The document discusses model-based calibration using MathWorks' Model-Based Calibration Toolbox software. It provides an overview of the model-based calibration process and examples of using it to optimize calibrations for diesel and gasoline engines. Customer examples are presented from companies like Ford, Toyota, John Deere, and GM Holden that demonstrate reducing testing needs and developing optimal engine maps.

1. Generating Optimal Engine Calibrations Using
Model-Based Calibration Toolbox
hWorks, Inc.
© 2009 The Math

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
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 Live Demonstration of Optimal CI Engine Calibration
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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
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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
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 Design of Experiments Tools To Reduce Testing
 Off-Shelf Software, Promoting Core Business Focus
 Facilitate Systematic Repeatable Process
Systematic,
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5. Model Based
Model-Based Calibration Process Overview
hWorks, Inc.
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6. Example CI Engine Calibration Problem
 Test Configuration
hWorks, Inc.
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7. Example CI Engine Calibration Problem
 Optimization Problem Setup
hWorks, Inc.
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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.
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Fuel Pressure Table VGT Rack Position Table
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9. Example SI Engine Calibration Problem
 Test Configuration
hWorks, Inc.
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10. Example SI Engine Calibration Problem
 Optimization Problem Setup: Stoich. Region
hWorks, Inc.
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11. Example SI Engine Calibration Problem
 Optimal Calibration Results
hWorks, Inc.
© 2009 The Math
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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
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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,
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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
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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
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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
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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
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18. Live Demonstration
Optimal CI Engine Calibration Development
hWorks, Inc.
© 2009 The Math
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19. Set U T t Pl
S t Up Test-Plan
hWorks, Inc.
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20. Design Experiment for Each Torque/Speed Mode
hWorks, Inc.
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•Script or GUI
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21. Export Experiment to .CSV or Direct to Dyno
CSV
hWorks, Inc.
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22. Import and Review Dyno Data From .XLS or Direct
hWorks, Inc.
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23. Set Up Local Model to Hybrid RBF for Each Mode
Point
hWorks, Inc.
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24. Fit Hybrid RBF Models at Each Mode Operating Point
hWorks, Inc.
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25. Remove Outliers, Review Fits by Model and Mode
hWorks, Inc.
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•View Mode Operating Points
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26. Make Boundary Models By Mode Operating Point
y y p g
hWorks, Inc.
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*Key Differentiating Product Feature
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27. Visually Review Models For Overfitting
hWorks, Inc.
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28. Export Models To MATLAB and SimuLink for Other Users
hWorks, Inc.
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*Key Differentiating Product Feature – Re-Use
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29. Models C
M d l Complete
l t
hWorks, Inc.
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30. Auto Export
Auto-Export Models to CAGE Optimization Tool
hWorks, Inc.
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•Starting-Point Optimization Setup and Tables
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31. Add Constraints to Optimization Setup
hWorks, Inc.
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32. Run Optimization by Mode and Review Results
hWorks, Inc.
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33. Set Up Cycle Weighted Optimization and Intialize From
Cycle-Weighted
Earlier Mode-point Optimization
hWorks, Inc.
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34. Run Cycle Weighted Optimization and Review Results
Cycle-Weighted
hWorks, Inc.
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35. Fill Calibration Tables With Optimal Results
hWorks, Inc.
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36. Export Calibration Tables to INCA .dcm
hWorks, Inc.
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