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April 25, 2012 A&D Automated Calibration Tool: ORION.

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Presentation on theme: "April 25, 2012 A&D Automated Calibration Tool: ORION."— Presentation transcript:

1 April 25, 2012 A&D Automated Calibration Tool: ORION

2 Overview: What is ORION ORION is a supervisory test cell control system ORION automates the characterization of engines ORION data is used to optimize engine control ORION supports a variety of DoE and Optimization tools –MBC toolbox from the Mathworks –Easy DoE from IAV –Excel spreadsheet Developed and maintained by A&D and IAV GmbH

3 Overview: What is ORION? User imports or defines a set of parameters and a sequence of actions to complete the tests Test plan can be DoE from several tools Takes control of ECU calibration system and test bench to run tests using action sequence with setpoints from experiments During test data is collected to be used to characterize the engine Data is then used to optimize the engine in the model based calibration process for optimization

4 EGR A/F ratio Environmental Conditions Spark Timing Shifts Start of Injection Exhaust Cam Timing Intake Cam Timing Drive by Wire Noise and Vibration Performance Emissions Driveability Requirements: New Processes and Tools Many Parameters to Vary Fuel Efficiency Overview: The Problem

5 Model Based Calibration Complexity Time Conventional Model Based Overview: The Solution

6 Full factorial map (18 points) Input Response Input Response DOE map ( 7 points) Overview: Aim of DoE Design

7 ORION test automation : ‒ Flexible test automation by user-defined test sequence ‒ Expandable function library ‒ Supports of a wide variety of DoE - and calibration tools ‒ Open workflow: advanced tools for experts or simplified GUI for standard tasks experiment design MBC Toolbox DoE expert or Simplified GUI (e.g. MBC-Commandline) calibration engineer … or other tools user for tool mapping MBC Toolbox DoE/calibration expert or Simplified GUI (e.g. MBC-Commandline) calibration engineer … or other tools user for tool optimization MBC Toolbox DoE/calibration expert or Simplified GUI (e.g. MBC-Commandline) calibration engineer … or other tools user for tool MPI² (or ATLAS) ORION calibration engineer modeling MBC Toolbox DoE expert or Simplified GUI (e.g. MBC-Command line) calibration engineer … or other tools user for tool measurement workflow company B workflow company A Overview: ORION Calibration Process

8 iTEST iTEST (or any DAC) ORION ORION (Supervisory Control) iTEST (Real-Time Control) – any DAC system possible with driver ANDROMEDA (ADX Dyno/Throttle Controller) DoE Tool CAS System ECU Development Tool (INCA/Vision) MathWorks ASAP3 Test Plan CONSTRAINTS (Data) 1. Exhaust Temp 2. Knock 1. Global ORION Communication iTEST Communication PROCEDURES 1. Start 2. ORION Command 3. Stop LIMITS (engine) 1. Temp 2. RPM 3. Pressure PIDs iCONNECT TEST BED 2. Local Spark Sweep 3. Local AFR Sweep ASAP 3 Overview: ORION in the Test Cell

9 Automated Engine Test Run Parameter Define Parameter Properties (e.g. limits, step width, channel names, …) ExcelMBC-Toolbox Test Plan Parameter Setup: Test bench system ECU Sequence Define Execution Order of Actions Set Action Options (choose parameter to set and limit parameter) Overview: Build Configuration

10 MDA – Measurement Definition Application: The Configuration GUI MA – Measurement Application: The Test Execution GUI Overview: ORION Programs

11 ORION Configuration ECU parameter and map names *.a2l file Test plan *.csv file (Excel, MBC-Toolbox, …) ORION Configuration Excel MBC-Toolbox match columns with parameter names Overview: File Input Interfaces

12 ORION ECU Calibration System PC Test Cell System PC ORION-Interface ETAS INCA Ethernet link ASAP3 on TCP/IP + UDP for high speed data transfer ORION High Speed Interface ORION-Interface ASAP3 Server A&D iTest/ADAPT ASAP3 Client ASAP3 Client Standardized protocol: ASAP3, ASAM-MCD3 ASAP3 Detail: Connection in Test Cell (1)

13 ORION ECU Calibration System PC Test Cell System PC ORION-Interface Vector CANape Ethernet link ASAP3 on TCP/IP + UDP for high speed data transfer ORION High Speed Interface ORION-Interface ASAP3 Server AVL PumaOpen ASAP3 Client ASAP3 Client Standardized protocol: ASAP3, ASAM-MCD3 COM Detail: Connection in Test Cell (2)

14 Load Configuration Start Pause Stop Step Level of Usage: Easy to use test run interface handled by test cell operator Running of predefined sequences for standard tests Required Skills: Experience of work at the test cell Work with standard PC program Using: Easy Interface for Operator

15 Level of Usage: Easy to use configuration GUI handled by calibration engineer and experienced test cell operator Modification of parameter properties (limits, step width) Changing test sequence by choosing functions from the Action Library Required Skills: Engine calibration experience Sequence Definition Test Plan Parameter Definition Using: Configuration by Engineer

16 Level of Usage: Open programming interface with templates to create user defined strategies Add new functions to the Action Library Support for different programming languages (Simulink, m-Files, C#, …) OutputsInputs Action Library Building Test Sequence User-defined Function Using: Customization by Expert

17 Offline ECU model calibration DoE-Model output => ECU model output rl=20% WOT Spark sweep Optimization Evaluation Filling ECU Maps Experimental Design Test Bench Measurements Model- Building Definition of Factors and Responses ORION Example ECU Structure: KFMIRL (calculation set value air mass) KFMDS (friction torque) ETADZW (spark dependence) ETALAM (lambda dependence) Model-Based Calibration Example ECU-torque model

18 Torque Ignition Angle 100% 45 °CA 10 °CA 0% Limit of: HC COV Catalyst Temperature Limit of: HC COV Knocking Limit torque max 1.Find MBT 2.Set Spark Timing Offset relative to MBT (value given by test plan) DoE-Instruction for Measurement (collect 2 data points per spark sweep) Model-Based Calibration Example

19 Spark Sweep SequenceParameter DefinitionLimit Definition Store Values For Reset all Maps, Parameters Start Parallel Control 1 + 2 Cntr1: CA50, Cntrl2: AFRCntrl1: Knock, Cntrl2: Exh.Temp. Set Operating Point Speed, Relative Load Set Direct Swirl Flap Set Stepwise Camshaft PositionCOV, HC Set Indirect EGR-Rate using EGR-ValveCOV, HC Stop Parallel Control Control 1: CA50, Control 2: AFR Optimize Torque by SparkTimingKnock, Exh.Temp.,COV, HC Stabilize Exhaust TemperatureKnock, Exh.Temp.,COV, HC Measure TimeKnock, Exh.Temp.,COV HC Set Stepwise SparkTiming OffsetKnock, Exh.Temp.,COV HC Measure TimeKnock, Exh.Temp.,COV HC Stabilize Exhaust TemperatureKnock, Exh.Temp.,COV HC Reset ECU all Maps, Parameters Model-Based Calibration Example

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21 Included Test Bench Integration Interfaces –iTest, ADAPT, PUMA, FEV TCM and others Included ECU Calibration Tool Interfaces –ETAS INCA, ATI Vision, Vector CANape Included Actions Configuration file –ORION XML configuration file Input files –*.csv DoE file, *.a2l file ECU parameters Output files –*.csv measurement file Specifications: Included Components

22 Using this process of combining ORION in the test cell for measurement with DoE and modeling tools has been used to turn test cycles of months into weeks –Accuracy of the calibration in all cases has been better or the same –Repeatability is always enhanced. ORION uses ASAM MCD interfaces where possible in the test cell environment to automate the difficult task of measurement –ORION adapts to existing test cell architectures as necessary. Summary


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