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1 Your Partner in Powertrain © AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties Controls and Software Development for Modern Diesel Engines Dr. Umut Genc Managing Director AVL Turkey Dr. Serkan Impram Team Leader AVL Turkey

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Controls and Software Development for Modern Diesel Engines

Dr. Umut Genc Dr. Serkan Impram

Managing Director Team Leader

AVL Turkey AVL Turkey

Your Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

1

AVL Your Global Powertrain Control Engineering Partner

Ann Arbor (USA)

Sdertlje (SWEDEN)

Steyr (AUSTRIA)

Istanbul (TURKEY)

Lake Forest (USA)

Dunton (UK)

Regensburg (GERMANY)

Graz (AUSTRIA)

Budapest (HUNGARY)2

Your Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

AVL Turkey

Founded in August 2008 Based in Tax-free Techno Park in Gebze near Istanbul (40km) Team of 16 electronics and mechanical engineers Serves Turkish industry both in engineering and test systems

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3

AVL Turkey Key Skills

SW & ElectronicsAlgorithm Dev. Function Dev. Software Dev. MIL/HIL Testing

CalibrationEmissions Aftertreatment Driveability

8 2 2

3

ElectrificationHybrid Vehicles E-Drives BatteriesYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

Test SystemsProject Management Service & Maintenance4

Powertrain Controls and Software Development Agenda

Introduction Model-Based Development Process Engine Models Controls Conclusions

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5

Powertrain Controls and Software Development Agenda

Introduction Model-Based Development Process Engine Models Controls Conclusions

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6

Powertrain Management System A Small Part of a Distributed Vehicle Control SystemCAN Class B CAN Class C MOST Bus Private Bus

25 MBaud 500 kBaud

83,3 kBaud

Conventional Wiring

Source: MaybachYour Partner in Powertrain AVL List GmbH

all Electronic Control Units: 767

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Powertrain Management System Example: ECU Requirements

HARD Emissions Fuel Economy Diagnostics

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8

Powertrain Management System Example: ECU Requirements

SOFT Torque Power Drivability NVH

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Powertrain Management System Example: Gasoline Engine Configuration

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10

Powertrain Management System Example: Diesel Engine Configuration

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11

Powertrain Management System Example: ECU Requirements

Ignition / Injection calculation Compensate for component aging and tolerances adaptation algorithms Interface to Powertrain TMS, ESP, ABS, Cluster, Immobilizer, . CO2 reduction measures Stop&Start, Battery management, .. Auxiliary functions A/C, heater control, cooling fan, .. Vehicle safety, monitoring

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Powertrain Management System Example: Generic ECU ConfigurationClutch Switch Brake Test Switch Manifold Air Flow Pedal Value Sensor 1/2 Temperature Coolant Throttle Position Fuel Pressure Manifold Air Pressure Knock Sensors LIN, FlexRay SENT, BSD Powertrain CAN Vehicle CAN Voltage Ignition (KL15) Voltage Main Relay (KL87) Voltage Battery (KL30) GROUND Battery (KL31) Sensor Supply Sensor GroundYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

COREDigital Interface Monitoring UnitSPI

Power Stage (Low SideHigh Side Driver)

Controller Analog Interface (signals multiplexed) Infineon, FreescaleSPI

Canister Purge Solenoid Variable Intake Manifold Main Relay Control Waste gate Malfunction Indication Lamp Fuel Pressure Actuator Piezo DI Injectors Solenoid DI Injectors External Ignition Drivers (TTL) Internal Ignition Stage Throttle Turbo EGR BOSCH LSU 4.9 NGK ZFAS U1/2 Solenoid Injector

Power Stage (Injection Driver)

Knock Interface Interfaces

SPI

FlexRay Controller

SPI

Ignition Driver

SPI

H-Bridges

CAN

SRAMSPI

Linear Lambda

EEPROM Power UnitSPI SPI

Injection Driver (MPI)

(DEKA 7)

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Powertrain Management System Software / System complexity

150 I/O (154 pin connector is standard, 196 pins for high-end) 700 system functions 10.000 A4 pages of specification 350.000 lines of code 20.000 parameters (~250 kbyte) 25% of customer object code (increasing) Complex and fast real-time behavior Software accounts for 50-70% of ECU development costs. Software & Electronics account for ~40% of vehicle cost with 13% of that coming from software alone.Your Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties60%

Tasks distribution50%

40%

30%

20%

More than 80% of code executed in less than 10 ms

10%

0% Ini 10 ms 20 ms 40 ms 100 ms 1000 ms Reset 1 ms 5 ms Seg

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Engine Management System Hardware and Software Architectures

EMS Hardware Architecture Overview, Block diagram Digital Core Inputs, Outputs Monitoring Unit EMS Software Architecture Infrastructure Layer Application Layer

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Engine Management System Main Hardware BlocksDigital CoreMicrocontroller Code Memory, Data Memory, Non-volatile memory Power Supply and Reset generator Manufacturing Test Interface, Debug and Emulation Interface Clock Circuitry

Inputs (sensors & signal acquisition) Outputs (actuators, power stages) Monitoring Unit

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Engine Management System Main Hardware Blocks Microcontroller State-of-the-Art Microcontrollers are 32-bit Typical performance values (e.g. Infineon TC1796):32-bit CPU Single precision FPU 2 MB Embedded Flash 144 kB internal RAM 32-bit Peripheral Control Processor Up to 129 digital I/O pins 36 + 4 analog input pins 4 x V2.0B CAN Controller 150 MHz@ -40 125 CYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

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Engine Management System Main Hardware Blocks MemoryThe memory sub-system can be located directly on the microcontroller (internal memory, on-chip), connected via a bus system to the microcontroller (external memory, off-chip), or both.Utilization Original programming Programmed at manufacturing and/or End-Of-Line Contents retained over lifetime

Code memory Flash, ROM

Program code storage Parameter storage Constants Initialization values

Data memory RAM

Program data storage

Generated during program execution Contents lost after power down

Non-volatile data memory Accumulated data Flash EEPROMAdaptation values Diagnostic/Error Codes

Programmed at manufacturing and changed during program execution Contents retained after power down

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Engine Management System Main Hardware Blocks MonitoringTypical 3-level monitoring of ECU

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Engine Management System Hardware and Software ArchitecturesWhat is an Engine Management System Hardware? EMS Hardware Architecture Overview, Block diagram Digital Core Inputs, Outputs Monitoring Unit EMS Software Architecture Infrastructure Layer Application Layer

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Engine Management System Software Architecture Top LevelDriver/Operator Demand Powertrain Coordinator Hybrid Coordinator Brake System

Diagnostic Services

Combustion Engine

Engine Exhaust

Transmission

Electrical Machine

Electrical Store

Alternative Energy

Body/Chassis other Systems

Control of System State

Engine Air (EngGas)

System interfaces

Safety Monitoring

Integration Platform AUTOSAR RTE or customer specific Basic Software Electronic Control Unit Combustion Engine Engine Exhaust System Transmission Electric Machine Hybrid Vehicle System

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21

Powertrain Controls and Software Development Agenda

Introduction Model-Based Development Process Engine Models Controls Conclusions

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Model-Based Development Process Factors Influencing SW Quality (bunu gostermeye gerek yok bence)

SW Quality

Process Quality

Project Quality

Work Environment Quality

Run Selection

Data Selection

Result view

PEOPLEYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

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Model-Based Development Process V-CycleV-Cycle development capabilities in all varieties V-Cycle development capabilities in all varietiesSYSTEM

Requirement engineering

RPT unit (RPU)

Verification and Validation

ALGORITHM Modeling & simulation

Testing / HIL

(Auto-) CodingSOFTWARE

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Model-Based Development Process Integrated Methods & ToolsProcess

Phase-Based-View

Methods

Configuration Management

Change Management

Verification & Validation

Requirement s Engineering

Project Management

Coding Guidelines

Architecture & Design

Project Management

Quality Assurance

AUTOSAR

Simulation

Release Management

Tools

AVL PoETYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

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Model-Based Development Process Integrated Methods & ToolsInternal development customer / target independentLabel repository

Customer / internal delivery

ModelingMatlab / Simulink Requirements TargetLink

Code Generation

SW Build

.o .s19 .hex

Ascet SEAscet MD Physical model (Floating-point) Implementation model (Fixed-point)

Code generator Configuration

.cFile

SW BuildMake, Perl,

.a2l .odxTools Compiler,

Project Config.

Compiler Options

MKS source

MKS Integrity

Application Lifecycle Management

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Model-Based Development Process Different Software Tests at Different Development Stages

MiL Model in the LoopFloating Point Arithmetic

Rapid Prototyping

PC

System test HiL, Car

Implementation: floating -> fixed-point

SiL Software in the LoopImplementation Code Fixed Point Arithmetic

Integration test

PC

HiL Hardware in the LoopOptimization for target C

Unit test PiL Processor in the LoopImplementation Code Fixed Point Arithmetic

Target HW

Debugger

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Model-Based Development Process MiL Model in the LoopTest execution on standard development PC, no real time behavior necessary Floating point execution of the function under development Plant model development and adaptation for test requirements Test script development and execution When all test criteria are fulfilled SiL, rapid prototyping

Model Based Function DevelopmentASCET, SIMULINK Response Stimulation

Test Automation

Developer PC

Plant ModelASCET, SIMULINKYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

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Model-Based Development Process SiL Software in the LoopFixed point C-code execution on developers PC, no real time behavior necessary Plant model and test script re-use from MiL tests Additional test scripts to detect implementation and code generation failures Tolerance band definition due to accuracy loss caused by implementation Comparison of test results with MiL test results

Automatic generated C-Code Hand written C-CodeResponse Stimulation

Test Automation

Developer PC

Plant ModelASCET, SIMULINKYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

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Model-Based Development Process HiL Hardware in the LoopFunction integration on target ECU Plant model executed in real time on HiL system Test script reuse from MiL / SiL / PiL tests Additional calibration system necessary Comparison of test results with SiL / PiL test results and function requirements

Target ECU Test Bench PC Wiring harness Calibration Link HiL Interface HiL Test Bench

TestAutomation Calibration System INCA, CalDesk HiL System Control Operator, Control DeskYour Partner in Powertrain AVL List GmbH

Real time Hardware

Plant Modelrunning in real time

30

AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

Powertrain Controls and Software Development Agenda

Introduction Model-Based Development Process Engine Models Controls Conclusions

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31

Powertrain Controls and Software Development Mean-Value Engine Models

Engines are nonlinear systems with multiple inputs and outputs Mean value models represent system behaviour over a cycle and are used for controls & software development

1 Wie (k ) = o 180

k 180

w

4

ie

( )d

( k 1)180 i =1

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32

Powertrain Controls and Software Development Mean-Value Engine Modelsk 180 4

1 Wie (k ) = 180o

w

ie

( )d

( k 1)180 i =1

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33

Powertrain Controls and Software Development Mean-Value Engine Models

Tw Pi Ti Wi P m V

Q Po To T Wo

Work

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34

Powertrain Controls and Software Development Mean-Value Engine Models

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35

Powertrain Controls and Software Development Mean-Value Engine Models

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36

Powertrain Controls and Software Development Engine Models AVL MoBEOEngine Model

Torquedem Engine speed

. m p,T

Engine Model comprises: ECU + sensors & actuators + engine + exhaust aftertreatment Semi-empirical engine model embedded in plant model.

Sensors & Actuators

Model ECU

Engine Hardware Model

p,T

Torque NOx, Soot, HC, CO, BSFC, Heat to coolantYour Partner in Powertrain AVL List GmbH

Engine model is mainly 0dimensional with volumes, restrictions and special components (e.g. combustion, turbine, catalyst). Resulting in states and fluxes in software platform (Matlab/Simulink).

MOBEO = Model Based Engine Optimisation37AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

Powertrain Controls and Software Development Engine Models AVL MoBEOControls & Diagnostics algorithm design in Matlab / Simulink Software function tests: - Test case design, automated execution & evaluation - MiL tests = SW + MoBEO engine & Exhaust Aftertreatment System simulator Offline pre-calibration using MoBEO Verification with production SW: - SiL tests = Production SW + MoBEO Verification in production ECU - HiL tests with signal stimulator - Calibration on HiL test rig with MoBEO

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38

Powertrain Controls and Software Development Engine Models AVL MoBEO

Controlalgorithm

TargetLink

MiL tests ECU Code Generated Customer Code Code

SiL tests

MoBEO

Selected Production SW Applications at AVL: DPF / Air Path Control & Diagnosis Software DOC / SCR Diagnosis SoftwareYour Partner in Powertrain AVL List GmbH AVL reserves all rights even in the event of industrial property rights. AVL reserves all rights of disposal such as copying and passing on to third parties

MoBEO = Model Based Engine Optimisation39

Powertrain Controls and Software Development Example: On-board DiagnosticsAVLs integrated tool chain allows development of OBD algorithms before hardware is available High-Quality BOOST models of exhaust components Defined model calibration procedure Simulated catalyst ageing Real time engine model to simulate engine-out emissions OBD software development in Simulink Pre-calibration on modelSCR Model

(c) AVL / DGE 2006 RTI Data CAN Co ntrol ler Setu p [DCU_ st_m]DC U_st_m Com _dmActPSCR Ctl1 ENG_nrpm _m AMB_m f kgps_m SCR _tcU p_m SCR _tcDwn_m INJ_mgpi_m EXH _phScrU p_m swDosingC ameo swC am eoOption AB_mf m gpsCameoD em AB_alphaCameoD em SC R_rppm NH 3Dwn CEB_rppm NoxEo EXH _m f kgps_m DC U_st AB_m f mgps_m INJ_mf m gpi_m AB_mf m gpsAdapt AdBlue ENG_nrpm _m AMB_mf kgps EXH_phScrUp_m

DCU_st_m [AB_mfmgp s_m] ENG_nrpm_m [AMB_ mfkgps_m] [SCR_ tcUp _m] [SCR_tcDwn_m] [INJ_mfmg pi_m] [EXH_ phScrUp_m] swDosi ngCame o swCameo Optio n AB_mfmg psCameoDem AB_a lpha CameoDem SCR_rp pmNH3Dwn CEB_rppmNoxEo [EXH_mfkg ps_ m] [SCR_rppmNoxUp_ m] [SCR_rNoxDwn_m] [EXH_mfkgps_m] [EXH_ph ScrUp_m] [SCR_ rppmNH3Dwn] [SCR_tcUp_m] [SCR_tcDwn_m] [AB_mfmgps_m] -K[AB_mfmgps_m] [INJ_mfmgpi _m] [ENG_nrpm_m] [AMB_mfkgp s_m]

(NH2)2CO - Urea inj ection (vi a CAN)

SCR _rN H3Dwn SCR _tcU p_m SCR _tcD wn_m AB_m f mgps_m SMF_rN H3 SCR _rppm NoxUp_m SCR _rN oxDwn_m EXH_m f kgps

DAC NH3 gas i njecti on (Anal og Si gnal Out)

Input MPE: DCU \ Gene ral Para meter \ NGK Sonde NGK_sw -CEnable SCR _rN oxUp_m SCR_rppmN oxUp_m SCR _rNoxD wn_m SCR_rppmNoxD wn_m SCR _rNoxEO_m SCR_rppmNoxEO_m NGK_st

SCR Strategy op en SCR Li brary SCR_rppmNoxUp_ m Goto18 pmNoxDwn_m SCR_rp Goto19 SCR_rppmNoxEO_m NGK_st Goto15 Goto2 0 open DCU.mat with MPE

[SCR_ rNo xUp_m] Goto [SCR_rNoxDwn_ m] Goto1

[ENG_nrpm_m]

EN G_nrpm _m

NGK Sonde Aktiva ti on / Recei ve / Send Bootschaft

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40

Powertrain Controls and Software Development Agenda

Introduction Model-Based Development Process Engine Models Controls Conclusions

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41

Powertrain Controls and Software Development Typical Common Rail Diesel System

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42

Powertrain Controls and Software Development Controls Torque Based Structure

TORQUE DEMAND FUELTIMING AMOUNT

AIRBOOST EGR

IDLE GOVERNOR AFTERTREATMENT

Fuel consumption Efficiency Emissions Performance Temperatures .A Good Control Strategy is Required A Good Control Strategy is Required

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43

Powertrain Controls and Software Development Controls Typical Feedback LoopPID gains usually depend on speed, load and possibly other parameters Each application may need up to 300 points tuned This makes the tuning process time consuming

Torque

Error

Speed

Precontrol

Setpoint

PID Controller

System Dynamics

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44

Powertrain Controls and Software Development Controls Exhaust Gas Recirculation (EGR)A certain amount of exhaust gas is recirculated back into the inlet manifold to improve NOx emissions EGR system could be high pressure or low pressure In modern diesel engines, EGR is controlled via EGR valve, and throttle valve.

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45

Powertrain Controls and Software Development Controls EGRTARGET: Regulate NOx Emissions Regulate EGR Valve position Control EGR Valve actuator Cascade control Inner loop: position control (PID) Outer loop: flow control (PID) Challenges Time delay, Multi Input (e.g. speed, torque demand, fuel & air flow)

Pre-control

Pre-control Engine Dynamics

Setpoint

Controller

Setpoint

Controller

EGR Valve

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46

Powertrain Controls and Software Development Controls EGRNormal Operation Conditions Controls to fulfill Emissions requirements Low fuel consumption Drivability Balancing production tolerances Balancing deviations over life time Adopting to environment in Engine Warm/cold Idling, part load, full load Vehicle Ambient temperature Ambient pressure Fault Operation Conditions Electrical failures Component failures Leakage Sensor Drift System failures Oil dilution OBD relevance Non-functional Requirements Performance Safety/monitoring Error handling & diagnosis Security Quality Robustness Testability Users' experience Reliability Modifiability C resources

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47

Powertrain Controls and Software Development Controls Performance / Boost ControlHistorically, turbo was utilized for increased engine performance. Nowadays, turbo is used also for engine downsizing leading to smaller & lighter engines. This, in turn, leads to lower fuel consumption & emissions while maintaining (or increasing) performance.

Turbine: rotates with power from exhaust gas Compressor: connected to same axis with turbine & compresses air into cylinders

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48

Powertrain Controls and Software Development Controls VGT operation

at high RPM

at low RPM

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49

Powertrain Controls and Software Development Controls Performance / Boost ControlBoost controller is similar to EGR controller

Pre-control

Pre-control

MAP Setpoint

Controller

Setpoint

Controller

VGT Vane Positions

Engine Dynamics

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50

Powertrain Controls and Software Development Controls Air Path (EGR & Boost)In most applications, EGR & Boost loops are assumed to be decoupled and, as such, controlled separately as shown previously In reality, however, there is strong interaction between these two loops Multi-Input / Multi-Output (MIMO) controllers might give improved results !

Air-PathEGR Controller

Ref

+VGT

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51

Powertrain Controls and Software Development Agenda

Introduction Model-Based Development Process Engine Models Powertrain Controls Conclusions

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52

Powertrain Controls and Software Development ConclusionsModern diesel engines are complex & sophisticated systems Controls & Software development for such systems requires well-established engineering processes well-structured multi-disciplinary teams advanced controls knowledge practical experience with state-of-the-art control systems handling a vast array of sensors & actuators good understanding of, and experience with, real-time systems hardware & software

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Many thanks for your time & attention !For more information: [email protected]

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