avl virtual testbed · 2016. 12. 7. · test bed virtual test bed vehicle testing using avl...
TRANSCRIPT
Confidential
AVL List GmbH
Daniele Basile
AVL VIRTUAL TESTBED™
Calibrate beyond the limits
CONTENT
CALIBRATION EVOLUTION
CUSTOMER CHALLENGE
AVL VIRTUAL TESTBED SOLUTION
USE CASES
HIGHLIGHTS
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 3Confidential
Challenge HighlightsSituation SolutionVIRTUAL TESTBED
CALIBRATION EVOLUTIONIN THE LAST 20 YEARS
ECU Parameters TCU Electr./Non-powertrain
1
~500
1
1
>30
~50k
>3Electrification
Months Months
>2
~5k
>2
>6
Months
Speed
Load
201520051995
Speed
Load
>50
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 4Confidential
Challenge HighlightsSituation SolutionVIRTUAL TESTBED
CALIBRATION EVOLUTIONIN THE LAST 20 YEARS
Virtual Calibration
Manual Calibration
Model-based Calibration
Processes & Models
Methods
ECU Access/Standards
ECU Parameters TCU Electr./Non-powertrain
1
~500
1
1
>30
~50k
>3Electrification
>50
Months Months
>2
~5k
>2
>6
Months
Speed
Load
201520051995
Speed
Load
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 5Confidential
Challenge HighlightsSituation Solution
THE CHALLENGES IN POWERTRAIN CALIBRATION ARE WELL KNOWN
VIRTUAL TESTBED
We need to manage …
CO2fuel consumption
Increasing system complexity
(EAS, OBD, hybridization)
Real DrivingConditions
Increasingdevelopmentcosts
Broad vehicleportfolio
Shorterdevelopmenttimes
Ambient Conditions
Increasing facilityand vehiclemanagementcomplexity
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 6Confidential
Challenge HighlightsSituation Solution
ONE OF THE CHALLENGES IN COMMERCIAL ENGINE CALIBRATION
VIRTUAL TESTBED
Emission compliance under various ambient conditions
Stationary (WNTE, NTE) & Real driving emissions (ISC)
Fulfillment performance demands
Achieving these results in a non-standard engine testbed (limited, high costs)
Sea level
1640m
>2000m
25°C 38°C
Capability standard testbed
NTE window
“Footprint” vehicle fleet
-7°C
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 7Confidential
Challenge Highlights BenefitsSituation Solution
VIRTUAL TESTBED
Approach
VIRTUAL TESTBED
Empowerment of theVirtual Environments
for Calibration until SoPVIRTUAL TESTBED
Calibration
Potential additional effort as consequence of more
stringent Legislation
Actual effort: 100%
S tart o f P roduction
Development Environments
VehicleTest Bed
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 8Confidential
Challenge HighlightsSituation Solution
CALIBRATE BEYOND THE LIMITS
Real time capable, powerful and accurate models with CRUISE M/MoBEO
Identical environment as on real testbeds, well known by calibration engineers
Training, application and support from experienced AVL engineers
The complete Turn Key Solution for Calibration
AVL VIRTUAL TESTBED ™
VIRTUAL TESTBED
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 9Confidential
Challenge HighlightsSituation Solution
AVL VIRTUAL TESTBED is an
advanced hardware-in-the-loop test
bed extended with:
VIRTUAL TESTBED
VIRTUAL TESTBED
Advanced semi-physical
powertrain model
(CRUISE M with MoBEO add-
on, Customer specific models)
PUMA & CAMEO
test bed automation
delivering identical
interface for the
calibration engineer as
on real test bed
SANTORIN Host
server connection storing
simulation results in same
format as real test data
CONCERTO
post-processing using
same layouts & scripts for
data analyzing
CRETA
dataset management
to store and share
the DCM calibrated
on VTB
Application software
(INCA,…)
dSpace or ETAS
pre-configured HiL System
with AVL specified extensions
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 10Confidential
Challenge HighlightsSituation Solution
FLEXIBILITY ENABLES EFFICIENCY
VIRTUAL TESTBED
ECU ActuatorsSensors
Testbed Vehicle ValidationVirtual Testbed
(closed loop)
Calibration Environment
Production Tolerances
AgingEffects
Transient Profiles
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 11Confidential
Challenge HighlightsSituation Solution
AVL VIRTUAL TEST FIELD
VIRTUAL TESTBED
AVL Graz:
25 Engine Test Beds
3 Chassis Dyno
1 Powertrain Test Bed
1 Climatic Test Bed
Real Virtual
AVL Graz:
12 VIRTUAL TESTBEDS
Almost 30% of
Test Beds are
VIRTUAL
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 12Confidential
Challenge HighlightsSituation Solution
AVL VIRTUAL TEST FIELD
VIRTUAL TESTBED
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 13Confidential
Challenge HighlightsSituation Solution
AVL VIRTUAL TEST FIELD
VIRTUAL TESTBED
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 14Confidential
Challenge HighlightsSituation Solution
AVL VIRTUAL TEST FIELD
VIRTUAL TESTBED
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 15Confidential
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
MODEL BASED DEVELOPMENTUSE CASES
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 16Confidential
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
MODEL BASED DEVELOPMENTUSE CASES
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 17Confidential
Used DoE approach:- Run critical full load points under certain ambient conditions
- Variation of EGR parameters
- Variation of VGT parameters
- Variation of Throttle valve parameters
- Variation of fuel derate
Constraints and targets:- Lowest possible fuel derate
- Minimum Lambda
- Maximum Turbo speed
- Maximum T_21
- Maximum T_31
- Engine out NOx 100-85 kPa P_amb Same NOx level as sea level in order to full fill NTE
- Engine out NOx 80-70-60 kPa P_amb Increased/phased out NOx levels with the aim to have as less de-rate as possible within engine constraints.
Ambient pressure [kPa] Ambient Temperature [°C]
70 -15 – -5 – 5 – 15 – 25 – 35 – 45 °C
75 -15 – -5 – 5 – 15 – 25 – 35 – 45 °C
80 -15 – -5 – 5 – 15 – 25 – 35 – 45 °C
85 -15 – -5 – 5 – 15 – 25 – 35 – 45 °C
90 -15 – -5 – 5 – 15 – 25 – 35 – 45 °C
95 -15 – -5 – 5 – 15 – 25 – 35 – 45 °C
100 -15 – -5 – 5 – 15 – 35 – 45 °C
VTB USE-CASE ON-ROAD ~2L PER CYL.NON-STANDARD CALIBRATION APPROACH
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 18Confidential
VTB USE-CASE ON-ROAD ~2L PER CYL.DOE APPROACH WITH CAMEO IN ORDER TO FIND OPTIMUM SETTINGS AT EACH AMBIENT CONDITION
Example of CAMEO output at 1500 rpm, and 70 kPa P_amb
P3/P2 demand correction Engine out Nox correction Fuel derate Throttle valve correction
La
mb
da
Tu
rbo
sp
eed
NO
xB
SF
CTo
rqu
e
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 19Confidential
VTB USE-CASE ON-ROAD ~2L PER CYL.ALTITUDE CALIBRATION 75 KPA – 25°C
750
850
950
1050
1150
1250
1350
1450
1550
1650
1750
1850
1950
2050
2150
Engine Speed [1/min]
Pe
ak F
irin
g P
ressu
reP
_M
X [
ba
r]
50
100
150
200
250
P_MX
Exce
ss A
ir R
atio
LA
V
1.0
1.2
1.4
1.6
1.8
2.0
2.2
LAV
Pre
tu
rbin
e te
mp
era
ture
T_
31
400
500
600
700
T_31
Tu
rbin
e s
pe
ed
[krp
m]
N_
TU
RB
_0
1 [
krp
m]
80
90
100
110
120
130
140
100 kPa; 25 degC; 55% HR_IA
75 kPa; 25 degC; 55% HR_IA - DAF calibration75 kPa; 25 degC; 55% HR_IA - AVL calibration
750
850
950
1050
1150
1250
1350
1450
1550
1650
1750
1850
1950
2050
2150
Engine Speed [1/min]
En
gin
e T
orq
ue
MD
[N
m]
800
1000
1200
1400
1600
1800
2000
2200
2400
MD
Fu
el C
on
su
mp
tio
nB
SF
C [
g/k
Wh
]
176
184
192
200
208
216
224
BSFC
Co
rr. N
Ox E
ng
ine
Ou
tB
S_
NO
x_
EO
[g
/kW
h]
0
2
4
6
8
10
BS_NOX_EO
100 kPa; 25 degC; 55% HR_IA
75 kPa; 25 degC; 55% HR_IA - DAF calibration75 kPa; 25 degC; 55% HR_IA - AVL calibration
- 100 kPa/25degC Iso conditions
- 75 kPa/25degC Customer calibration
- 75 kPa/25degC AVL calibration MoBEO/HIL/CAMEO
Torque increase by
optimization
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 20Confidential
VTB USE-CASE ON-ROAD ~2L PER CYL.BENEFIT VIRTUAL TESTING
Test space taking in
account real engine
limits
Test space exceeding
real engine limits
Real engine limits are exceeded and hence the optimum can be found within the
test space
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 21Confidential
MODEL BASED CALIBRATION APPROACH
Virtual Calibration Approach:
Calibration on VTB instead of Test Bed
80% Test Bed Time Saved for this use case
Time saved per mode: X engine modes, X variants
Test Bed available for Frontloading Tasks
Dataset Quality & Maturity increased in earlier phase of Development
Example based on customer feedback:
NTE, Engine Protection and Ambient Corrections (1 Engine Mode)
Climatic Test Bed Time in Hours
Conventional Approach
Model Based Approach
100 150 10
40
200
Calibration Validation Available testbed time for additional calibration tasks
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 22Confidential
MODEL BASED DEVELOPMENTUSE CASES
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 23Confidential
MODEL BASED DEVELOPMENT IN-USE TESTING
In-use compliance/conformity and not to exceed area
• Calibration of not to exceed area for non standard ambient conditions
• Model based pre-calibration of ambient correction functions to fulfil in-use compliance
• Validation of calibration using portable emission measurement systems (PEMS) on the vehicle
Test bed Virtual test bed Vehicle testing using AVL M.O.V.E
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 24Confidential
MODEL BASED DEVELOPMENT IN-USE TESTING
reference Work kWh 18.90 Valid Windows No. - 40219.00
EU Power Threshold % 20.00 Valid Windows Perc % 94.59
min Power % 20.01 Data Coverage No. - 42884.00
max Power % 99.35 Data Coverage Perc % 99.96
Conformity Factor 1.50
ave BS CO g/kWh 0.00
min BS CO g/kWh 0.00
max BS CO g/kWh 0.00
90%Perc BS CO g/kWh 0.00
Conformity Factor CO - 0.00
ave BS NOx g/kWh 0.65
min BS NOx g/kWh 0.27
max BS NOx g/kWh 14.77
90%Perc BS NOx g/kWh 0.92
Conformity Factor NOx - 2.29
ave BS THC g/kWh 0.00
min BS THC g/kWh 0.00
max BS THC g/kWh 0.00
90%Perc BS THC g/kWh 0.00
Conformity Factor THC - *
ave BS HC+NOx g/kWh 0.65
min BS HC+NOx g/kWh 0.27
max BS HC+NOx g/kWh 14.77
90%Perc BS HC+NOx g/kWh 0.92
Conformity Factor HC+NOx - *
ave BS NMHC g/kWh 0.00
min BS NMHC g/kWh 0.00
max BS NMHC g/kWh 0.00
90%Perc BS NMHC g/kWh 0.00
Conformity Factor NMHC - 0.00
ave BS PM g/kWh 0.01
min BS PM g/kWh 0.01
max BS PM g/kWh 0.02
90%Perc BS PM g/kWh 0.01
Conformity Factor PM - 0.38
ave BS Soot g/kWh 0.01
min BS Soot g/kWh 0.01
max BS Soot g/kWh 0.02
90%Perc BS Soot g/kWh 0.01
ave BS Soot Meas g/kWh 0.01
min BS Soot Meas g/kWh 0.01
max BS Soot Meas g/kWh 0.02
90%Perc BS Soot Meas g/kWh 0.01
ave BS CH4 g/kWh 0.00
min BS CH4 g/kWh 0.00
max BS CH4 g/kWh 0.00
90%Perc BS CH4 g/kWh 0.00
ave BS CO2 g/kWh 730.50
min BS CO2 g/kWh 705.14
max BS CO2 g/kWh 939.95
90%Perc BS CO2 g/kWh 756.68
Case: PEMS_HD 'PEMS HD'
Start Date: 05/16/2012
Start Time: 00:00:00.0Page: Work Window
Version: v4_3_50
AVL PEMS Postprocessor, 2011
PEMS Current Case: d:\AVL Concerto\WorkEnvironments\PEMS_v4_3_50\PEMS\PEMS_HD.pms_c
PEMS Result Filename: d:\AVL Concerto Pems\4.4\..\MyData\TransportFiles\PEMS_HD.ctf
Input Filename: undefined (single case calculation)
Lug Curve Filename: undefined (single case calculation)
Vehicle: /
Engine: HD / Tier4f
NOx Correction: 8 - NONE
Humidity Correction: 1 - ISO16183 [Default]
PEMS analysis according to EU legislation
PEMS analysis according to US legislation
Post-processing according to
legislative requirements -
Independent if virtual or real testing
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 25Confidential
MODEL BASED DEVELOPMENTUSE CASES
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 26Confidential
Lead App Light Lead App Lead App
Light Light Light
Light
Lead App
Lead App
Lead App
Lead App
Lead App
Light Light
AVL MULTI-VARIANT CALIBRATION APPROACH
Engine Families
…
Applied Power
210 kW190 kW180 kW
170 kW160 kW150 kW
140 kW125 kW110 kW
130 kW120 kW110 kW
100 kW90 kW80 kW
80 kW70 kW60 kW
…
EAS
…
Product Requirements (Engine Specification, EAS Piping, etc.)
…
Ma
chin
es
Machines Group 1
Engine Variant
140 kW
170 kW
210 kW
80 kW
100 kW
130 kW
…
Certification
Certification
Certification
Certification
Certification
Certification
1 base app per engine variant(each HW or Full load curve change)
LE
GIS
LA
TIO
N (N
RT
C, e
tc.)
critical critical critical
Machines Group 2 Machines Group 3
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 28Confidential
Volume
Element
Flow
Element
Intake Manifold
Cylinders
CAC
TC
C TCleaner
EAS, Piping
Exhaust Manifold
MODEL BASED DEVELOPMENTVARIANT CALIBRATION – EASY ADAPTATION OF MODEL
Change of CAC & EGR cooler efficiency
as well as pressure drop within 1 day possible
Change of Air Filter & EAS
pressure drop within a ½ day
Change of EAS Volume
within a ½ day
Change of connecting pipe
easy possible within 1 day
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 29Confidential
MODEL BASED DEVELOPMENTUSE CASES
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 30Confidential
VTB USE-CASE ON-ROAD ~2L PER CYL.OPTIMIZATION OF THERMAL MANAGEMENT
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
N_Matrix [1/min]
Haeu
fig
keit
_Z
yklu
s_A
SC
II_M
ari
jn#M
d_M
atr
ix [
mg
/str
]
-400
-200
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
0.50.5 0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.50.5
0.5
0.75
0.7
5
0.75
0.75
0.7
5
0.75
0.75
0.75
0.75
0.750.75
0.7
5
11
1
1
1
1
1
1.25
1.25
1.25
1.25
1.2
51.
25
1.5 1.5
1.5
1.5
1.5
1.51.7
5
2
0.25
0.25
0.25
0.25
0.25
0.2
5
0.25
0.25
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.75
0.7
5
0.75
0.75
0.75
0.75
0.75
1 1
1
1
1
1.2
5
1.2
5
1.25
1.25
1.2
51.2
51.5
1.5
1.51.7
5
2
0
0.25
0.5
0.75
1
1.25
1.5
1.75
2
2.25
2.5
2.75
3
3.25
3.5
74122 10730 calibration.355_FTP_1.txt
DoE load point definition out of load point occurrence in HDDTC
Engine speed
[rpm]
Torque
[Nm]
T_water
[°C]
900 400 30, 50, 70
1100 1700 30, 50, 70
1300 1000, 1600 30, 50, 70
1500 1000, 1700 30, 50, 70
1550 700 30, 50, 70
To
rqu
e [N
m]
Engine speed [rpm]
Occu
rre
nce
[%
]
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 31Confidential
VTB USE-CASE ON-ROAD ~2L PER CYL.OPTIMIZATION OF THERMAL MANAGEMENT
Impact DoE variations at 50°C coolant temperature – 1500 rpm – 1700 Nm
P3/P2 demand correction Engine out Nox correctionTiming Throttle valve correction
T_
51
MF
_E
XH
LA
VB
SF
CE
ngin
e o
ut
NO
xE
nth
alp
y
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 32Confidential
VTB USE-CASE ON-ROAD ~2L PER CYL.VERIFICATION OF THERMAL MANAGEMENT
0 100 200 300 400 500 600 700 800 900 1000 1100 1200Zeit [s]
Engin
e S
peed
n [
rpm
]
0
800
1600
2400
Engin
e T
orq
ue
md
[N
m]
-2000
0
2000
T_31
T_
31
[°C
]
0
150
300
450
600
750
T_51
T_
51
[°C
]
0
100
200
300
400
500
T_coola
nt
T_
co
ola
nt
[°C
]
0
30
60
90
74122 10730 calibration.7598110730.150 ProjSpecREC_10Hz_1[1]
10730.166 ProjSpecREC_10Hz_1[1]
10730.171 ProjSpecREC_10Hz_1[1]
DAF FTPAVL HiL FTP
AVL HiL FTP AA opti
AVL HiL FTP BPV opti
- HDDTC testbench
- HDDTC MoBEO/HIL
- HDDTC MoBEO/HIL enthalpy optimization 1
- HDDTC MoBEO/HIL enthalpy optimization 2
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 33Confidential
VTB USE-CASE ON-ROAD ~2L PER CYL.OPTIMIZATION OF THERMAL MANAGEMENT
100 200 300 400 500 600 700 800 900 1000 1100 1200Zeit [s]
Engin
e S
peed
n [
rpm
]
-1000
0
1000
2000
Engin
e T
orq
ue
md
[N
m]
-3000
0
3000
Enth
alp
y inte
gra
ted
Int
en
th e
xh
DA
F
-40
0
40
80
120
160
200
T_coola
nt
T_
co
ola
nt
[°C
]
20
40
60
80
100
Enth
alp
yE
nth
DA
F r
ec [
g/s
]
-200
0
200
400
600
800
74122 10730 calibration.7598110730.150 ProjSpecREC_10Hz_1[1]
10730.166 ProjSpecREC_10Hz_1[1]10730.171 ProjSpecREC_10Hz_1[1]
DAF FTPAVL HiL FTP
AVL HiL FTP AA optiAVL HiL FTP BPV opti
- HDDTC testbench
- HDDTC MoBEO/HIL
- HDDTC MoBEO/HIL enthalpy optimization 1
- HDDTC MoBEO/HIL enthalpy optimization 2
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 34Confidential
MODEL BASED DEVELOPMENTUSE CASES
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 35Confidential
Use-case: Robustness investigation of a emission threshold monitor
Robustness investigation shall be considered for the following variations
Cartesian product of the specification limits yields the experimental space (𝐸𝑆)
Find areas of the hyper sphere with high probability of fault code activation
Considered Variations Specifications Limits
Ageing Factor [km] 0 100000 200000
EGR Fouling [dp_delta@ …L/min] 𝟎 2 4
Ambient Temperature [°C] [−20,+40] [−20, +40] [−20,+40]
Ambient Pressure [kPa] [+60,+100] [+60, +100] [+60, +100]
Ta_aCAC [°C] [−20,+60] [−20, +60] [−20,+60]
NOx Sensor Deviation [%] [−5,+5] [−10, +10] [−10,+10]
Fuelling [mg/str] [−5,+5] [−5, +5] [−5,+5]
Turbine Efficiency [%] [−2, +2] [−2,+2] [−2, +2]
EGR Restriction [mm] hole after valve [18,20] [18,20] [18,20]
ROBUSTNESS INVESTIGATIONCONSIDERED VARIATIONS
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 36Confidential
ROBUSTNESS INVESTIGATIONMETHODOLOGY
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 39Confidential
ROBUSTNESS INVESTIGATIONPHASE 4: OUTCOME STATISTICAL DATA ANALYSIS
0.2 0.2 0.2 0.2 0.2 0.1 0 0 0 0
0.2 0.2 0.2 0.2 0.2 0.1 0 0 0 0
0.2 0.2 0.2 0.2 0.2 0.1 0 0 0 0
0.2 0.2 0.2 0.2 0.2 0.1 0 0 0 0
0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.1 0.1 0.1
0.5 0.5 0.5 0.5 0.5 0.2 0.2 0.2 0.2 0.2
0.5 0.5 0.5 0.5 0.5 0.2 0.2 0.2 0.2 0.2
0.7 0.7 0.7 0.5 0.5 0.2 0.2 0.2 0.2 0.2
0.7 0.7 0.7 0.5 0.5 0.2 0.2 0.2 0.2 0.2
0.7 0.7 0.7 0.5 0.5 0.2 0.2 0.2 0.2 0.2
Var 1
Var 2
0
0-1
1
1-1
0= no failure activation
1= guarantied failure activation
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 40Confidential
MODEL BASED DEVELOPMENTUSE CASES
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 41Confidential
MODEL BASED EAS OBD CALIBRATIONSCR EFFICIENCY
SCOPE OF WORK
Determine worst case in terms of SCR efficiency among two power variantson a FTP* cycle.
METHODOLOGY
Degradation of NOx conversion efficiency is modelled via a „SCR performance factor“ applied within CruiseM/Mobeo EAS model.
Correlation between „SCR performance factor“ and SCR coating content is checked and validated
For each power rating, aforementioned „SCR performance factor“ is then varied via automated CAMEO test sequences.
* Federal Test Procedure – US Heavy Duty Diesel Transient Cycle
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 42Confidential
MODEL BASED EAS OBD CALIBRATIONSCR EFFICIENCY
EMISSIONS FTP COLD/WARM
10 20 30 40 50 60 70 80 90 100 110SCR Performance Factor
Estim
ate
d a
vera
ge N
Ox c
onvers
ion e
ffic
iency
1 -
(N
Ox T
P /
NO
x E
O)
[%]
0,40
0,45
0,50
0,55
0,60
0,65
0,70
0,75
0,80
0,85
0,90
0,95
1,00
CETO-20160428-DAF_MX13LR-340kW_AVL_FTP-DEMO_FTP_ID66_SCREff_100-20_6_Bla.ctfCETO-20160428-DAF_MX13LR-303kW_AVL_FTP-DEMO_FTP_ID66_SCREff_100-30_4_Bla.ctf
10 20 30 40 50 60 70 80 90 100 110SCR Performance Factor
COLD WARM
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 43Confidential
MODEL BASED EAS OBD CALIBRATIONSCR EFFICIENCY
EMISSIONS FTP COLD/WARM
10 20 30 40 50 60 70 80 90 100 110SCR Performance Factor
NO
x T
P c
ycle
results
[g/k
Wh]
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
Emission Threshold
OBD Threshold
CETO-20160428-DAF_MX13LR-340kW_AVL_FTP-DEMO_FTP_ID66_SCREff_100-20_6_Bla.ctfCETO-20160428-DAF_MX13LR-303kW_AVL_FTP-DEMO_FTP_ID66_SCREff_100-30_4_Bla.ctf
10 20 30 40 50 60 70 80 90 100 110SCR Performance Factor
Emission Threshold
OBD Threshold
10 20 30 40 50 60 70 80 90 100 110SCR Performance Factor
Emission Threshold
OBD Threshold
COLD WARM WEIGHTED
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 44Confidential
MODEL BASED EAS OBD CALIBRATIONEGR LOW FLOW
SCOPE OF WORK
Determine emission impact caused by an EGR Low Flow.
RMC* has been selected as relevant emission cycle.
METHODOLOGY
RMC Preconditioning Cycle with EGR Orifice = 51.8mm (initial)
RMC Cycle with changed EGR Orifice: 51.8 mm to 22 mm
The EGR Orifice is then varied via automated CAMEO test sequences
*Ramped Mode Cycle – US Heavy Duty Stationary Cycle
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 45Confidential
MODEL BASED EAS OBD CALIBRATIONEGR LOW FLOW
EMISSIONS RMC
21 24 27 30 33 36 39 42 45 48 51 54
EGR Orifice
NO
x E
O c
ycle
resu
lts [g
/kW
h]
4.8
5.6
6.4
7.2
8.0
8.8
9.6
10.4
11.2
12.0
12.8
13.6
14.4
CETO_EGR_LF_orifice_Dia_51.8_22mm.ctf
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
EGR Orifice
NO
x T
P c
ycle
re
sults
[g/k
Wh
]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
Emission Threshold
OBD Threshold
CETO_EGR_LF_orifice_Dia_51.8_22mm.ctf
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 46Confidential
MODEL BASED EAS OBD CALIBRATIONEGR LOW FLOW
EMISSIONS RMC
21 24 27 30 33 36 39 42 45 48 51 54
EGR Orifice
Cyc
le w
ork
[kW
h]
87
90
93
96
99
102
105
108
111
114
117
120
123
CETO_EGR_LF_orifice_Dia_51.8_22mm.ctf
21 24 27 30 33 36 39 42 45 48 51 54
EGR Orifice
BS
FC
[g
/kW
h]
188.8
189.2
189.6
190.0
190.4
190.8
191.2
191.6
192.0
192.4
192.8
193.2
193.6
CETO_EGR_LF_orifice_Dia_51.8_22mm.ctf
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 47Confidential
MODEL BASED DEVELOPMENTUSE CASES
Calibration
Driving Cycle
Environment
Production Tolerances Aging Effects
Powertrain calibration tasks used cases for HiL
Pre-calibration of different calibration work packages:
Calibration for non-standard ambient conditions
Calibration of component protection
In-Use Compliance - PEMS
Vehicle/Engine derivate calibration
Real world fluid consumption optimization
Sensitivity/Robustness studies taking into account system
interactions
OBD – Pre-calibration Diagnoses
Software and dataset validation
Post SOP support
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 48Confidential
MODEL BASED DEVELOPMENTPOST SOP SUPPORT
Case:
• Field issue reported on boost control deviation
• Difficult test bench availability at customer for reproducing issue
Solution:
• Model and load drawer of SOP engine still available
• Implemented Model + hardware on available VTB station (~2h)
• Reproduced field issue on VTB (~1h)
• Supplied customer with solution (~2h)
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 49Confidential
CHANGING CALIBRATION PARADIGMSUCCESSFUL MODEL VERIFICATION
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 50Confidential
MODEL ACCURACY – COMMERCIAL VEHICLEGOOD EXTRAPOLATION AS BASE FOR MODEL BASED CALIBRATION
Example of Off-Road Calibration Project
Engine Model parameterized based on 1 Engine Map and a double NRTC (Cold and Hot) from Test Bed at ambient condition (97kPa, 25°C)
EAS Model parameterized based on Synth Gas Test Bed Data and a double NRTC from Test Bed at ambient condition (97kPa, 25°C)
Models run on HiL on Steady State Condition with underhoodcondition adaptation and compared to vehicle data performed at -15°C and 97kPa
1 2 3 4 5 6 7 8 9 10 11
LogPt
Int.
Man
. T
em
pera
ture
[°C
]
0
8
16
24
32
Int.
Man
. P
ressu
re [
kP
a]
80
120
160
200
240
Int.
Air
Tem
pera
ture
[°C
]
-16
-12
-8
-4
Up
. D
OC
Tem
pera
ture
[°C
]
200
250
300
350
400
Up
. S
CR
Tem
pera
ture
[°C
]
200
240
280
320
360
Dw
n. A
SC
Tem
pera
ture
[°C
]
200
240
280
320
360
Experimental Vehicle Measurement
HiL Simulation
1 2 3 4 5 6 7 8 9 10 11
LogPt
-
To
rqu
e [
-]
0,2
0,4
0,6
0,8
1,0
Air
Mass F
low
[kg
/h]
200
400
600
800
1000
Fu
el M
ass F
low
[kg
/h]
0
6
12
18
24
Lam
bd
a [
-]
1,8
2,4
3,0
3,6
4,2
Sp
eed
[rp
m]
1400
1600
1800
2000
2200
NO
X_E
O [
g/h
]
200
400
600
800
1000
Experimental Vehicle Measurement
HiL Simulation
Model Extrapolation Behavior well reproduced:
In cold Condition: -15°C
As well in Vehicle condition
Model can be used for Non-Standard Ambient Calibration!
AVL List GmbH | Calibration and Virtual Testing Solutions | 23 November 2016 | 51Confidential
Challenge HighlightsSituation Solution
CALIBRATE BEYOND THE LIMITS
Easy to use: Environment already well known by calibration engineers
Increases quality: Reproducibility and good extrapolation capability due to model
Run 24/7 in automatic mode
VIRTUAL TESTBED
Time saving on real testbed and altitude chamber frontloading
Flexible: Can be controlled remotely
www.avl.com
THANK YOU