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

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

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

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

7. Overview: ORION Calibration Process
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
measurement
modeling
MBC Toolbox
DoE expert
or Simplified GUI
(e.g. MBC-Command line)
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
mapping
MBC Toolbox
DoE/calibration expert
or Simplified GUI
(e.g. MBC-Commandline)
calibration engineer
… or other tools
user for tool
ORION
workflow company A
MPI² (or ATLAS)
workflow company B
calibration engineer

8. Overview: ORION in the Test Cell
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

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

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

11. Overview: File Input Interfaces
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

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

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

14. Using: Easy Interface for Operator
Load
Configuration
Start
Pause
Step
Stop
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

15. Using: Configuration by Engineer
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
Parameter Definition
Sequence Definition
Test Plan
Required Skills:
Engine calibration experience

16. Using: Customization by Expert
Building Test Sequence
Action Library
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#, …)
User-defined
Function
Inputs
Outputs

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

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

19. Model-Based Calibration Example
Spark Sweep Sequence
Parameter Definition
Limit Definition
Store Values For Reset
all Maps, Parameters
Start Parallel Control 1 + 2
Cntr1: CA50, Cntrl2: AFR
Cntrl1: Knock, Cntrl2: Exh.Temp.
Set Operating Point
Speed, Relative Load
Set Direct
Swirl Flap
Set Stepwise
Camshaft Position
COV, HC
Set Indirect
EGR-Rate using EGR-Valve
COV, HC
Stop Parallel Control
Control 1: CA50, Control 2: AFR
Optimize
Torque by SparkTiming
Knock, Exh.Temp.,COV, HC
Stabilize
Exhaust Temperature
Knock, Exh.Temp.,COV, HC
Measure
Time
Knock, Exh.Temp.,COV HC
Set Stepwise
SparkTiming Offset
Knock, Exh.Temp.,COV HC
Stabilize
Exhaust Temperature
Knock, Exh.Temp.,COV HC
Measure
Time
Knock, Exh.Temp.,COV HC
Reset ECU
all Maps, Parameters

21. Specifications: Included Components
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

22. Summary
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.