Engine Calibration - General

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Engine Calibration - General

  1. 1. Generating Optimal Engine Calibrations Using Model-Based Calibration Toolbox hWorks, Inc. © 2009 The Math
  2. 2. Topics  Green Economy Marketplace Drivers  Response to Marketplace Drivers  Model-Based Calibration Process Overview  Example CI and SI Engine Calibration Problems hWorks, Inc.  Customer Application Examples © 2009 The Math  Live Demonstration of Optimal CI Engine Calibration 2
  3. 3. Marketplace Drivers The Green Economy Dictates Stringent Performance, Emissions, and Fuel Economy Requirements:  Engineers R E i Respond b Addi M d by Adding Many E i A t t Engine Actuators hWorks, Inc.  Engineering Resources are Scarce and Expensive © 2009 The Math 3
  4. 4. Response to Marketplace Drivers The Green Economy Dictates Stringent Performance, Emissions, and Fuel Economy Requirements:  Engineers R E i Respond b Addi M d by Adding Many E i A t t Engine Actuators  Increased Understanding via Accurate Statistical Models  Make Numerical Calibration Optimization Accessible p hWorks, Inc.  Engineering Resources are Scarce and Expensive © 2009 The Math  Design of Experiments Tools To Reduce Testing  Off-Shelf Software, Promoting Core Business Focus  Facilitate Systematic Repeatable Process Systematic, 4
  5. 5. Model Based Model-Based Calibration Process Overview hWorks, Inc. © 2009 The Math 5
  6. 6. Example CI Engine Calibration Problem  Test Configuration hWorks, Inc. © 2009 The Math 6
  7. 7. Example CI Engine Calibration Problem  Optimization Problem Setup hWorks, Inc. © 2009 The Math 7
  8. 8. Example CI Engine Calibration Problem  Optimal Calibration Results MAIN SOI Table MAIN Fuel Table F l T bl EGR M Mass F ti T bl Fraction Table hWorks, Inc. © 2009 The Math Fuel Pressure Table VGT Rack Position Table 8
  9. 9. Example SI Engine Calibration Problem  Test Configuration hWorks, Inc. © 2009 The Math 9
  10. 10. Example SI Engine Calibration Problem  Optimization Problem Setup: Stoich. Region hWorks, Inc. © 2009 The Math 10
  11. 11. Example SI Engine Calibration Problem  Optimal Calibration Results hWorks, Inc. © 2009 The Math 11
  12. 12. Customer Application Examples: Ford Key Point:  Process to develop optimal multi-inject diesel calibration using Model-Based Calibration hWorks, Inc. © 2009 The Math From: “Using Model-Based Calibration Toolbox Multimodels for Cycle-Optimized Diesel Calibration Calibration”, MathWorks Automotive Conference 2008 Joshua Styron Ford Motor 2008, Styron, Company 12
  13. 13. Customer Application Examples: Toyota Key Points:  Full-Factorial Testing No Longer Feasible for optimal results  Model-Based hWorks, Inc. Calibration Process Required and © 2009 The Math Developed From: “Steady-State Engine Modeling for Calibration: A Productivity and Quality Study Study”, MathWorks Automotive Conference 2007 Toyota/A&D/IAV 2007, 13
  14. 14. Customer Application Examples: John Deere pp p hWorks, Inc. © 2009 The Math “Analytical Engine Calibration at JohnDeere” Jason Schneider, John Deere Power Sys. 2007 SAE Commercial Vehicle Eng Conf. Panel on Analytical Calibration 14
  15. 15. Customer Application E C t A li ti Examples: GM H ld l Holden Key Points:  Significant reduction in g test points compared with ‘one parameter at a time’ or factorial test methods hWorks, Inc.  Model re-use: MBC models are engine test- test © 2009 The Math bed simulator From: “Cold Engine Emissions Optimization Using Model Based Calibration”, MathWorks Automotive Conference 2007, Dr. Clive Tindle, GM Holden 15
  16. 16. Customer Application Examples: Literature pp p  Model-Based Calibration Toolbox http://www.mathworks.com/products/mbc  MathWorks Automotive Conference Papers  Ford: http://www.mathworks.com/industries/auto/macde2008  Toyota / GM Holden: http://www mathworks com/industries/auto/mac2007 http://www.mathworks.com/industries/auto/mac2007  Model-Based Calibration Toolbox Related SAE Papers and Presentations http://www.mathworks.com/industries/auto/technicalliterature.html http://www mathworks com/industries/auto/technicalliterature html SAE COMVEC Panel on Analytical Calibration hWorks, Inc.   SAE 2008-01-1366: “A Model Based Calibration Process for Robust Optimal Cam Position Selection Under all Engine Operating Conditions” – GM Holden © 2009 The Math  SAE 2009-01-0246: “Objective Determination of Minimum Engine Mapping Requirements for Optimal SI DIVCP Engine Calibration” – The MathWorks, Inc.  SAE 2005-01-3833: Improving Base Engine Calibrations for Diesel Vehicles through the use of DoE and Optimization Techniques – Mahle Powertrain 16
  17. 17. Contact Info Pete Maloney The MathWorks Consulting Novi, Novi Michigan USA hWorks, Inc. 248-596-7928 pmaloney@mathworks.com pmaloney@mathworks com © 2009 The Math 17
  18. 18. Live Demonstration Optimal CI Engine Calibration Development hWorks, Inc. © 2009 The Math 18
  19. 19. Set U T t Pl S t Up Test-Plan hWorks, Inc. © 2009 The Math 19
  20. 20. Design Experiment for Each Torque/Speed Mode hWorks, Inc. © 2009 The Math •Script or GUI 20
  21. 21. Export Experiment to .CSV or Direct to Dyno CSV hWorks, Inc. © 2009 The Math 21
  22. 22. Import and Review Dyno Data From .XLS or Direct hWorks, Inc. © 2009 The Math 22
  23. 23. Set Up Local Model to Hybrid RBF for Each Mode Point hWorks, Inc. © 2009 The Math 23
  24. 24. Fit Hybrid RBF Models at Each Mode Operating Point hWorks, Inc. © 2009 The Math 24
  25. 25. Remove Outliers, Review Fits by Model and Mode hWorks, Inc. © 2009 The Math •View Mode Operating Points 25
  26. 26. Make Boundary Models By Mode Operating Point y y p g hWorks, Inc. © 2009 The Math *Key Differentiating Product Feature 26
  27. 27. Visually Review Models For Overfitting hWorks, Inc. © 2009 The Math 27
  28. 28. Export Models To MATLAB and SimuLink for Other Users hWorks, Inc. © 2009 The Math *Key Differentiating Product Feature – Re-Use 28
  29. 29. Models C M d l Complete l t hWorks, Inc. © 2009 The Math 29
  30. 30. Auto Export Auto-Export Models to CAGE Optimization Tool hWorks, Inc. © 2009 The Math •Starting-Point Optimization Setup and Tables 30
  31. 31. Add Constraints to Optimization Setup hWorks, Inc. © 2009 The Math 31
  32. 32. Run Optimization by Mode and Review Results hWorks, Inc. © 2009 The Math 32
  33. 33. Set Up Cycle Weighted Optimization and Intialize From Cycle-Weighted Earlier Mode-point Optimization hWorks, Inc. © 2009 The Math 33
  34. 34. Run Cycle Weighted Optimization and Review Results Cycle-Weighted hWorks, Inc. © 2009 The Math 34
  35. 35. Fill Calibration Tables With Optimal Results hWorks, Inc. © 2009 The Math 35
  36. 36. Export Calibration Tables to INCA .dcm hWorks, Inc. © 2009 The Math 36

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