Model Based Development and Calibration Guillaume Broustail & Srinivasan Ananthan AVL UK Expo 215 1
Challenges in the Powertrain Development and AVLs Solutions CO2 / Fuel Consumption Real Driving Emissions Reduction of development costs Increased system complexity (EAS, OBD, Hybridization) 1 Keep quality standards Reduction of development time Broad Vehicle Portfolio AVL Solutions Clustering of hardware and engineering activities Multi-variant simulation with the same engine family (RDE, OBD, EAS) Reduced test facilities/variant through front-loading 1 Improved quality and robustness through additional virtual validation Independence of environmental testing from seasonal conditions and vehicles availability Model-Based Development AVL UK Expo 215 2
Need for Model Based Development Front Loading: from Road to Office Measuring Post Processing Validation Actual effort Planning / Monitoring Dataset Management Test Field Host Test Bed Vehicle Data Vehicle Test Environments AVL UK Expo 215 3
Need for Model Based Development Front Loading: from Road to Office Measuring Post Processing Validation Actual effort Planning / Monitoring Dataset Management Test Field Host Test Bed Vehicle Data Vehicle Extension to the Virtual Environments MOBEO Methodology Test Environments AVL UK Expo 215 4
Need for Model Based Development Front Loading: from Road to Office Measuring Post Processing Validation Actual effort Advanced Test Automation CAMEO, PUMA, (SDS, RTC, imean) Planning / Monitoring MOBEO Methodology Dataset Management Test Field Host Test Bed Vehicle Data Vehicle Extension to the Virtual Environments MOBEO Methodology Test Environments AVL UK Expo 215 5
Need for Model Based Development Front Loading: from Road to Office Measuring Post Processing Validation Actual effort Advanced Post Processing Concerto Planning / Monitoring MOBEO Methodology Advanced Test Automation Dataset Management Test Field Host Test Bed Vehicle Data Vehicle Extension to the Virtual Environments MOBEO Methodology Test Environments AVL UK Expo 215 6
Need for Model Based Development Front Loading: from Road to Office Measuring Post Processing Validation Actual effort Quality Management Calibration Process, CRETA Planning / Monitoring MOBEO Methodology Advanced Test Automation Advanced Post Processing Quality Management Dataset Management Test Field Host Test Bed Vehicle Data Vehicle Extension to the Virtual Environments MOBEO Methodology Test Environments AVL UK Expo 215 7
Model Based Development CRUISE M and MoBEO MoBEO Modules Parameterization Wizard Model 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 SCR Scalable physical modeling depth for concept, calibration and test Engine After Treatment Flow Driveline Single platform for all AVL powertrain real-time models Multi-physics system simulation Open interfaces to 3rd party tools supporting standards (FMI) AVL UK Expo 215 8
MOBEO Model overview AVL UK Expo 215 9
Model Based Engine Optimization What is it? Model based development using a real time capable engine model Starting from concept phase until SOP calibration Engine model based on semiphysical 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 AVL UK Expo 215 1
Model Based Development -MoBEO Modelling Approach Virtual Basic model setup MoBEO Semi-physical Basic Model without measurement data refined model setup MoBEO Semi-physical Thermodynamic NOx-Emission EAS System (DOC, DPF, SCR, NLT) Empirical static global HC, CO, Soot, SPL, Cameo M&M Combinedmodel Increased number of engine specific outputs Model refinement HiL Setup MiL Setup fox Cal Model-based calibration of various variants Variant specific hardware change (e.g. intake piping, ) (No combustion HW change) Robustness analysis Pre-calibration Testbed results DoE Test Results Pre-calibration Field data Emission validation First engine Run Puma / Cameo T&M Base engine testbed development Puma / Cameo T&M DoE Measurements Puma / Cameo T&M Environmental validation Real Extension to the Virtual Environments Advanced Test Automation Post- Processing 11
Model Based Development -MoBEO Step 1 Modeling EU6 Base Engine HP EGR cooler Intake throttle valve Engine Model combined with EAS Model Modular combined Semiphysical models with high flexibility charge air cooler HP EGR walve turbocharger intake manifold cylinders exhaust manifold air cleaner SCR LP EGR cooler LP EGR valve DOC/DPF closed coupled AdBlue AVL UK Expo 215 12
Model Based Development -MoBEO Step 2 Modelling of Different Elements HP EGR cooler Intake throttle valve charge air cooler Change of EGR Cooler HP EGR walve turbocharger intake manifold cylinders exhaust manifold Change of T/C characteristics air cleaner SCR LP EGR cooler LP EGR valve DOC/DPF closed coupled AdBlue Change of EAS Components 13 P.GNANAM PTE 25 Feb 215
Development Process Consequent usage of real-time system simulation Concept / Layout Component and system development Endurance testing Calibration / Validation Consequent usage of real-time system simulation Start of Production AVL data base, measurements of single components Data engine test bed Data vehicle testing Modelquality AVL UK Expo 215 14
MOBEO Application environment AVL UK Expo 215 15
Changing Calibration Paradigm The right application environment at the right time MiL Setup HiL Setup Model in the Loop (MiL) Advantages + Simulation faster than real time (app. 5 to 1 times faster) + No hardware parts needed + Simulation on normal PC possible 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 - Availability of software ECU - Often not all ECU functionalities available 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 AVL UK Expo 215 16
WORK ENVIRONMENTS - XIL-STATION HiL Cabinet, including AVL Load-Drawer + HIL Base System (e.g. dspace, ETAS) with RTPC and I/O boards Operator Station, including 4 x 24inch Monitors PUMA CAMEO PUMA Testbed Workstation HIL SW INCA CAMEO Workstation HiL Host PC including, HiL Operator Software and ECU Application Software AVL UK Expo 215 17
AVL Standardized HiL Simulator Concept Real ECU & MoBEO Models in an Closed Loop I/O Actuators: e.g.: Throttle body, injectors, EGR valve, real ECU Closed Loop MoBEO Sensors: e.g.: Pressures, Temperatures, Speeds, AirFuelRatio, AVL UK Expo 215 Full Size HiL System 18
MOBEO Model accuracy AVL UK Expo 215 19
Model Accuracy in NEDC Passenger Car High model accuracy as base for model based calibration Torque [Nm] Speed [rpm] 35 29 23 17 11 5 2 15 1 5 Measurement Simulation UDC 1 EUDC NOx [mg/km] CO2 [g/km] model 173.91 165.6 measurement 163.8 161.3 deviation 6.23 % 2.6 % 6 5 NOx [g/h] 4 3 2 UDC 1 EUDC 1 Temp. Us. TC [ C] CO2 [kg/h] 6 45 3 15 6 4 2 Model is only adopted on one steady state operating map and one NEDC 5 1 15 2 time [s] 75 8 85 9 95 1 15 11 115 12 time [s] AVL UK Expo 215 2
Model Accuracy in Artemis Passenger Car High model accuracy as base for model based calibration CO2 [kg/h] Temp. Us TC [ C] NOx [g/h] Torque [Nm] Speed [rpm] 3 25 2 15 1 5 2 15 1 5 6 5 4 3 2 1 5 4 3 2 1 3 2 1 Measurement Simulation NOx [mg/km] CO2 [g/km] model 38.54 183.23 measurement 294.66 178.65 deviation 4.5 % 2.5 % 1 2 3 4 5 6 7 8 9 1 time [s] Minimal parameterization effort due to semiphysical modeling approach Simulation of different driving profiles without model refinement possible High model quality independent from calibration and operating conditions AVL UK Expo 215 21
Engine Speed [%] Intake Air Massflow [%] Opacity [%] Model Accuracy Commercial Vehicle High model accuracy as base for model based calibration 1 5 1 8 6 4 2 5 4 3 2 1 Typical deviations of the cycle emissions and fuel consumption as well as achievable temperature accuracy: Fuel Consumption < 3% NOx Emission < 1% Insoluble Particulate Emission < 15% Temperature Intake Side < 1 C Temperature Exhaust Side < 2 C 4 45 5 55 6 65 7 75 8 AVL UK Expo 215 22 Time [s] Measurement Simulation 1 8 6 4 2 1 8 6 4 2 55 5 45 4 35 3 Torque [%] NOx Concentration [ppm] T. Turbine-Inlet [ C]
MODEL BASED DEVELOPMENT Use - Cases AVL UK Expo 215 23
Model Based Development Concept Investigations Model based concept investigations Assessment of technology route Simulation of transient behaviour of engine in early concept phase on MiL environment 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 215 24
Model Based Development Powertrain Use cases HW Testing & Calibration engine & EATS modeling Virtual Testing & Calibration 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 AVL UK Expo 215 25
Model Based Development Calibration of Ambient Corrections Simulation of full load altitude operation for validation of ambient correction and engine protection functions 97mbar = 35m (Graz) 75mbar = 25m 66mbar = 35m 54mbar = 5m Limits for component protection Temp. upstr.turbine [ C] Pressure upstr. Turbine [kpa] HP TC Speed [rpm] 8 6 4 2 5 375 25 125 15 125 1 75 5 Limit temperature upstream turbine Limit temperature downstream compressor Limit pressure upstream turbine Limit LP turbochargerspeed Limit HP turbochargerspeed 2 1 1 5 LP TC Speed [rpm] Temp. ds. Compressor [ C] 7 8 9 1 11 12 13 14 No derating up to 25 m 15 16 17 18 19 2 AVL UK Expo 215 Engine Speed [1/min] 26 24 16 8 BMEP [kpa]
Model Based Development Calibration of Component Protection Functions Simulation of engine failure at full load for validation of engine protection functions Limits for component protection HP TC Speed [rpm] Pressure upstr. Turbine [kpa] Temp. upstr.turbine [ C] 8 6 4 2 5 375 25 125 15 125 1 75 5 Limit temperature upstream turbine Limit temperature downstream compressor Limit pressure upstream turbine Limit LP turbochargerspeed Limit HP turbochargerspeed 2 1 1 5 Temp. ds. Compressor [ C] LP TC Speed [rpm] 7 8 9 1 11 12 13 14 15 16 17 18 19 2 AVL UK Expo 215 Engine Speed [1/min] 27 24 16 8 BMEP [kpa]
Model Based Development OBD validation Simulation of Low Pressure EGR valve struck Low Pressure EGR Valve - Normal Low Pressure EGR Valve - struck @ 25% Low Pressure EGR Valve struck @ 5% AVL UK Expo 215 28
Model Based Calibration on XiL - test beds Virtual Test Beds as Extension of Real Test Facilities Calibration Driving Cycle Environment Boarders of applicability for HiL test bed Final Calibration Validation Certification Durability testing Pre-calibration of Start and Cold Start Idle stability Missfire Production Tolerances Aging Effects AVL UK Expo 215 29
Model Based Calibration on XiL - test beds Front Loading Ideal Lead Variant Calibration Project (i.e. no relevant H/W changes) Facilities HiL Engine Testbed Chassy Dyno Road AVL UK Expo 215 3
Model Based Calibration on XiL - test beds Front Loading Ideal Lead Variant Calibration Project (i.e. no relevant H/W changes) Facilities HiL Engine Testbed Chassy Dyno Road 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 AVL UK Expo 215 31
Model based calibration approach Example based on customer feedback: 1 NTE, Engine Protection and Ambient Corrections (1 Mode) Test Bed Time in Hours Conventional Approach 15 Calibration Validation Frontloading 8% Test Bed Time saved! Model Based Approach 2 1 4 Cal. Quality AVL Diesel-Calibration Quality Gates G5 Validated G4 Robust G3 Test Bed Target Achievement G2 Emission Targets Achieved G1 Engine Runnable G Engine Startable conventional Calibration process model based Calibration process Frontloading Quality SOP Model Based Calibration Approach: Calibration on XiL instead of Test Bed 8% Test Bed Time Saved per Engine Mode Test Bed available for Frontloading Tasks AVL UK Expo 215 32 Time Dataset Quality & Maturity increased in earlier phase of Development
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 AVL UK Expo 215 33