model based development and calibration

1

Model Based Development and Calibration

Guillaume Broustail & Srinivasan Ananthan – AVL UK Expo 2015

AVL UK Expo 2015 2

Challenges in the Powertrain Developmentand AVLs Solutions

Model-Based Development

CO2 / Fuel Consumption

Real Driving Emissions

Broad Vehicle Portfolio

AVL Solutions

Reduction of

development costs€

Reduction of

development time

Keep quality standards1

Clustering of hardware

and engineering activities

Increased system

complexity (EAS, OBD, Hybridization)

Multi-variant simulation with the

same engine family (RDE, OBD, EAS)

Reduced test facilities/variant

through front-loading

Improved quality and robustness

through additional virtual validation1

Independence of environmental testing

from seasonal conditions and vehicles

availability

AVL UK Expo 2015 3

Need for Model Based DevelopmentFront Loading: from Road to Office

Test Field Host

Planning / Monitoring

Test Environments

Actual effort

Vehicle Data

Dataset Management

Measuring

Post Processing

Validation

VehicleTest Bed

AVL UK Expo 2015 4


Test Field Host


Test Environments

Actual effort

Vehicle Data

Dataset Management

Measuring

Post Processing

Validation

VehicleTest Bed

Extension to the Virtual

EnvironmentsMOBEO

Methodology

AVL UK Expo 2015 5


Test Field Host


Test Environments

Actual effort

Vehicle Data

Dataset Management

Measuring

Post Processing

Validation

VehicleTest Bed


EnvironmentsMOBEO

Methodology

MOBEO Methodology

Advanced Test Automation

CAMEO, PUMA, (SDS, RTC,

iMean)

AVL UK Expo 2015 6


Test Field Host


Test Environments

Actual effort

Vehicle Data

Dataset Management

Measuring

Post Processing

Validation

VehicleTest Bed


EnvironmentsMOBEO

Methodology

MOBEO Methodology

Advanced Post ProcessingConcerto


AVL UK Expo 2015 7


Test Field Host


Test Environments

Actual effort

Vehicle Data

Dataset Management

Measuring

Post Processing

Validation

VehicleTest Bed


EnvironmentsMOBEO

Methodology

MOBEO Methodology


Quality Management

Advanced Post Processing

Quality ManagementCalibration

Process, CRETA

AVL UK Expo 2015 8

Model Based Development CRUISE M and MoBEO

EngineAfter

Treatment Flow Driveline

� Scalable physical modeling depth for

concept, calibration and test

� Single platform for all AVL powertrain

real-time models

� Open interfaces to 3rd party tools

supporting standards (FMI)

� Generic semi-physical combustion model

� Exhaust gas after treatment

� Advanced heat transfer models in the gas path

� Sensor and actuator models

� Calibration know-how included

� Parameterization wizards for cylinder and SCRModel

MoBEO Modules

Multi-physics system simulation

Parameterization Wizard

AVL UK Expo 2015 9

MOBEO

Model overview

AVL UK Expo 2015 10

• Model based development using a

real time capable engine model

• Starting from concept phase until

SOP calibration

• Engine model based on semi-

physical modeling approach

� empirical model components

derived from AVL experience and

test bed data

� physical components increase

the range of application due to

better extrapolation

• Easy usability due to the use of

suitable simulation environments

Model Based Engine OptimizationWhat is it?

11

Model Based Development -MoBEOModelling Approach

Te

stb

ed

resu

lts

EAS System (DOC,

Semi-physical

Thermodynamic

NOx-Emission

EAS System (DOC, DPF, SCR, NLT)

Empirical

static global

HC, CO, Soot, SPL,…

Cameo M&M

Empirical

static global

HC, CO, Soot, SPL,…

Cameo M&M

DoE MeasurementsPuma / Cameo

T&M

DoE MeasurementsPuma / Cameo

T&M

Combined-model

Increased number of engine specific outputs

Combined-model

Increased number of engine specific outputs

HiL SetupHiL Setup

MiLSetupfOXCal

MiLSetupfOXCal

Baseengine testbeddevelopment

Puma / Cameo T&M


Puma / Cameo T&M


Puma / Cameo T&M

Emission validationEmission validation

Environmental validationEnvironmental validation

Modelrefinement

Pre

-ca

libra

tio

n

Do

E T

est R

esu

lts

Fie

ld d

ata

Robustness analysis

Pre

-ca

libra

tio

n

First engineRun

Puma / Cameo T&M

First engineRun

Puma / Cameo T&M

Basic model setup

MoBEO

Basic model setup

MoBEO

refined model setup

MoBEO

Semi-physical

Basic Model without

measurement data

Virtual

RealPost-

ProcessingPost-

ProcessingAdvanced Test

AutomationAdvanced Test

AutomationExtension to the

Virtual EnvironmentsExtension to the

Virtual Environments

Model-based calibration of various variants

Variant specific hardware change(e.g. intake piping, …)(No combustion HW change)

AVL UK Expo 2015 12AdBlue

SCR

LPEGR

cooler

DOC/DPFclosed

coupled

turbocharger

exhaust manifold

intake manifold

cylinders

air cleaner

HPEGR

walve

charge aircooler

HP EGR cooler Intake throttle valve

LPEGRvalve

Engine Model combined with EAS Model – Modular combined Semi-

physical models withhigh flexibility

Model Based Development -MoBEOStep 1 – Modeling EU6 Base Engine

13P.GNANAM | PTE | 25 Feb 2015 |

AdBlue

SCR

LPEGR

cooler

DOC/DPFclosed

coupled

turbocharger

exhaust manifold

intake manifold

cylinders

air cleaner

HPEGR

walve

charge aircooler

HP EGR cooler Intake throttle valve

LPEGRvalve

Change of EGR Cooler

Change of T/C characteristics

Change of EAS Components

Model Based Development -MoBEOStep 2 – Modelling of Different Elements

AVL UK Expo 2015 14

Concept / Layout

Start

of

Production

Endurance testing

Development ProcessConsequent usage of real-time system simulation

Modelquality

AVL data base,

measurements of

single components

Component

and system

developmentCalibration / Validation

Data vehicle testing

Data engine test bed

Consequent usage of real-time system simulation

AVL UK Expo 2015 15

MOBEOApplication environment

AVL UK Expo 2015 16

HiL Setup

MiLSetup

Model in the Loop (MiL)

Advantages

+ Simulation faster than real time (app. 5 to 10 times faster)

+ No hardware parts needed

+ Simulation on normal PC possible

Disadvantages

- Availability of software ECU

- Often not all ECU functionalities available

Hardware in the Loop (HiL)

Advantages

+ All ECU functions available

+ Pre-Calibration of all ECU functions possible

+ Possibility of ECU software and dataset validation

Disadvantages

- Only real time simulation possible

- Need of hardware in the loop test bed

� Both environments can be used for pre-calibration of specific tasks

Changing Calibration ParadigmThe right application environment at the right time

AVL UK Expo 2015 17

PUMA TestbedWorkstation

CAMEO Workstation

HiL Host PC including, HiL Operator Software and

ECU Application Software

PUMACAMEO

HIL SW INCA

Operator Station,including 4 x 24inch Monitors

HiL Cabinet, including AVL Load-Drawer + HIL Base System (e.g. dSPACE, ETAS) with RTPC and I/O boards

WORK ENVIRONMENTS - XIL-STATION

AVL UK Expo 2015 18Full Size HiL System

AVL Standardized HiL Simulator ConceptReal ECU & MoBEO Models in an Closed Loop

realECU

Actuators:e.g.: Throttle body, injectors,

EGR valve,…

…

Sensors:e.g.: Pressures, Temperatures,

Speeds, AirFuelRatio,…

…

I/O

ClosedLoop MoBEO

AVL UK Expo 2015 19

MOBEOModel accuracy

AVL UK Expo 2015 20

To

rqu

e [

Nm

]

0

50

100

150

200

Sp

eed

[rp

m]

500

1100

1700

2300

2900

3500MeasurementSimulation

EUDC

UDC 1

0 50 100 150 200time [s]

Tem

p. U

s. T

C [

°C]

0

150

300

450

600

NO

x [

g/h

]

0

10

20

30

40

50

60

CO

2 [

kg

/h]

0

20

40

60

UDC 1

750 800 850 900 950 1000 1050 1100 1150 1200time [s]

EUDC

NOx [mg/km] CO2 [g/km]

model 173.91 165.6

measurement 163.08 161.3deviation 6.23 % 2.6 %

Model is only adopted on one steadystate operating map and one NEDC

Model Accuracy in NEDC – Passenger CarHigh model accuracy as base for model based calibration

AVL UK Expo 2015 21

Sp

eed

[rp

m]

500

1000

1500

2000

2500

3000

To

rqu

e [

Nm

]

0

50

100

150

200

MeasurementSimulation

0 100 200 300 400 500 600 700 800 900 1000

time [s]

Tem

p. U

s T

C [

°C]

100

200

300

400

500

NO

x [

g/h

]

0

10

20

30

40

50

60

CO

2 [

kg

/h]

0

10

20

30

NOx [mg/km] CO2 [g/km]

model 308.54 183.23measurement 294.66 178.65deviation 4.5 % 2.5 %

• Minimal parameterization effort due to semi-physical modeling approach

• Simulation of different driving profiles without model refinement possible

• High model quality independent from calibration and operating conditions

Model Accuracy in Artemis – Passenger CarHigh model accuracy as base for model based calibration

AVL UK Expo 2015 22

Model Accuracy – Commercial VehicleHigh model accuracy as base for model based calibration

Typical deviations of the cycle emissions and fuel consumption as well as achievable temperature accuracy:

• Fuel Consumption < 3%

• NOx Emission < 10%

• Insoluble Particulate Emission < 15%

• Temperature Intake Side < 10°C

• Temperature Exhaust Side < 20°C400 450 500 550 600 650 700 750 800

Time [s]

T.

Tu

rbin

e-I

nle

t [°

C]

300350400450500550

NO

x C

on

ce

ntr

ati

on

[p

pm

]

02004006008001000

Op

ac

ity

[%

]

01020304050

En

gin

e S

pe

ed

[%

]

050

100

To

rqu

e [

%]

020406080100

Inta

ke

Air

Ma

ss

flo

w [

%]

020406080

100

MeasurementSimulation

AVL UK Expo 2015 23

MODEL BASED DEVELOPMENTUse - Cases

AVL UK Expo 2015 24

Model Based Development Concept Investigations

Model based concept investigations

� Assessment of technology route

� Simulation of transient behaviour of engine in early concept phase on MiLenvironment

� Definition of possible concepts considering the interaction between

� engine

� exhaust aftertreatment system

� software and calibration

� Sensors and actuators

� environmental conditions

Vehicle & drivetrain simulation

AVL UK Expo 2015 25

Powertrain Calibration tasks for MiL/HiL:

� RDE – Real Driving Emission evaluation

� EAS Simulation

� Calibration for non-standard ambient conditions

� Calibration of component protection

� In-Use Compliance - PEMS

� Sensitivity studies taking into account system interactions

� OBD – Diagnoses, IUPR

� Software and dataset validation

HW Testing & Calibration

Virtual Testing & Calibration

engine & EATS modeling

Model Based Development Powertrain Use cases

AVL UK Expo 2015 26

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

Engine Speed [1/min]

Tem

p. u

pstr

.Tu

rbin

e [

°C]

0

200

400

600

800

Pre

ssu

re u

pstr

. T

urb

ine [

kP

a]

0

125

250

375

500

LP

TC

Sp

eed

[rp

m]

0

50000

100000

HP

TC

Sp

eed

[rp

m]

50000

75000

100000

125000

150000

Tem

p. d

s. C

om

pre

sso

r [°

C]

0

100

200

BM

EP

[kP

a]

800

1600

2400

Model Based DevelopmentCalibration of Ambient Corrections

Simulation of full load altitude operation for validation of ambient correction and engine protection functions

970mbar = 350m (Graz)750mbar = 2500m660mbar = 3500m540mbar = 5000m

Limits for component protection

Limit temperature upstream turbine

Limit temperature downstream compressor

Limit pressure upstream turbine

Limit LP turbochargerspeed

Limit HP turbochargerspeed

No derating up to 2500 m

AVL UK Expo 2015 27

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

Engine Speed [1/min]

Tem

p. u

ps

tr.T

urb

ine [

°C]

0

200

400

600

800

Pre

ss

ure

up

str

. T

urb

ine [

kP

a]

0

125

250

375

500

LP

TC

Sp

eed

[rp

m]

0

50000

100000

HP

TC

Sp

eed

[rp

m]

50000

75000

100000

125000

150000

Tem

p. d

s. C

om

pre

sso

r [°

C]

0

100

200

BM

EP

[kP

a]

800

1600

2400

Model Based Development Calibration of Component Protection Functions

Simulation of engine failure at full load for validation of engine protection functions

Limit temperature upstream turbine

Limit temperature downstream compressor

Limit pressure upstream turbine

Limit LP turbochargerspeed

Limit HP turbochargerspeed

Limits for component protection

AVL UK Expo 2015 28

Model Based Development OBD validation

Low Pressure EGR Valve - Normal

Low Pressure EGR Valve - struck @ 25%

Low Pressure EGR Valve – struck @ 50%

Simulation of Low Pressure EGR valve struck

AVL UK Expo 2015 29

Calibration

Driving Cycle

Environment

Production Tolerances Aging Effects

Boarders of applicability for HiL test bed

� Final Calibration Validation

� Certification

� Durability testing

� Pre-calibration of Start and Cold Start

� Idle stability

� Missfire

Model Based Calibration on XiL - test beds Virtual Test Beds as Extension of Real Test Facilities

AVL UK Expo 2015 30

FacilitiesHiL

Engine Testbed

Chassy Dyno

Road

Ideal Lead Variant Calibration Project (i.e. norelevant H/W changes)

Model Based Calibration on XiL - test beds Front Loading

AVL UK Expo 2015 31

FacilitiesHiL

Engine Testbed

Chassy Dyno

Road

Ideal Lead Variant Calibration Project (i.e. no relevant H/W changes)

Multi-variant projects can be addressed by: an extension of the test environment through HiL (MiL/SiL) Testing• Keep calibration quality through additional HiL testing, though high number of variants• Multi-variant simulation (calibration clustering, RDE, EAS, OBD)• Keep test facilities usage by a feasible level• Make environmental testing more flexible and efficient

Model Based Calibration on XiL - test beds Front Loading

AVL UK Expo 2015 32

1040

200

Model Based Approach

150

100

Conventional Approach

Calibration

Validation

Frontloading

Model based calibration approach

Model Based Calibration Approach:

Example based on customer feedback:

NTE, Engine Protection and Ambient Corrections (1 Mode)

80% Test Bed Time saved!

Test Bed Time in Hours

SO

P

AVL D

iesel-

Calibra

tion

Quality

Gate

s

Time

Cal. Quality

G1 – Engine Runnable

G2 – Emission Targets Achieved

G3 – Test Bed Target Achievement

G5 – Validated

G4 – Robust

conventional Calibration process

model based Calibration process

G0 – Engine Startable

� Calibration on XiL instead of Test Bed

� 80% Test Bed Time Saved per Engine Mode

� Test Bed available for Frontloading Tasks

� Dataset Quality & Maturity increased in earlier phase of Development

FrontloadingQ

uality

AVL UK Expo 2015 33

Changing Calibration Paradigm:Innovative ways to increase xCU calibration quality

AVL model based

development

methodology is the

consequent usage

of real-time

system simulation

from concept to

SOP on suitable

development

environments with

smart calibration

tools

model based development and calibration

Documents