Model-based Calibration of HD Engines. Benjamin Tilch, Rico Möllmann, Axel Steinmann, Dr. Reza Rezaei GT-SUITE Conference, Frankfurt, October 2014

Model-based Calibration of HD Engines Benjamin Tilch, Rico Möllmann, Axel Steinmann, Dr. Reza Rezaei GT-SUITE Conference, Frankfurt, October 2014

Model-based Calibration of HD Engines Contents Introduction and motivation Model based calibration methodology Calibration of engine protection functions Conclusion 2

Model-based Calibration of HD Engines Contents Introduction and motivation Model based calibration methodology Calibration of engine protection functions Conclusion 3

Introduction and motivation Continuous Use of Physical Simulation Combustion Concept / Design System- / Function Development Powertrain Calibration / Test Vehicle Calibration / Test ICE First model setup and validation Continuous model adjustment Continuous model adjustment EAT Potential determination Component Investigations Concept layout Periphery design Choice of components Function development First desk calibration MIL/SIL tests Trouble-shooting from Back-office HIL-tests Model-based calibration Extrapolation of boundary conditions (altitude, climate) Vehicle Robustness testing 4

Introduction and motivation Continuous Use of Physical Simulation Combustion Concept / Design System- / Function Development Powertrain Calibration / Test Vehicle Calibration / Test ICE First model setup and validation Continuous model adjustment Continuous model adjustment EAT Potential determination Component Investigations Concept layout Periphery design Choice of components Function development First desk calibration MIL/SIL tests Trouble-shooting from Back-office HIL-tests Model-based calibration Extrapolation of boundary conditions (altitude, climate) Vehicle Robustness testing 5

Model-based Calibration of HD Engines Contents Introduction and motivation Model based calibration methodology Calibration of engine protection functions Conclusion 6

X86 Controller Model-Based Calibration Methodology Virtual Development Platform Standard-Application Process ETK/CCP INCA-FLOW COM Interface INCA ECU Read / Write Calibration Data Engine Dyno Test Vehicle Model-Based Calibration Object Code from Ascet / Simulink / GT SUITE RT Intecrio *.a2l-file Sensorand Actuator Models Soft-ECU ICE- and EAT-Model Simulation 7

Model-Based Calibration Methodology Software Tool Chain Model-Based Calibration Object Code from Ascet / Simulink / GT-SUITE-RT Intecrio *.a2l-file Sensorand Actuator Models Soft-ECU ICE- and EAT-Model Simulation *.a2l-file ETAS INTECRIO Engine Control Ascet EAT Control Simulink Engine Model GT-SUITE / GT-SUITE-RT IAV Phenomenological Combustion Model INCA INCA-FLOW 8

Model-Based Calibration Methodology Coupling GT Models to Tool Chain Variant 1 GT-POWER s-function Simulink.six C++ Compiler Simulink Coder ASCET.six INTECRIO.a2l INCA Variant 2 GT-POWER.dat Simulink.six GT-SUITE-RT Simulink Coder

Model-Based Calibration Methodology Open-Loop vs. Closed Loop Calibration Open-Loop Calibration x x Calibration of functions for steady-state operation, min/max-values etc. Preparation of maps based on simulation results Validation on engine test bench e.g. NH 3 dosing (map filling) Closed-Loop Calibration Calibration of functions for transient operation + Model/Software-In-the-Loop Simulation Validation on engine test bench e.g. soot loading, NH 3 storage, in cylinder measures 10

Model-based Calibration of HD Engines Contents Introduction and motivation Model based calibration methodology Calibration of engine protection functions Conclusion 11

Model-Based Calibration Method Calibration Engine Safety Functions Calibration of engine safety functions under extreme conditions like altitude, coldness or even damages in engine parts like blocking the intake air path. The complete engine model was calibrated and validated with steady-state measurements (engine map) and transient measurements (NRTC). The IAV physical-based combustion model is applied for a predictive simulation. A good match between measurement and simulation results is achieved. 12

Model-Based Calibration Method Engine Process and Combustion Modeling Example results of the IAV phenomenological combustion model (A: 1200 min -1, B: 1500 min -1, C: 1900 min -1 ; 25 % - 100 % Load). See also SAE International Journal of Engines 5(3): 2012 und SAE 2012-01-1065 13

Model-Based Calibration Method Calibration Engine Safety Functions Validation of the model-based calibration engine safety function in real-life cycle at ca. 800m altitude. Failure case: Blocking of the wastegate valve which leads to high turbocharger temperature and speed. The failure is detected by exceeding the boost pressure to the limit which is given as input to the model. The failure is detected by the model, the boost protection modus is activated. In protection modus, the injected fuel mass is reduced to decrease the temperature and also TC-speed. 14

Model-based Calibration of HD Engines Contents Introduction and motivation Model based calibration methodology Calibration of engine protection functions Conclusion 15

Model-based Calibration of HD Engines Summary and Conclusion 16

Model-based Calibration of HD Engines Summary and Conclusion 17

Model-based Calibration of HD Engines Summary and Conclusion 18

Model-based Calibration of HD Engines Summary and Conclusion 19

Model-based Calibration of HD Engines Summary and Conclusion 20

Model-based Calibration of HD Engines Summary and Conclusion 21

Thank You Benjamin Tilch P&E Concepts / Functions, MD-N21 Commercial Vehicle Powertrain Business Area Powertrain Mechatronics IAV GmbH Nordhoffstrasse 5, 38518 GIFHORN (GERMANY) Tel. +49 5371 80-53021 benjamin.tilch@iav.de www.iav.com 22