model-based calibration of hd engines - engine and vehicle ...model-based calibration of hd engines...

Benjamin Tilch, Rico Möllmann, Axel Steinmann, Dr. Reza Rezaei

GT-SUITE Conference, Frankfurt, October 2014

Model-based Calibration of HD Engines

Model-based Calibration of HD Engines Contents

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• Introduction and motivation

• Model based calibration methodology

• Calibration of engine protection functions

• Conclusion

2


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• Conclusion

3

• First model setup

and validation

• Potential

determination

• Component

Investigations

• Concept layout

• Periphery design

Powertrain

Calibration / Test

Vehicle

Calibration / Test

System- / Function

Development

Concept /

Design

Introduction and motivation Continuous Use of Physical Simulation

• Continuous model

adjustment

• Choice of

components

• Function

development

• First “desk”

calibration

• MIL/SIL tests

• Robustness testing


adjustment

• Trouble-shooting from

“Back-office”

• HIL-tests

• Model-based calibration

• Extrapolation of

boundary conditions

(altitude, climate)

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ICE

EAT

Vehicle

Combustion

• First model setup

and validation

• Potential

determination

• Component

Investigations

• Concept layout

• Periphery design

Powertrain

Calibration / Test

Vehicle

Calibration / Test

System- / Function

Development

Concept /

Design

Introduction and motivation Continuous Use of Physical Simulation


adjustment

• Choice of

components

• Function

development

• First “desk”

calibration

• MIL/SIL tests

• Robustness testing


adjustment

• Trouble-shooting from

“Back-office”

• HIL-tests

• Model-based calibration

• Extrapolation of

boundary conditions

(altitude, climate)

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ICE

EAT

Vehicle

Combustion


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• Conclusion

6

Model-Based Calibration Methodology Virtual Development Platform

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INCA

COM

Interface

Read / Write

Calibration Data

INCA-FLOW®

ETK/CCP

Simulation

X86 C

on

tro

ller

Engine Dyno

Test Vehicle

ECU

ICE- and EAT-Model Soft-ECU

Sensor-

and

Actuator

Models

Standard-Application Process

Model-Based Calibration

Object Code from

Ascet / Simulink / GT SUITE RT

Intecrio *.a2l-file

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Model-Based Calibration Methodology Software Tool Chain

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Simulation

ICE- and EAT-Model Soft-ECU

Sensor-

and

Actuator

Models

Model-Based Calibration

Object Code from

Ascet / Simulink / GT-SUITE-RT

Intecrio *.a2l-file

IAV

Phenomenological

Combustion Model

Engine Model

GT-SUITE /

GT-SUITE-RT

Engine Control

Ascet

EAT Control

Simulink

INCA INCA-FLOW

ETAS INTECRIO

*.a2l-file

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Model-Based Calibration Methodology Coupling GT Models to Tool Chain

.six

Variant 1

C++ Compiler

s-function

Simulink Coder

.six GT-POWER Simulink

ASCET .a2l INTECRIO INCA

Variant 2

GT-SUITE-RT

.dat

Simulink Coder

.six GT-POWER Simulink

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Model-Based Calibration Methodology Open-Loop vs. Closed Loop Calibration

• Calibration of functions for

steady-state operation,

min/max-values etc.

• Preparation of maps based on

simulation results

• Validation on engine test bench

• e.g. NH3 dosing (map filling)

• Calibration of functions for

transient operation

• Model/Software-In-the-Loop

Simulation

• Validation on engine test bench

• e.g. soot loading, NH3 storage,

in cylinder measures

x x

„Open-Loop“ Calibration

„Closed-Loop“ Calibration

+

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• Conclusion

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Model-Based Calibration Method Calibration Engine Safety Functions

• Calibration of engine safety functions under extreme conditions like altitude,

coldness or even damages in engine parts like blocking the intake air path.

• The complete engine model was calibrated and validated with steady-state

measurements (engine map) and transient measurements (NRTC).

• The IAV physical-based combustion model is applied for a predictive simulation.

• A good match between measurement and simulation results is achieved.

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• Example results of the IAV phenomenological combustion model (A: 1200 min-1, B: 1500 min-1, C: 1900 min-1 ;

25 % - 100 % Load). See also SAE International Journal of Engines 5(3): 2012 und SAE 2012-01-1065

Model-Based Calibration Method Engine Process and Combustion Modeling

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Model-Based Calibration Method Calibration Engine Safety Functions

• Validation of the model-based

calibration engine safety function in

real-life cycle at ca. 800m altitude.

• Failure case: Blocking of the waste-

gate valve which leads to high

turbocharger temperature and speed.

• The failure is detected by exceeding

the boost pressure to the limit which is

given as input to the model.

• The failure is detected by the model,

the boost protection modus is

activated.

• In protection modus, the injected fuel

mass is reduced to decrease the

temperature and also TC-speed.

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• Conclusion

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Model-based Calibration of HD Engines Summary and Conclusion

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Thank You

Benjamin Tilch

P&E Concepts / Functions, MD-N21

Commercial Vehicle Powertrain

Business Area Powertrain Mechatronics

IAV GmbH

Nordhoffstrasse 5, 38518 GIFHORN (GERMANY)

Tel. +49 5371 80-53021

[email protected]

www.iav.com

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model-based calibration of hd engines - engine and vehicle ...model-based calibration of hd engines...

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