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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


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

    2. 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

    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. 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

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

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

    7. 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

    8. 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

    9. 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

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

    11. 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

    12. 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

    13. 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

    14. 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

    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. 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

    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 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

    19. 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

    20. 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

    21. 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.