanning / Monitoring

Test Field Host

Dataset Management

Measuring

Post Processing

ValidationMOBEO

Methodology

Advanced Test Automation

Quality ManagementCalibration

Process, CRETA, Quality

Dashboard, CVP

Quality Management

Advanced Post Processing

Diesel Calibration Methodology and Tools for a more efficient calibration


MOBEOModel overview


• Model based development using a real time capable engine model

• Starting from concept phase until SOP calibration

• Engine model based on semi-physical modeling approach

� empirical model components derived from AVL experience and test bed data

� physical components increase the range of application due to better extrapolation

• Easy usability due to the use of suitable simulation environments

Increasing system

robustness within given

development duration

and budget by transferring

development from

real to virtual testing

Changing Calibration ParadigmOverview


DoE and BeyondThe evolution of the methodology approach

Legislation / Technology

Area ofOptimization

Measurement Effort

1 Engine

1 Variant

1 Engine

n Variants

1 Engine

n Variants

n Conditions

Real DrivingOptimization

E4 / E5n actuatorsn variants

EU6

Local PointsOptimization

E2 / E3Turbo / EGR

Best Point

FF

GlobalOptimization

E3 / E4Common Rail

Polynomial

Model

Models

Experiment Designs

Neural

Network

Semi-

Physical

Global DoE

Dynamic

Extraploration


Definitions - Model Accuracy Levels

Maturity Level Description Use Cases

Level 1 Only the main geometrical

data of the engine are used

as input for model set-up

• Concept study and decision

• ECU algorithm design

• Exhaust gas aftertreatment (EAS)

concept

Level 2 Measurement data is used

to make a refinement of the

model to increase accuracy.

• Pre-Calibration: the possible

calibration tasks depends on focus

of the model parameterization

• Used for specific calibration tasks

Level 3 Model is adapted to steady

state and transient data,

measured at AVL. Highest

accuracy which is needed

for model based calibration.

• Variant calibration support

• Ambient correction calibration

(altitude/hot/cold)

• EAS calibration strategy

• OBD calibration support

• Robustness investigations

• ECU algorithm verification

9


Concept / Layout

Start

of

Production

Endurance testing

Development ProcessConsequent usage of real-time system simulation

Model quality

AVL data base,

measurements of

single components

Component

and system

developmentCalibration / Validation

Data vehicle testing

Data engine test bed

Consequent usage of real-time system simulation


Model Based Development

Modelling Approach

Te

stb

ed

resu

lts

EAS System (DOC,

Semi-physical

Thermodynamic

NOx-Emission

EAS System (DOC, DPF, SCR, NLT)

Empirical

static global

HC, CO, Soot, SPL,…

Cameo M&M

Empirical

static global

HC, CO, Soot, SPL,…

Cameo M&M

DoE

Measurements

Puma / Cameo T&M

DoE

Measurements

Puma / Cameo T&M

Combined-model

Increased number of engine specific outputs

Combined-model

Increased number of engine specific outputs

HiL

Setup

HiL

Setup

MiL

Setup

fOXCal

MiL

Setup

fOXCal

Base

engine testbed

development

Puma / Cameo T&M

Base

engine testbed

development

Puma / Cameo T&M

Base

engine testbed

development

Puma / Cameo T&M

Emission validationEmission validation

Environmental validationEnvironmental validation

Modelrefinement

Pre

-ca

libra

tio

n

Do

E T

est R

esu

lts

Fie

ld d

ata

Robustness analysis

Pre

-ca

libra

tio

n

First engine

Run

Puma / Cameo T&M

First engine

Run

Puma / Cameo T&M

Basic

model setup

MoBEO

Basic

model setup

MoBEO

refined model

setup

MoBEO

Semi-physical

Basic Model without

measurement data

Virtual

RealPost-

ProcessingPost-

ProcessingAdvanced Test

AutomationAdvanced Test

AutomationExtension to the

Virtual EnvironmentsExtension to the

Virtual Environments

Model-based calibration of various variants

Variant specific hardware change(e.g. intake piping, …)(No combustion HW change)


MOBEOModel accuracy


en

gin

e t

orq

ue [

Nm

]

0

50

100

150

200

en

gin

e s

peed

[rp

m]

500

1100

1700

2300

2900

3500

extra urban

urban 1

0 50 100 150 200

time [s]

Tem

p.

us.

TC

[°C

]

0

150

300

450

600

NO

x [

g/h

]

0

10

20

30

40

50

60

CO

2 [

kg

/h]

0

20

40

60

urban 1

750 800 850 900 950 1000 1050 1100 1150 1200

time [s]

extra urban

NEDC

MOBEO – Model Based Development

ACCURACY IN DIFFERENT CYCLES


engin

e s

peed [rp

m]

500

1100

1700

2300

2900

3500

engin

e torq

ue [N

m]

0

50

100

150

200

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800time [s]

Tem

p. us. TC

[°C

]

0

150

300

450

600

NO

x [g/h

]

0

20

40

60

80

100

120

CO

2 [kg/h

]

0

20

40

60

WLTC






engin

e s

peed [rp

m]

500

1000

1500

2000

2500

3000

engin

e torq

ue [N

m]

0

50

100

150

200

0 400 800 1200 1600 2000 2400 2800 3200 3600time [s]

Tem

p. us T

C [°C

]

100

200

300

400

500

NO

x [g/h

]

0

10

20

30

40

50

60

CO

2 [kg/h

]

0

10

20

30

ARTEMIS gesamt


MOBEO - Model Based Development

Model Accuracy – Commercial Vehicle

Typical deviations of the cycle emissions and fuel consumption as well as achievable temperature accuracy:

• Fuel Consumption < 3%

• NOx Emission < 10%

• Insoluble Particulate Emission < 10%

• Temperature Intake Side < 10°C

• Temperature Exhaust Side < 20°C400 450 500 550 600 650 700 750 800

Time [s]

T.

Tu

rbin

e-I

nle

t [°

C]

300

350

400

450500

550

NO

x C

on

ce

ntr

ati

on

[p

pm

]

0

200400

600

800

1000

Op

ac

ity

[%

]

010

20

3040

50

En

gin

e S

pe

ed

[%

]

050

100

To

rqu

e [

%]

0

20

4060

80

100

Inta

ke

Air

Ma

ss

flo

w [

%]

0

20

4060

80

100

Measurement

Simulation


MOBEOApplication environment


HiL Setup

MiLSetup

Model in the Loop (MiL)

Advantages

+ Simulation faster than real time (app. 5 to 10 times faster)

+ No hardware parts needed

+ Simulation on normal PC possible

Disadvantages

- Availability of software ECU

- Often not all ECU functionalities available

Hardware in the Loop (HiL)

Advantages

+ All ECU functions available

+ Pre-Calibration of all ECU functions possible

+ Possibility of ECU software and dataset validation

Disadvantages

- Only real time simulation possible

- Need of hardware in the loop test bed

� Both environments can be used for pre-calibration of specific tasks

Changing Calibration Paradigm

The right application environment at the right time


PUMA TestbedWorkstation

CAMEO Workstation

HiL Host PC including, HiL Operator Software and

ECU Application Software

PUMACAMEO

HIL SW INCA

Operator Station,including 4 x 24inch Monitors

HiL Cabinet, including AVL Load-Drawer + HIL Base System (e.g. dSPACE, ETAS) with RTPC and I/O boards

WORK ENVIRONMENTS - XIL-STATION


Sil System integrating Mobeo

20

AVL Mobeo Engine Model

Transient Cycle fromthe Testbed


21

ECU Parameters

• _ : Engine model output• - - : Measurement



22

• -- : Engine model output• - - : Measurement

Reduction of the– Demand EGR

rate� Increase of

the NOx Emissions



23

• _ : Engine model output• - - : Measurement

Reduction of the ambientpressure (from 1000 to 700

mbar)� Increase of the exhaust

gas temperature



Generic Mobeo – SIL Environment

Import Model

Import Calibration Data

Run Simulation

Manual Changes Cycle Definition

Ambient ConditionsOutput Folder

Simulation results

5-10x real time!!


MOBEOUse Cases


Model Based Development Concept Investigations

Model based concept investigations

� Assessment of technology route

� Simulation of transient behaviour of engine in early concept phase on MiL

environment

� Definition of possible concepts considering the interaction between

� engine

� exhaust after-treatment system

� software and calibration

� Sensors and actuators

� environmental conditions

Vehicle & drivetrain simulation


MOBEO - Model Based DevelopmentUSE CASES

Powertrain Calibration tasks for MiL/HiL:

� RDE – Real Driving Emission evaluation

� EAS Simulation

� Calibration for non-standard ambient conditions

� Calibration of component protection

� In-Use Compliance - PEMS

� Sensitivity studies taking into account system interactions

� OBD – Diagnoses, IUPR

� Software and dataset validation

HW Testing & Calibration

Virtual Testing & Calibration

engine & EATS modeling


700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

Engine Speed [1/min]

Tem

p. u

pstr

.Tu

rbin

e [

°C]

0

200

400

600

800

Pre

ssu

re u

pstr

. T

urb

ine [

kP

a]

0

125

250

375

500

LP

TC

Sp

eed

[rp

m]

0

50000

100000

HP

TC

Sp

eed

[rp

m]

50000

75000

100000

125000

150000

Tem

p. d

s. C

om

pre

sso

r [°

C]

0

100

200

BM

EP

[kP

a]

800

1600

2400

Model Based DevelopmentCalibration of Ambient Corrections

Simulation of full load altitude operation for validation of ambient correction and engine protection functions

970mbar = 350m (Graz)750mbar = 2500m660mbar = 3500m540mbar = 5000m

Limits for component protection

Limit temperature upstream turbine

Limit temperature downstream compressor

Limit pressure upstream turbine

Limit LP turbochargerspeed

Limit HP turbochargerspeed

No derating up to 2500 m


700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

Engine Speed [1/min]

Tem

p. u

ps

tr.T

urb

ine [

°C]

0

200

400

600

800

Pre

ss

ure

up

str

. T

urb

ine [

kP

a]

0

125

250

375

500

LP

TC

Sp

eed

[rp

m]

0

50000

100000

HP

TC

Sp

eed

[rp

m]

50000

75000

100000

125000

150000

Tem

p. d

s. C

om

pre

sso

r [°

C]

0

100

200

BM

EP

[kP

a]

800

1600

2400

Model Based Development Calibration of Component Protection Functions

Simulation of engine failure at full load for validation of engine protection functions

Limit temperature upstream turbine

Limit temperature downstream compressor

Limit pressure upstream turbine

Limit LP turbochargerspeed

Limit HP turbochargerspeed

Limits for component protection


Calibration

Driving Cycle

Environment

Production Tolerances Aging Effects

Borders of applicability for HiL test bed

� Final Calibration Validation

� Certification

� Durability testing

� Pre-calibration of Start and Cold Start

� Idle stability

� Missfire

Model Based Calibration on XiL - test beds Virtual Test Beds as Extension of Real Test Facilities


Changing Calibration Paradigm:Innovative ways to increase xCU calibration quality

AVL model based

development

methodology is the

consequent usage

of real-time

system simulation

from concept to

SOP on suitable

development

environments with

smart calibration

tools

32P.GNANAM | PTE | 25 Feb 2015 |

AVL LIST GMBHYour Independent Engineering Partner

Thank you for your attention

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MoBEO: Model based Engine Development and Calibration · 2016-09-28 · MoBEO: Model based Engine...

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