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GM Powertrain Europe Engineering Center
Powertrain Electronic Control Units: development, models, analysis and tests
according to General Motors
Alessandra Neri Hardware Electrical Architecture Development Engineer
GM vision and brands General Motors Vision: Design, Build and Sell the World’s Best Vehicles
Jiefang
GM Powertrain 2005-2013
• GM 104 years-old• GMPT/Torino 8 years-old• Average age 35, 25% under 30• 20% are women
GMPT-E Italy activities
Diesel Engine EngineeringDiesel Engine design & testingComputer Aided Engineering (CAE) & SimulationExhaust AftertreatmentTurbocharging
Controls EngineeringDiesel Control (HW&SW)Engine Management System ComponentsGM is the only auto maker with complete software and systemsexpertise in control of Gasoline & Diesel engines and transmissions
Diesel Hybrid EngineeringEngine system configuration modelling & optimizationDiesel Hybrid verification
GLOBAL RESP IN TORINO
GLOBAL RESP IN TORINO
GLOBAL RESP IN TORINO
GMPT-E Italy Figures
• €30 million initial Investment• 624 office places• 15 Test Cells
• 12 Laboratories• Workshops • Chassis Dyno
€20 million new investment (2011-2014)50% of IP developed by GM Powertrain in Europe comes from Torino
GMPT-E Italy Diesel Portfolio2.5-2.8L 2.0L CDTI
1.0L CDTI 2.2L CDTI 1.3L CDTI
1.7L CDTI
Controller D1Plus:
Opel InsigniaOpel Astra
Opel CorsaChevrolet Beat
Chevrolet Colorado
Chevrolet Orlando
New 1.6-liter diesel engine MDE
7
Engine Control System Development
Control System Architecture
Requirement Definition
Algorithm and Software
Design
HW and SW test
Control System
Validation
Controller D1Plus
Diesel controls developmentOur Teams
8
Electronic EngineeringElectrical architecture and interfacerequirements Worst case and variation analisysController hardware engineeringTarget software build
Control system tools and testingHIL set up Tools developmentTest automationsHIL testing
Algorithm and softwareModel based approachAdvanced signal processing and robust controlRapid prototyopingAutomatic code generation
11
24
1012
13
15
16
17
1819
20
2123
2526
3 32
33
9
2
1
5 6
4
22
to the vehicle
7 8
14
29
28
30
31
34
27
35
36
EURO5 typical architecture
9
1. Tank2. Electric Fuel-feeding Pump3. Fuel Filter Assembly4. Damper Volume5. High Pressure Pump6. Fuel metering Valve7. Rail8. Rail Pressure Sensor9. Solenoid Injectors10. Air Filter11. Air Flow Meter (+Air Temperature Sensor)12. Compressor13. Intercooler14. Electronic Throttle Body15. Electronic EGR Valve16. EGR Cooler with pneumatic on/off by-pass valve 17. Intake Manifold Pressure + Temperature Sensor18. Crankshaft Position Sensor19. Camshaft Position Sensor20. Coolant Temperature Sensor21. Oil Minimum pressure switch 22. Oil Level Sensor switch23. Metallic/Ceramic Low Voltage Glow Plugs 24. Variable Geometry Turbine25. VGT Vacuum Modulator26. VGT position feedback27. Lambda Sensor28. Main Cat29. Diesel Particulate Filter30. Temperature Sensor31. DPF Relative to Ambient Pressure Sensor32. Pedal Assembly33. ECU34. Electronic Variable swirl actuator35. Temperature Sensor36. Pre Cat
PRIMARY MICRO
SECONDARYMICRO
ANALOGINPUTS ADC
POWERSUPPLY
HS/LSDRIVERS
BARO
INJBANKS
COMPLEXOUTPUTS
HBRIDGES
COMM
SENSORS
BATTERY
DISCRETEINPUTS
RELAYSACTUATORS
DCMOTORS
FUELINJECTORS
INJHEATERS
GPIO
PULSE/FREQINPUTS EMIOS
ETPU
CORE
ADC TEST
SYS VOLT
SENSORS
SWITCHES
ECM: block diagram
COMM
SPI comm