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1© 2017 The MathWorks, Inc.
Engine Plant Model Development and Controller
Calibration using Powertrain BlocksetTM
Brad Hieb Application Engineering
Scott Furry Consulting Services
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Key Take-Away’s
▪ Engine model parameterization is a very non-
trivial task
▪ Engine controller calibration is a very non-trivial
task
▪ MathWorks has tools to help make these two
tasks more manageable
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Problem Statement
▪ How do I use the Powertrain Blockset engine and controller models for my
application so I can:
– Design engine controls?
– Perform fuel economy and emissions studies?
– Create and validate dynamometer test plans?
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What we’ll Cover Today
▪ Parameterizing a Powertrain Blockset engine model
– Workflow
– Example: parameterizing a mapped engine model
▪ Calibrating a Powertrain Blockset engine controller
– Workflow
– Example: calibrating an engine controller
![Page 5: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/5.jpg)
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What are we Parameterizing and Calibrating?
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What we’ll Cover Today
▪ Parameterizing a Powertrain Blockset engine model
– Workflow
– Example: parameterizing a mapped engine model
▪ Calibrating a Powertrain Blockset engine controller
– Workflow
– Example: calibrating an engine controller
![Page 7: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/7.jpg)
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Powertrain Blockset Si Mapped Engine Model
▪ Contains 2D LUT’s for
each model output
▪ Easy to parameterize
▪ Great for system level
design and
development
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing an Engine Model- Workflow
▪ Model-Based Calibration Toolbox
provides tools for the process:
– Creating the Design of
Experiments
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing an Engine Model- Workflow
▪ Model-Based Calibration Toolbox
provides tools for the process:
– Creating the Design of Experiments
– Gather the data
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Engine System(Change operating points,
fixed calibration) Dynamometer
Speed Cmd
Torque Measured
Speed Measured
Crankshaft
Data Logger
Measurements
· Air Flow· Fuel Flow· Exhaust Temp· Emissions· BSFC
Measurements
Torque Cmd.
Speed Measured
Dynamometer Control
(Steady State)
Parameterizing an Engine Model- Get the data “as calibrated”
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing an Engine Model- Workflow
▪ Model-Based Calibration Toolbox
provides tools for the process:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models
(RSM, statistical) to the data
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing an Engine Model- Workflow
▪ Model-Based Calibration Toolbox
provides tools for the process:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models
– Developing engine performance
maps from RSM’s
![Page 13: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/13.jpg)
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing an Engine Model- Workflow
▪ Model-Based Calibration Toolbox
provides tools for the process:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models
– Developing engine performance maps
– Validate the result
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Launch MBC Toolbox
▪ From Apps tab
▪ From command line
>> mbcmodel
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Launch MBC Toolbox
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Parameterizing a Mapped Engine Model- Importing existing data
▪ Mapped engine model workflow:
– Importing existing data
Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
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Import Data- Inspect the data
▪ Look for
anomalies or gaps
▪ Filter data to
remove anomalies
▪ Add derived
quantities and unit
conversions
▪ Graphical views
speed inspection
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing a Mapped Engine Model- Fitting response surface models
▪ Mapped engine model workflow:
– Importing existing data
– Fitting response surface models
(RSM, statistical) to the data
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Fitting Models to the Data- Generate response surface models
▪ Default models
automatically
fitted to all
responses
▪ Inspect quality
of fit
▪ Try out
alternatives
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing a Mapped Engine Model- Developing engine performance maps
▪ Mapped engine model workflow:
– Importing existing data
– Fitting response surface models
– Developing engine performance
maps from RSM’s
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Calibration Generation Tool
▪ Fill tables
▪ Export cal tables
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Calibration Generation Tool- Generating look up tables
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Calibration Generation Tool- Fill tables
▪ Inspect surfaces
▪ Adjust table
values in
extrapolation
areas
▪ Export to
MATLAB, Excel
or Cal tool
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing a Mapped Engine Model- Export and validate result
▪ Mapped engine model workflow:
– Importing existing data
– Fitting response surface models
– Developing engine performance maps
– Export and validate the result
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Export Tables to MATLAB
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Validate the Result
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Validate the Result
▪ Accuracy for 1200 sec
of FTP75 sim:
– % diff in FE was 0.31%
▪ Run time for 1200 sec
of FTP75 sim:
– PTBS Mapped engine
model 28.4 sec
– GT Power FRM engine
model 1449 sec
– Mapped engine model
sim ~51x faster
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Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Parameter Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
Parameterizing a Mapped Engine Model- Summary
▪ Mapped engine model workflow:
– Importing existing data
– Fitting response surface models
(RSM, statistical) to the data
– Developing engine performance
maps from RSM’s
– Validate the result
![Page 29: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/29.jpg)
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What we’ll Cover Today
▪ Parameterizing a Powertrain Blockset engine model
– Workflow
– Example: parameterizing a mapped engine model
▪ Calibrating a Powertrain Blockset engine controller
– Workflow
– Example: calibrating an engine controller
![Page 30: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/30.jpg)
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What are we Parameterizing and Calibrating?
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What are we Calibrating?
Throttle area
percent (TAP)
Exhaust Cam
Retard
Intake Cam
Advance
Lambda
Spark
Advance
Wastegate
Fraction
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Calibrating Optimal Base Engine Control Tables- Workflow
▪ Model-Based Calibration Toolbox
provides tools for the process:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models (RSM,
statistical) to the data
– Developing optimal base calibration
tables
– Export calibration to controller
Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
![Page 33: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/33.jpg)
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Calibrating Optimal Base Engine Control Tables- Creating the DoE
▪ Optimal base engine control
calibration workflow:
– Creating the Design of
Experiments
Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
![Page 34: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/34.jpg)
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ICP
Minimum BSFC
Exhaust Temperature
ECP
Spark Advance
RPM
Load
Objective
Constraints
Optimal Tables
TableBreakpoints
I/O of Turbocharged Direct-Injection 1.5L DOHC Engine Model withDual-Independent Continuously Variable Cam Phasing
Turbocharger Speed
Waste-gate area
Intake Manifold Pressure
Auxiliary Table
TAP
Optimal Tables
Knock limit
AFR
Residual Fraction
Calibrating Optimal Base Engine Control Tables- Creating the DoE
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Calibrating Optimal Base Engine Control Tables- Creating the DoE
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Calibrating Optimal Base Engine Control Tables- Gather the data
▪ Optimal base engine control
calibration workflow:
– Creating the Design of Experiments
– Gather the data
Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
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Calibrating an Optimal Base Cal Table- Get the data “from CAE engine models”
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· Air Flow· Fuel Flow· Exhaust Temp· Emissions (EO/TP)· MAP
· MAT· A/F· Turbo Speed· Turbine press ratio· Compressor press ratio
· Turbine temp out· Compressor temp out· EGR pct.· EGR cooler temp out· Intercooler temp out
Measurements
Torque Cmd.
Speed Measured
Engine(Change operating points and sweep Actuator Cmds)
Dynamometer
Speed Cmd
Torque Measured
Speed Measured
Crankshaft
Dynamometer Control
(Steady State)
Data Logger
Actuator Cmds.
Measurements
Calibrating Optimal Base Engine Control Tables- Get the data “from calibration sweeps”
• Throttle• Wastegate• Injector• Spark
• Intake cam • Exhaust cam • EGR valve • Turbo
Actuator Commands
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Calibrating Optimal Base Engine Control Tables- Fitting response surface models
▪ Optimal base engine control
calibration workflow:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models
(RSM, statistical) to the data
Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
![Page 40: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/40.jpg)
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Calibrating Optimal Base Engine Control Tables- Generate response surface models from data
▪ Default models
automatically
fitted to all
responses
▪ Inspect quality
of fit
▪ Try out
alternatives
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Calibrating Optimal Base Engine Control Tables- Develop optimal base calibration tables
▪ Optimal base engine control
calibration workflow:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models
– Developing optimal base
calibration tables from RSMs Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
![Page 42: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/42.jpg)
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Calibrating Optimal Base Engine Control Tables- Developing calibration tables
▪ Import response surface
models
▪ Run optimizations
▪ Analyze tradeoffs and
sensitivity
▪ Fill tables
▪ Export cal tables
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Calibrating Optimal Base Engine Control Tables- Developing calibrations from response surface models
▪ Import response surface
models
▪ Run optimizations
▪ Analyze tradeoffs and
sensitivity
▪ Fill tables
▪ Export cal tables
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Calibrating Optimal Base Engine Control Tables- Run optimizations
▪ Define objective
▪ Define constraints
▪ Determine operating
point weights
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How to calculate the weights for a sum optimizationUse MATLAB to calculate weights for a drive cycle
Histogram
Weights as % from
total time
Drive cycle data
MATLAB program reads
measurements from
Excel measurement file
and calculate weights
automatically
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Calibrating Optimal Base Engine Control Tables- Run optimizations
▪ Evaluate
optimization results
▪ Diagnose
optimization
convergence issues
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Calibrating Optimal Base Engine Control Tables- Analyze tradeoffs and sensitivity
▪ Evaluate local
sensitivity
▪ Determine if
tradeoffs are
needed
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Calibration Generation Tool- Fill tables
▪ Inspect surfaces
▪ Export to
MATLAB, Excel
or Cal tool
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Optimal Base Calibrations Completed
Throttle area
percent (TAP)
Exhaust Cam
Retard
Intake Cam
Advance
Lambda
Spark
Advance
Wastegate
Fraction
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Calibrating Optimal Base Engine Control Tables- Export and validate the result
▪ Optimal base engine control
calibration workflow:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models
– Developing optimal base calibrations
– Export calibration to controller Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
![Page 51: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/51.jpg)
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Export Tables to Calibration Tool
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Calibrating Optimal Base Engine Control Tables- Summary
▪ Optimal base engine control
calibration workflow:
– Creating the Design of Experiments
– Gather the data
– Fitting response surface models
– Developing optimal base calibrations
– Export calibration to controller
Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
![Page 53: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/53.jpg)
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Key Take-Away’s
▪ Engine model parameterization is a very non-
trivial task
▪ Engine controller calibration is a very non-trivial
task
▪ MathWorks has tools to help make these two
tasks more manageable
![Page 54: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/54.jpg)
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Contact us to Learn More
▪ Scott Furry
▪ Brad Hieb
Results
Fast, Accurate Engine
Model for HIL and
System Simulation
Optimal Engine
Calibration
Parameters
Calibration Generation
Data Modeling
Engine DynamometerCAE Engine Model
Design of Experiments
![Page 55: Engine Model Development and Calibration …...2 Key Take-Away’s Engine model parameterization is a very non- trivial task Engine controller calibration is a very non-trivial task](https://reader036.vdocument.in/reader036/viewer/2022062506/5f07d14a7e708231d41ee638/html5/thumbnails/55.jpg)
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Q & A
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