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?
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
Many Parameters to Vary
Intake
Cam Timing
Environmental
Conditions
Shifts
Start of
Injection
Spark
Timing
A/F ratio
Exhaust
Cam Timing
EGR
Drive by
Wire
Fuel Efficiency
Noise and
Vibration
Driveability
Emissions
Performance
Requirements: New Processes and Tools
Overview: The Solution
Model Based Calibration
Time
Conventional
Model Based
Complexity
Response
Overview: Aim of DoE Design
Full factorial map
(18 points)
Input
Response
DOE map ( 7 points)
Input
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
measurement
modeling
optimization
mapping
ORION
MBC Toolbox
MBC Toolbox
MBC Toolbox
DoE/calibration expert
DoE/calibration expert
MBC Toolbox
ステータス
コントロールパネル
DoE expert
計測定義ファイル読込
コメント
AND3k WD
SparkSweep.tdf
設定確認
運転開始
50
MPI² (or ATLAS)
モデル作成用計測
Online
Optimize
OK
一時停止
運転終了
RPT WD
OK
AND3k Log
Logging
AND3k Log
Logging
トルク
VVT
%
5
10
20
5
10
20
EGR
%
*
*
0
5
10
15
Spark
20
25
計測・制御値
50
スロットル開度
40
*
*
*
30
20
0
DoE expert
20
10
10
20
30
40
10
20
Operating Point
10
… or other tools
Throttle
%
10
20
40
10
20
40
High Limit
calibration engineer
Boost
kPa
NaN
NaN
NaN
NaN
NaN
NaN
Low Limit
or Simplified GUI
(e.g. MBC-Commandline)
計測点を指定する
SPEED
rpm
1000
1000
1000
2000
2000
2000
*
*
30
計測点読込
No.
1
2
3
4
5
6
*
*
40
運転パターン表示
*
*
*
*
*
*
1000
2000
3000
回転数
HC
120 ppm
Knock
35 mbar
ExGasTemp
480 ℃
CataTemp
650 ℃
Spark
4000
5000
6000
30
or Simplified GUI
or Simplified GUI
or Simplified GUI
(e.g. MBC-Command line)
(e.g. MBC-Commandline)
(e.g. MBC-Commandline)
calibration engineer
calibration engineer
calibration engineer
25 deg
0
20
40
60
計測値・制御値
80
100
… or other tools
… or other tools
… or other tools
コメント表示
MBT : Spark 19 [deg] -à Torque 40.5 [Nm]
Optimize 終了
user for tool
calibration engineer
user for tool
user for tool
workflow company A
user for tool
workflow company B
Overview: ORION in the Test Cell
ORION Communication
ORION (Supervisory Control)
iTEST Communication
iTEST (Real-Time Control) – any
DAC system possible with driver
ORION
DoE Tool
MathWorks
Test Plan
1. Global
2. Local Spark Sweep
3. Local AFR Sweep
CONSTRAINTS (Data)
1. Exhaust Temp
2. Knock
iTEST (or any DAC)
PROCEDURES
1. Start
2. ORION Command
3. Stop
ASAP 3
TEST BED
iCONNECT
LIMITS (engine)
1. Temp
2. RPM
3. Pressure
PIDs
ECU
Development
Tool
(INCA/Vision)
ASAP3
INCA
CAS
ANDROMEDA
(ADX Dyno/Throttle Controller)
CAS System
Overview: Build Configuration
Sequence
Parameter
Test Plan
Excel
MBC-Toolbox
Parameter Setup:
• Test bench system
• ECU
• Define Execution Order
of Actions
• Set Action Options
(choose parameter to set
and limit parameter)
Automated Engine
Test Run
• Define Parameter
Properties
(e.g. limits, step width,
channel names, …)
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
Detail: Connection in Test Cell (1)
ORION
ORION High Speed Interface
ORION High Speed Interface
Ethernet link
ASAP3 on TCP/IP
+ UDP
for high speed data transfer
ORION-Interface
ASAP3
Client
ORION-Interface
ASAP3
Server
Standardized protocol:
ASAP3, ASAM-MCD3
ETAS INCA
ECU Calibration System PC
ASAP3
ASAP3
Client
A&D
iTest/ADAPT
Test Cell System PC
Detail: Connection in Test Cell (2)
ORION
ORION High Speed Interface
ORION High Speed Interface
Ethernet link
ASAP3 on TCP/IP
+ UDP
for high speed data transfer
ORION-Interface
ASAP3
Client
ORION-Interface
ASAP3
Server
Standardized protocol:
ASAP3, ASAM-MCD3
Vector CANape
ECU Calibration System PC
COM
ASAP3
Client
AVL
PumaOpen
Test Cell System PC
Using: Easy Interface for Operator
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
Load
Configuration
Start
Pause
Step
Stop
Using: Configuration by Engineer
Level of Usage:
Easy to use configuration GUI
handled by calibration engineer
and experienced test cell
operator
Parameter Definition
Modification of parameter
properties (limits, step width)
Changing test sequence by
choosing functions from the
Action Library
Sequence Definition
Test Plan
Required Skills:
Engine calibration experience
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#, …)
Outputs
Inputs
User-defined
Function
Model-Based Calibration Example
ECU-torque model
Definition of
Factors and
Responses
Zündwinkelschleifen
Spark sweep n = 1000 min
Example ECU Structure:
-1
130
KFMIRL (calculation set value air
mass)
110
Experimental
Design
WOT
KFMDS (friction torque)
ORION
ETADZW (spark dependence)
70
ETALAM (lambda dependence)
50
120
rl=20%
30
100
ETADZW / %
Test Bench
Measurements
Drehmoment / Nm
90
10
80
60
40
20
-10
0
6
0
10
5
20
30
40
50
Zündwinkel-Spätverstellung / °KW
4
3
-30
-15
-5
5
15
25
35
DZWOLA
ModelBuilding
2
1
0
-1
Zündwinkel / °KWvOT
-2
-3
-4
Optimization
Evaluation
Filling
ECU Maps
-5
0.65
0.75
0.85
0.95
1.05
Lambda
102 / -
Offline ECU model calibration
DoE-Model output => ECU model output
ETALAM / %
101
100
99
98
97
96
0.6
0.7
0.8
0.9
Lambda / -
1
1.1
Model-Based Calibration Example
DoE-Instruction for Measurement (collect 2 data points per spark sweep)
Torque
Limit of:
HC
COV
Catalyst Temperature
0%
45 °CA
Limit of:
HC
COV
Knocking Limit
10 °CA
100 %
torquemax
1.
2.
Find MBT
Set Spark Timing Offset relative to MBT
(value given by test plan)
Ignition Angle
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
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
Cntrl1: Knock, Cntrl2: Exh.Temp.
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
• 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.