PROJECT WORK. NAME Engine base calibration process. TUTORs Amorese Stefano. JOB POSITION Engine calibration test bench engineer

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1 Engine base calibration process TUTORs Amorese Stefano Engine calibration test bench engineer 1) Development of base engine calibration data: Performance optimization (maximum torque and power levels, fuel economy) in both nominal and off nominal boundary conditions Sensors and actuators characteristic and control (e.g. GDI, valves timing, ignition, throttle, boost, air to fuel ratio) Engine and component protection from: knocking and abnormal combustions, turbocharger surging and choking, turbocharger and catalyst overheating, excessively high in cylinder pressure, engine overspeeding Models: trapped air charge and throttle flows, fuel flow, torque, exhaust gas and catalyst temperature, oil temperature, exhaust backpressure 2) Support the vehicle calibration teams (emission optimization, driveability, diagnostics) as well as the base engine development and durability teams 3) Take part to the process of developing calibration methodologies and tools 4) Share information and collaborate with the team leaders to meet the milestones of the project Development of base engine calibration data on engine test bench. The activities involve the following steps: Performing test plans on the engine test bench in both steady state and dynamic calibration. The engineer has to make sure the tests are run in the proper way and at the appropriate timing with respect to the project plan Analyse and process through specific tools the data from the engine bench in order to populate the calibration maps in such a way to meet the key performance indicator metrics on performance, functionality of the engine and of its components, accuracy of the models Verification and validation of the calibration data on both engine test bench and vehicle Collaboration along with the whole calibration team in the continuous process of defining more effective and efficient calibration methodologies and tools. At an early stage of the project the engineer may be involved in the process of performing tests to provide data helpful to define the choice of the engine HW (e.g. turbomatching, valves timing and lifts).

2 Development aftertretament system (ATS) for post Euro 6 emissions legislation. TUTOR LANFRANCO Enrico Base Control Function Specialist 1) Development of aftertreatment base control functions: Concept definition (including rapid prototyping and engine test) Function development and specification (taking into account the functional safety and OBD regulation) Function verification and approval (tests at Hardware in theloop/engine/vehicle) 2) Function pre calibration and calibration subsets, according to application responsibility assignment 3) Support to Application (e.g. troubleshooting, calibration guidelines ) Development, specification, model design and test of SCRoF (SCR on Filter) ATS strategies for Diesel passenger car applications: SCRoF catalyst model o NH3 storage o Conversion efficiency o Downstream NOx emissions o NH3 slip o Temperature model (multi brick) o Catalyst aging o HC poisoning Urea dosing request o State machine for dosing release o Feed forward controller o Wall film model o Load governor o Dosing adaptation based on downstream NOx sensor feedback Coordination w/ other ATS components (if present, depending on ATS configuration) o Optimize pscr underfloor load and efficiency o Manage interaction with LP EGR, DPF regeneration, NSC purge events

3 OBD monitoring strategies

4 Engine Application Program Management TUTORs Ricca Carlo Assistant application manager 1) To analyse and answer to Study Request for new programs in terms of timing and costs 2) Define application plans and activities scheduling (macro planning & micro planning) 3) Agree with the Calibration Manager if it s necessary or not to outsource activities 4) Responsible for engines and parts procurement to perform test bench activities 5) Responsible for application vehicles scheduling and inventory 6) Supervise the application plans execution and target achievement in terms of timing / cost / KPI Training on the different calibration phases of a new production intent program. The activities involve the following steps: Base calibration procedures on test bench and vehicle Driveability and startability issues on vehicle Emissions requirements for homologation cycle and real driving conditions Performance and fuel consumption targets on vehicle EOBD diagnosis tuning on vehicle Fleet validation activities FCA standards for calibration testing and project management The first part of the training work will be focused on calibration activity contents and the second one more related to project management, planning and documentation.

5 Development engine simulator to test the logic of management after treatment system (ATS) for post Euro 6 emissions legislation TUTOR TUCCI Vittorio Antonio HIL (Hardware In the Loop) Specialist HIL simulators allow simulating the neighbourhood around an electronic control unit to allow design, calibration, verification and validation for the control software. Each HIL requires specific design, setup and test to reach the requested level of accuracy, repeatability and reliability in order to perform the planned activities. For Powertrain domain, electronic control unit tested on HIL are engines, transmissions and drivelines management systems. Thus, main tasks are the following: Definition of HIL specifications for the selected ECU (including wiring harness, real and emulated components) Development and maintenance of powertrain models Validation of HIL simulators (I/O and models) Development and maintenance of test automation platform Design, setup, configuration and validation of a system HIL for an engine management system for a diesel engine equipped by SCRoF (SCR on Filter) ATS strategies for Passenger Car applications: Definition of HIL specifications for SCR system, investigating the possibility to emulate real loads as urea injector and pump Development and validation of ATS models in order to perfom model based calibration Development of automated testing for SCR system

6 Dual Clutch Trasmission Calibration Process TUTORs Porta Attilio NMT calibration Engineer 1) Development of Transmission calibration data: Performance optimization to reduce fuel consumption according with drivability constrains ( shift maps ) Optimization/development of specific strategies for fuel saving ( Stop & start, Free wheel function ) and Interaction with powertrain energy management ( Aux compensation, smart alternator, Battery management ) and with vehicle ( slope, cornering ) Impact analysis of specific strategies on DDCT base transmission ( actuators, base transmission ) Optimization of specific gearshift calibration strategy according with engine management capability ( cut off strategy during gear shift, energy dissipation ) Benchmarking vs different strategies calibration and competitors 2) Support the vehicle calibration teams (emission optimization, drivability, diagnostics) as well as the base transmission development and reliability ( impact of strategies on Hw robustness ) 3) Support the powertrain control team in strategy definition/development 4) Take part to the process of developing calibration methodologies and tools 5) Share information and collaborate with the team leaders to meet the milestones of the project Development of DDTC calibration on specific test bench and vehicle.the activities involve the following steps: Performing test plans on the transmission test bench ( roller test bench, HIL bench ) following the activities described upon. The engineer has to make sure the tests are run in the proper way and at the appropriate timing with respect to the project plan Analyse and process through specific tools ( AVL Cameo & Drive ) the data in order to define best fit calibrations to meet the key performance indicator metrics on performance, functionality of the DDCT and its base components Verification and validation of the calibration on the transmission/roller test bench and on vehicle Collaboration along with the whole calibration team in the continuous process of defining more effective and efficient calibration methodologies and tools.