S. Jabez Dhinagar Ph.D Vice President. TVS Motor Company Ltd. 21 st November 2008, NI Bangalore

Transcription

1 S. Jabez Dhinagar Ph.D Vice President Advanced Engineering TVS Motor Company Ltd. 21 st November 2008, NI Bangalore

2 CONTROL SYSTEM DEVELOPMENT CYCLE System Definition System Testing Rapid Prototyping Hardware in Loop Testing Targeting Footer.. 2

3 Front Panel of RCP ECU Footer.. 3

4 Front Panel of HIL Simulator Footer.. 4

5 Block Diagram of Engine Simulator CONTROLLER ENGINE VEHICLE Spark Angle Torque Fuel Quantity TPS Engine Speed Road Torque Engine Speed Temperature Vehicle Speed Road load DRIVER Gear Position Clutch Brake Vehicle Speed Footer.. 5

6 ENGINE SIMULATOR SETUP Footer.. 6

7 Engine Calibration Engine calibration is the adjustment and modification of engine control parameters to: 1) Yield optimal performance, 2) Meet emission norms, 3) Get best fuel efficiency 4) Protect the engine for undesirable engine phenomenon's like knocking and over heating which can lead to engine seizure. Footer.. 7

8 Calibration Process Online/Offline Calibration Engineer Calibration Tool Engine Control unit Parameters Curves Maps Parameters Curves Maps Block diagram of calibration process Footer.. 8

9 Engine Maps in Controller-ROM Espeed1 TPS1 Spark Angle Map Footer.. 9

10 Conventional Method - Engine Tuning Start A No Engine is running at Operating point (TPS1,ESpeed1) Want to change Spark Timing Go to the programming page and change the SA timing for (TPS1,ESpeed1) Reprogram the IDI Involves many steps. Time consuming. Yes Stop the Engine and dyno Disconnect the Spark plug connection from IDI unit Connect the Programmer to IDI unit Connect the Spark plug to IDI and start the engine with dyno Check for performance and different parameter with new SA timing System has to be shut down every time to change the parameter. Tedious process for the engine tuning engineer A Stop Flow chart of conventional engine tuning Footer.. 10

11 Modern Method - Engine Tuning Start Engine is running at Operating point (TPS1,ESpeed1) No Want to change Spark Timing Yes Change the SA Timing point in the Excel sheet map Press Upload button from the calibration tool Check for performance and different parameter with new SA timing Stop Flow chart of modern engine tuning Footer.. 11

12 Calibration Tool Available in the Industry Dspace-CalDesk Vector-CANape Footer.. 12

13 Why LabView Tool? Easy to design and develop. Low Cost Solution. Reduces the development time. Supports RS 232 communication Protocol. Can be extended to CAN in future,with substantially less time. Footer.. 13

14 Calibration System via RS 232 Host PC with LabView ECU Computation Loop RS 232 Calibration Using RS 232 Communication Footer.. 14

15 Calibration System A) Calibration - Variable - Curves(2D) - Maps(3D) B) Data Measurement and Display of Engine/Vehicle Parameters C) Data Acquisition and Storage of Engine/Vehicle Parameters 3 main steps required in a calibration system Footer.. 15

16 Calibration Process Using the Tool Engine Controller LabView MAP-Excel Sheet Calibration Memory in RAM/ Flash ROM Engine Maps in ROM Calibration Process Using the Calibration Tool Footer.. 16

17 Trimming Options Engine Controller LabView Engine Parameters From RAM % Increase & decrease in final parameters Trimming Options:Direct control on final engine parameters Footer.. 17

18 Engine Controller Data Acquisition LabView Excel Sheet Engine/Vehicle Parameters Data-Measurement and Acquisition of engine parameters Footer.. 18

19 Screen Shot of Calibration Tool Front Panel Front Panel-LabView Footer.. 19

20 Screen Shot of Calibration Tool Control Panel Control Panel-LabView Footer.. 20

21 IDI Calibration-Desktop Setup IDI Calibration setup Footer.. 21

22 Future Expansion of the Work 3-D Engine Map 3-D Graphical Engine Map Graphically changed 3-D map Footer.. 22

23 Future Expansion of the Work Host PC with LabView NI CAN Card ECU CAN Driver ECU Calibration Using Controller Area Network Footer.. 23

24 Savings from use of NI based calibration tool Effort : Time : Cost : 300 man hours 15 days Nil Deployment time : 2 days Portability Expandability Customisation Data trasfer rate All machines Unlimited By user 100 ms for full data transfer Data storage format : Excel, csv, rtf Data acquisition mode: unlimited capability Footer.. 24

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28 Thank You Footer.. 28