GM POWERTRAIN EUROPE ENGINEERING CENTERPowertrain Electronic Control Units: development, models,

analysis and tests according to General Motors

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WHO I AMAlessandra Neri Hardware Electrical Architecture Development EngineerControl System - Analysis & SimulationGeneral Motors Powertrain - Europe S.r.l.Corso Castelfidardo 36 - 10129 Turin - Italyalessandra.neri@gm.com

Education:Politecnico di Torino:

Professional Engineering Qualification PHD – Metrology – Electronic Measurement Electronic Engineering - Mater Degree and First Level Degree

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GENERAL MOTORS VISION: DESIGN, BUILD AND SELL THE WORLD’S BEST VEHICLES

BAOJUNSAIC WU LING

HOLDEN

FIRST AUTOMOTIVE WORKS

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GM POWERTRAIN 2005-2015 GMPT-E Torino 10 years-old Total Site People: 606 Average age 37 (20% under 30) 16% are women 60 new engineers in 2015 Still growing…

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GMPT-E ITALY ACTIVITIES

Diesel Engine EngineeringDiesel Engine design and Simulation / AnalysisDiesel Engine Validation and TestingDiesel Technologies Development (Injection,. Charging,

Combustion, Aftertreatment

Controls EngineeringDiesel Control (HW&SW)Diesel Function and AlgorithmsDiesel Subsystem definition and EMS development

Diesel Hybrid EngineeringDiesel Engine system configuration, modelling & optimizationDiesel Hybrid verification

GLOBAL RESP IN TORINO

GLOBAL RESP IN TORINO

GLOBAL RESP IN TORINO

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GMPT-E ITALY FIGURES

€30 million initial Investment 704 office places 19 Test Cells

6 Laboratories 4 Workshops 1 Chassis Dyno

50% of IP developed by GM Powertrain in Europe comes from Torino

€27 million new investment (2011-2015)

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GMPT-E ITALY DIESEL PORTFOLIO

Controller D1Plus:

2.0L CDTI

2.2L CDTI 1.3L CDTI

1.6L CDTI

Opel CorsaOpel Antara

Opel Zafira Opel Insignia

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GMPT-E ITALY DIESEL PORTFOLIO

Controller D1Plus:

2.5-2.8L 2.0L

1.0L 1.3L

Chevrolet Cruze

Chevrolet SailChevrolet Beat

Chevrolet Colorado

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ENGINE CONTROL SYSTEM DEVELOPMENT

Control System Architecture

Requirement Definition

Algorithm and Software

DesignHW and SW

testControl System

Validation

Controller D1P

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DIESEL CONTROLS DEVELOPMENT

Our Teams

Electronic EngineeringElectrical architecture and interfacerequirements Worst case and variation analysisController hardware engineeringTarget software build

Control system tools and testingHIL set up Tools developmentTest automationsHIL testing

Algorithm and softwareModel based approachAdvanced signal processing and robust controlRapid prototypingAutomatic code generation

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EURO5 TYPICAL ARCHITECTURE

11

24

1012

13

15

16

17

1819

20

2123

2526

3 32

33

9

2

1

5 6

4

22

to the vehicle

7 8

14

29

28

30

31

34

27

35

36

1. Tank2. Electric Fuel-feeding Pump3. Fuel Filter Assembly4. Damper Volume5. High Pressure Pump6. Fuel metering Valve7. Rail8. Rail Pressure Sensor9. Solenoid Injectors10. Air Filter11. Air Flow Meter (+Air Temperature Sensor)12. Compressor13. Intercooler14. Electronic Throttle Body15. Electronic EGR Valve16. EGR Cooler with pneumatic on/off by-pass valve 17. Intake Manifold Pressure + Temperature Sensor18. Crankshaft Position Sensor19. Camshaft Position Sensor20. Coolant Temperature Sensor21. Oil Minimum pressure switch 22. Oil Level Sensor switch23. Metallic/Ceramic Low Voltage Glow Plugs 24. Variable Geometry Turbine25. VGT Vacuum Modulator26. VGT position feedback27. Lambda Sensor28. Main Cat29. Diesel Particulate Filter30. Temperature Sensor31. DPF Relative to Ambient Pressure Sensor32. Pedal Assembly33. ECU34. Electronic Variable swirl actuator35. Temperature Sensor36. Pre Cat

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WHAT IS AN ECU?

HWIO Application Software

HWIO Software Interfaces

Application Software

Microcontroller

OS ServicesOSEK

DeviceDrivers

CommunicationDrivers

Embedded Real Time System

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ECU BLOCK DIAGRAM

PRIMARY MICRO

SECONDARYMICRO

ANALOGINPUTS ADC

POWERSUPPLY

HS/LSDRIVERS

BARO

INJBANKS

COMPLEXOUTPUTS

HBRIDGES

COMM

SENSORS

BATTERY

DISCRETEINPUTS

RELAYSACTUATORS

DCMOTORS

FUELINJECTORS

INJHEATERS

GPIO

PULSE/FREQINPUTS EMIOS

ETPU

CORE

ADC TEST

SYS VOLT

SENSORS

SWITCHES

COMM

SPI comm

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ECU SYSTEM VOLTAGE/TEMPERATURE RANGES

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Q&A