Applicazioni e prospettive del controllo nei veicoli May 10, 2007 Politecnico di Milano Dipartimento di Elettronica e Informazione GMPT Approach to PWT Controls Alberto PISONI Diesel Controls Chief Engineer General Motors Powertrain Europe Torino, Italy
Controls Background Critical to business Quality Functionality Cost Rapid complexity growth Control functions Powertrain interaction Vehicle interaction Different industry change rate and life cycle Moore s law opportunities Obsolescence and manufacturing changes Limited management understanding Not always actively managed
GM Powertrain Controls History 1979 First electronic engine controls 1988 First electronic transmission controls 1991 First standard electrical interface (PPEI) defined 1993 First controller outsourcing project 1999 First internally developed software in production 2005 First strategic EMS in production
GM Powertrain Controls Strategy - 1 Protect strategic IP, achieve competitive advantages Reduce cost through competition at component level, not system level Reduce supplier dependence
GM Powertrain Controls Strategy - 2 Broad and deep competence in all aspects of controls engineering Proactive management of architectures to enable reuse and fast applications Fast, integrated engineering process based on modern engineering tools Capable suppliers focused on components and manufacturing Global integration of product line, engineering process and project execution Exploit IP for sourcing flexibility, cost advantage and revenue
Then and Now Past Engine specific controls architectures Engine specific software Multiple engineering processes Product specific engineering teams Sourcing by engine program Supplier dependence Application specific interfaces Ad hoc quality management Present Common, flexible controls architectures Common, transportable application software Common, capable engineering process Globally integrated engineering teams Sourcing consolidated global volume Supplier independence Common, managed interfaces (PPEI/PTEI) Systemic quality management In 2007, 8 mil insourced Controls will be applied to GM Powertrains
GMPT Control System Core Engineering Locations GMPT-NA Gas engine control systems Transmission control systems exc DCT Hybrid control systems GMPT-E Diesel engine control systems DCT controls
Where we are in Europe Trollhaettan: Gas vec calibration Diagnostic DCT Soedertalje: Algo&Sw engineering Gas Turbo functions dev. Strasbourg: AT Transmission Controls DCT GMPT Europe Torino: Core Ds Controls Ds functions dev Ds base calibration Rüsselsheim: Controls integration Gas base&vec calibration Ds vec calibration European HQ
V Model then and now System Requirements Functional Requirements Controls Architecture Acceptance Test System Test GMPT 1992 Algorithms Integration Test Software Unit Test GMPT 2003
Control System Engineering Process Click on links to find Documents Process Overview Document Develop New Features (De -coupled) Deploy Production Control System Advanced Development Explore Options Feasible Technologies Business Inputs Define Control System Requirements Program Timing: Controls POE Engineer Control System Architecture SDSS Interface Reqts Linkage to Base Hardware Engineer Sensor & Actuator CTS Engineer Controller CTS Parts BOMs Proven Arch High Maturity Product Requirements Select Control System Architecture Deploy Sensor & Actuator SORs Deploy Controller SOR HWIO Controller Application Center Calibrate Control System Release of Control System Validate Control System in Vehicle HWIO Algorithm Requirements Development Algorithm & Software Design Software Implementation Software Integration Validate Controller System Technical Resource Center Core Engineering Supporting Processes General DocMngt MVP Tools Reviews CST Schematics SDSS
Sw development: System Partitioning The system may be partitioned by two methods: Functional decomposition into functional areas (e.g., exhaust gas recirculation, fuel level) Structural decomposition into classifications (e.g., controller inputs, control, outputs)
Sw development: Classifications&Functional Areas Controller Inputs Control Actuator Outputs System Diagnostics On-Vehicle Communications Off-Vehicle Communications Configuration EGR Fuel Level A/C Compressor Engine Coolant Temperature Engine Overspeed Protection Fuel Pump Spark
Sw development: Ring Definition Initial system partitioning is based upon functional areas Relatively high coupling and cohesion between different classifications within the same functional area A Ring represents the collection of all the classifications associated with a functional area
Sw development: System Partitioning Functional Area C l a s s i f i c a t i o n Controller Inputs Control Actuator Outputs System Diagnostics On-Vehicle Communications Off-Vehicle Communications Configuration E G R F L V A C C Ring E C T........................ E O P F P U
Sw development: Standard Structure of a Ring Inputs from other Rings On-Vehicle Communications Off-Vehicle Communications Controller Inputs Control Actuator Outputs Configuration System Diagnostics Outputs to other Rings
Sw development: Mapping of Feature to Systems Customer Feature ETC TCS UI-SMCC Mapping of Features to Rings and Rings to Build Allows mapping of Feature to Build PCM SW Build #1 GMPT Improvement EGR Pintle Clean Purge valve driver Crank fuel prime Algo / SW Standard Parts RINGs Idle Ring Torq Ring Spark Ring ECM SW Build #2 Feature Enhance New CL fuel gain New table axis Shift Point Ring CL Fuel Ring TCM SW Build #3
Sw development: Ds vs Gas Reuse 74 10 23 25 5 Rings that can be common without change Rings that can be common after modification Rings that will need Diesel Gasoline Flavors Rings not used by D-One. Most of them will need Non Functional flavors New Diesel only Rings. Will have NF flavors for Gasoline
Controller Price and Content Trend % 200 180 160 140 120 100 80 60 40 20 0 Controller Cost Controller Memory Legacy Generation 1 Generation 2 MB 6 5 4 3 2 1 0
GMPT HISTORICAL EMS/CONTROLLER IPTV WARRANTY COMPARSION (2006 MY Projection as of July QIS Data) 120 100 100,00 ECM/PCM Replaced ECM/PCM Reprogramming Ignition & ESC Fuel Delivery % IPTV 80 60 43,69 EVAP Emissions Catalytic Converters Cranking Systems Oxygen Sensors 40 Oil/Temp/Pressu re Sensors EGR 20 Air Delivery Total EMS Warranty 0 2001 MY 2006 MY
2006 JD Powers QIS Comparison - Controls 5 4 3 2 1 0 GMPT Toyota Honda
Conclusion Our competence in Controls Design will remain a competitive advantage when current Powertrain technologies will be obsolete