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

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April 25 2012

A&D Automated Calibration Tool: ORION

April 25, 2012


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

Overview: What is ORION


Overview what is orion1

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


Overview the problem

Environmental

Conditions

Intake

Cam Timing

Shifts

Start of

Injection

Spark

Timing

Exhaust

Cam Timing

A/F ratio

Drive by

Wire

EGR

Overview: The Problem

Many Parameters to Vary

Fuel Efficiency

Noise and

Vibration

Emissions

Performance

Driveability

Requirements: New Processes and Tools


Overview the solution

Overview: The Solution

Model Based Calibration

Conventional

Model Based

Time

Complexity


Overview aim of doe design

Full factorial map(18 points)

Response

Input

DOE map( 7 points)

Response

Input

Overview: Aim of DoE Design


April 25 2012

experiment design

modeling

optimization

mapping

MBC Toolbox

MBC Toolbox

MBC Toolbox

MBC Toolbox

DoE expert

DoE/calibration expert

DoE/calibration expert

DoE expert

or Simplified GUI

(e.g. MBC-Commandline)

or Simplified GUI

(e.g. MBC-Commandline)

or Simplified GUI

(e.g. MBC-Commandline)

or Simplified GUI

(e.g. MBC-Command line)

calibration engineer

calibration engineer

calibration engineer

calibration engineer

… or other tools

… or other tools

… or other tools

… or other tools

workflow company A

workflow company B

user for tool

user for tool

user for tool

user for tool

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

measurement

ORION

MPI² (or ATLAS)

calibration engineer


Overview orion in the test cell

ORION

iTEST (or any DAC)

iTEST

PIDs

ASAP 3

ORION Communication

iTEST Communication

Overview: ORION in the Test Cell

ORION (Supervisory Control)

iTEST (Real-Time Control) – any DAC system possible with driver

DoE Tool

Test Plan

1. Global

2. Local Spark Sweep3. Local AFR Sweep

TEST BED

CONSTRAINTS (Data)

PROCEDURES

iCONNECT

1. Start2. ORION Command3. Stop

1. Exhaust Temp 2. Knock

MathWorks

LIMITS (engine)

1. Temp2. RPM3. Pressure

ECUDevelopment Tool (INCA/Vision)

ASAP3

ANDROMEDA(ADX Dyno/Throttle Controller)

CAS System


Overview build configuration

Sequence

Parameter

Test Plan

Excel

MBC-Toolbox

  • Define Execution Order of Actions

  • Set Action Options(choose parameter to set and limit parameter)

  • Define Parameter Properties(e.g. limits, step width, channel names, …)

  • Parameter Setup:

  • Test bench system

  • ECU

Overview: Build Configuration

Automated Engine

Test Run


Overview orion programs

Overview: ORION Programs

MDA – Measurement Definition Application: The Configuration GUI

MA – Measurement Application: The Test Execution GUI


Overview file input interfaces

ORION Configuration

ECU parameter

and map names

*.a2l file

ORION Configuration

Excel

Test plan *.csv file

(Excel, MBC-Toolbox, …)

MBC-Toolbox

match columns with parameter names

Overview: File Input Interfaces


Detail connection in test cell 1

ORION High Speed Interface

ORION High Speed Interface

Ethernet link

ASAP3 on TCP/IP

+ UDP

for high speed data transfer

ORION-Interface

ASAP3

Client

ASAP3

Server

ASAP3

Standardized protocol:

ASAP3, ASAM-MCD3

ASAP3

Client

A&D

iTest/ADAPT

Test Cell System PC

Detail: Connection in Test Cell (1)

ORION

ORION-Interface

ETAS INCA

ECU Calibration System PC


Detail connection in test cell 2

ORION High Speed Interface

ORION High Speed Interface

Ethernet link

ASAP3 on TCP/IP

+ UDP

for high speed data transfer

ORION-Interface

ASAP3

Client

ASAP3

Server

COM

Standardized protocol:

ASAP3, ASAM-MCD3

ASAP3

Client

AVL

PumaOpen

Test Cell System PC

Detail: Connection in Test Cell (2)

ORION

ORION-Interface

Vector CANape

ECU Calibration System PC


Using easy interface for operator

Using: Easy Interface for Operator

Load

Configuration

Start

Stop

Pause

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 configuration by engineer

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


Using customization by expert

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


Model based calibration example

Definition of

Factors and

Responses

Spark sweep

Experimental

Design

WOT

Test Bench

Measurements

ORION

rl=20%

Model-

Building

OptimizationEvaluation

Filling

ECU Maps

Model-Based Calibration Example

ECU-torque model

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


Model based calibration example1

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

10 °CA

45 °CA

0

%

1

0

0

%

Torque

torquemax

  • Find MBT

  • Set Spark Timing Offset relative to MBT(value given by test plan)

Ignition Angle


Model based calibration example2

all Maps, Parameters

Store Values For Reset

Cntr1: CA50, Cntrl2: AFR

Cntrl1: Knock, Cntrl2: Exh.Temp.

Start Parallel Control 1 + 2

Speed, Relative Load

Set Operating Point

Swirl Flap

Set Direct

Camshaft Position

COV, HC

Set Stepwise

EGR-Rate using EGR-Valve

COV, HC

Set Indirect

Control 1: CA50, Control 2: AFR

Stop Parallel Control

Torque by SparkTiming

Knock, Exh.Temp.,COV, HC

Optimize

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

Model-Based Calibration Example

Spark Sweep Sequence

Parameter Definition

Limit Definition


Specifications included components

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


Summary

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.


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