Up Coming Requirements in Calibration for Alternative Fuels

8/12/2019 Up Coming Requirements in Calibration for Alternative Fuels

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Up Coming requirementsUp Coming requirements

in Calibration forin Calibration for

H.S.Sohi

AVL ITC, Gurgaon

Alternative Fuels


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Upcoming Requirements in Calibration for Alternative Fuels, 24th April 2007 2

Sophistication and increasing trend of Calibration

Calibration needs for Alternative Fuels

System integration process for reliable calibration

Managing complexity of system integration & monitoring

Medium type CNG / LPG Calibration Project

Additional Calibration requirements

AVL Advantages

OverviewOverview


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Sophistication of Powertrain to meet Emission, FE

targets, NVH, Driveability demands...

Engine Hardware Intake Air : VNT, TC with waste

gate, Swirl, VVT, VGIS etc.

No of valve / cylinder (2 to 4 valve)

Transmission

Several new gearbox concepts (MT,AT,CVT, 4WD...) Torque Limiting, Shift point strategy, Shifting comfort,

Clutch control etc...

Control Strategies Multi injection strategies Variable Fuel rail pressure After treatments strategies

HPL & LPL EGR

EGR Cooler & Cooler bypass etc..

DFCO Logics

OBD / EOBD, Diagnostic Trouble

Error (DTC) & MIL management etc.


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Calibration parameters of sophisticated Power trains

3.000 calibration parameters

Time for Calibration work:

20 months = 360 days

Calibration team:

10 Calibration engineers

18 Calibration Parameters18 Calibration Parameters

to be calibratedto be calibrated

per day per staff memberper day per staff member

5 vehicle Variants

Example

10,000 calibration parameters

(10000+3000) X 5 = 65000 / 360 = 180/10 = 18,(10000+3000) X 5 = 65000 / 360 = 180/10 = 18,

Calibration parameter: constant value / characteristic /Calibration parameter: constant value / characteristic / mapmap


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Example: Increasing complexity of ECU ...

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6/41Upcoming Requirements in Calibration for Alternative Fuels, 24th April 2007 6

2005 20101995 20152000

Actuators &sensors

Calibration parameter,

Applications effort

Development-

time

Automotive Industry trendAutomotive Industry trend









AVL Advantages

OverviewOverview



Alternative Fuels OverviewAlternative Fuels Overview



Interfacing of Alternative Fuel Technologies in

existing Engine / New Engine

Transmission

DFCO Logic Optimization Torque limiting, Gear shift point strategy

Functionality related to Clutch control etc...

Change in Engine Hardware Higher Compression Ratio

Engine Cooling & Lubrication

Valve Timing Optimization

Fuel System Packaging

Valve Seat & Cylinder Head

Errors Handling MIL for sensor Failures

DTC errors Handling, Threshold limits

OBD / EOBD, EGAS monitoring etc

Adopting Alternative Fuel Alternative fuel components

Dual Fuel management

Close loop & EGAS logic

Mono & Bi Fuel / Ignition



Example:Basic EMS Components for Injection Kit

ITEM Qty Remarks

VSS 1 Vehicle Speed Sensor

ECTS 1 Engine Coolant Temperature sensor

MAP + MAT 1 Manifold air pressure & Temperature

1 Mono Fuel1+1* * Bi-Fuel (Gasoline + CNG / LPG)

Ignition Coil *Option of Distributor OR Individual coil as

per # of Cylinders

Throttle Body 1* Option: Wire / Wire less

Injectors * * Depending on # of cylinders

TPS 1 Throttle position sensor

IAC 1 Idle Air control Valve

CNG /LPG Mono Fuel not required

Bi-Fuel (Gasoline-CNG / LPG Prefered)Heated Lambda Sensor

(Up Stream)1 BS-IV and for catalyst safety / OBD

Crank Angle Sensor 1

Camshaft Position Sensor 1

EGR Valve Option May be required for BS-IV / EURO IVAir Mass Flow Sensor Option With EGR closed loop control

Electronic Control Unit

*Knock Sensor



Example : Close Loop Bi-Fuel layout for LPG(Gasoline + LPG Venturi Type)

Source Vialle



Example : Bi-Fuel EMS layout for CNG(Gasoline + CNG Injection )

Source Omnitek

Sequential Injection (4 - Cyl.)



Example : Bi-Fuel - Close Loop layout for LPG(Gasoline + LPG Injection)

Source Vialle









AVL Advantages

OverviewOverview


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System integration for Reliable Calibration


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Kick-off meeting

Parts procurement (engines, vehicles, spares, data set, documentation)

Engine and vehicle built, instrumentation (installation of measurementequipment, run-in and correlation tests (to verify base data of

engine and vehicle and to verify correlation of facilities)

Initial pre-calibration on engine test bed and in vehicle (to verify

synchronization of all sensor and functionalities, hardware and

software concept, to check emission potential, to verify technical

and engineering targets)

Meeting with Customer(Result discussion, interim report, decision on furtherprocedure and time schedule)

-24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13

PROJECT START OEM / AVL

KICK-OFF MEETING / 1st ENGINE AVAILABLE OEM / AVL / FIE

1st VEHICLE AVAILABLE OEM / AVL

ENGINE & VEHICLE ASSESSMENT

Preparation Work AVL / OEM

Initial Steady State Engine Assessment AVL

Initial Vehicle Assessment AVL

montNo. Work Steps

Job split

OEM/AVL

Phase 1 : Start of the project


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Objective: Development of EMS calibration for series production, includingrobustness investigations and climate test trips.

Test to be organised to carry-out, post-process and analyse all tests necessary toachieve a robust calibration for series production. In the following the work scope isdescribed in detail for the following topics:

Emissions and FC development Cold Start

Driveability Optimization Altitude Calibration

Controllers and Driveability Climate Test Trips

Noise and NVH Robustness Investigations

OBD / EOBD / DTC Errors Pre-Data Set release

-22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1

2.2. PHASE 2: TEST BED CALIBRATION

2.2.1. Calibration Work on Engine Test Bed AVL

2.2.2. Transient Dynamometer Calibration AVL

2.2.3. Engine Power Homologation Test (OPTION) AVL / OEM

2.3. PHASE 3: VEHICLE DEVELOPMENT

2.3.1. Development Work Vehicle Concept A/T & Veh. C. M/T

2.3.2. Optimisation of Emissions and FC AVL

2.3.3. Controller Calibration, Driveability Development AVL

2.3.4. Check and Verification of Vehicle NVH AVL

2.3.5. Calibration of EOBD, verification of diagnosis AVL

2.3.6. Cold Calibration AVL

2.3.7. Verification of Hot Start and Drive-off AVL

2.3.8. Climate / High Altitude Testing AVL / OEM Sign-Off Test

2.3.9. PHASE 2/3: Robustness Investigations (OPTION) AVL

Work Steps Job splitOEM/AVLNo. months to SOP

W SS

Phase 2 : Calibration on Engine Test Bed & Vehicle


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Calibration activities till SOPCalibration activities till SOP

Engine base mapping (steadyEngine base mapping (steady--state / transient)state / transient) Engine & Vehicle performanceEngine & Vehicle performance (full load, limitations, etc.)(full load, limitations, etc.)

Emissions, Fuel consumption, Evaporative emissionsEmissions, Fuel consumption, Evaporative emissions

NVH optimisationNVH optimisation

Driveability calibrationDriveability calibration Knock controlKnock control

Exhaust gas after treatment systems calibrationExhaust gas after treatment systems calibration

Transmission calibrationTransmission calibration (shifting points, converter clutch, etc.)(shifting points, converter clutch, etc.)

Hot, Cold & Altitude calibrationHot, Cold & Altitude calibration CruiseCruise--control, Drivecontrol, Drive--byby--wire conceptwire concept

(E)OBD calibration, DTC errors etc(E)OBD calibration, DTC errors etc

Adaptation on market requirementsAdaptation on market requirements (fuel, driveability, emissions, etc.)(fuel, driveability, emissions, etc.)

Climate test tripsClimate test trips Service tester, End of line testingService tester, End of line testing

InterfacesInterfaces (transmission, traction(transmission, traction--control, etc.)control, etc.)

HomologationHomologation (full execution or preparation / support)(full execution or preparation / support)

PrePre--production validationproduction validation

Fleet support / managementFleet support / management (OBD fleet, durability fleet, etc.)(OBD fleet, durability fleet, etc.)

Production rampProduction ramp--up / Postup / Post--production supportproduction support


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Engine / Vehicle in the latest development status

Calibration data:

Pre-Masterdata set (for final evaluation at customer) File for each interim release

Calibration data comparison (DCM), comparing actual and previouscalibration, by means of the AVL Calibration Database, including writtendocumentation and corresponding test results

Reporting:

Monthly intermediate project reports containing updated schedule,

project progress and calibration progress

Special reports requested for certain milestones, including climate tests

Final project report

Deliverables


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AVL Advantages

OverviewOverview


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Defining- processes to be followed,

- methodologies to be used,

- tools to be applied

Setting- milestones and clear responsibilities

- release procedures

to guarantee the required SOP-quality

Calibration guidelines as part of a standardised

work flow


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0

1

2

3

4

5

Stat

us

C alibration Progress Plan Vehicle A

Dec.0

1

Aug.01

Oct.0

1

Feb.0

2

Apr.02

Jun.0

2

Aug.02

Oct.0

2

Dec.0

2

Feb.'0

3

Apr.'03

Jun.'0

3

Aug.'03

Oct.'0

3

Status "5" ... not calibrated yet

Status "3" ... calibrated, changes are expectedStatus "1" ... calibrated, no further changes expected

Vehicle B Vehicle C Vehicle D

Additional Ressources

Additional Ressources

Delayed

Parts / Vehicle

Availability

New Software Status

Monitoring of Calibration Progress

(Calibration Database - CRETA)


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AVL Advantages

OverviewOverview


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Calibration Project Duration (tentative):

PRIMARY TYPE MEDIUM TYPE LIGHT TYPE

New engine

calibration

Existing engine

calibration

Existing engine /

vehicle

re-calibration

First ECU SOPNew vehicle

calibration

Similar vehicle

class

New SW functions

to be calibrated

New emission

regulation(e.g BS-III to BS-IV)

Same Gear Type

(MT or AT)

New exhaust after

treatment

New FIE / Slight

change in engine

hardw are

No new SW

functionality

required

Intensive f leet

testing

Pow er limiting for

other variant

No change in

engine hardw are

~ 24 Months 15 ~ 18 Months 6 ~ 9 Months

DURATION / PERIOD


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Example:Material required for a Medium Type

Calibration Project

2 ~ 3 Engines : for Engine test bed along with Alternative Fuel Kit

1 - 2 engines for calibration (no. depending on scope of work)

1 spare engine

3 ~ 4 Vehicles :

1 Vehicle for emission calibration / robustness investigations

1 Vehicle for driveability calibration and climate test trips

1 Vehicle for OBD / EOBD and cross checks

1 pre-series vehicle for evaluation and fine tuning

Tools & Spares:Application ECU, A2l & Hex, Customer-specific

Calibration and diagnostic tool, Spares and Prototype parts etc..


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Engine

PUMA 5.5.Xor

PUMA 7

Pre CatEmission

Bench

P/K-Check

I670

INDI MasterIFEM

Charg

e

Amplifier

CAMEOIndi COM

ECU with ETK

INCA / FIE

specific

INCA VMEEMCON 300

Pedal-Simulator

TCP/IP ConnectionRS232 Connection

E

ngine

Stop

n-x

Control

Analog Connection

6x

1x

DAC

1x

8x+1x

ASAP1

ode

r

CANC

CP

Fuel / Gas

Flow meter

1x

ASAP3

ACISimulink

Intime RTC

CAN-Bus

Standard Test-bed Set-up for EMS Calibration(Example)

Post Cat

Emission

Bench


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Calibration Strategy for Alternative Fuels (CNG / LPG)

Selection of Suitable Alternative Fuel Components

Synchronization of all Signals and Functionalities

Injection control w.r.t Speed density and correction

with Lambda Values

Idle RPM control strategy for mono / bi-fuel with

Ambient, Coolant Temp.,Engine / Accessories load

and for Catalyst faster light off.

Multi-spark for better startability

Closed Loop control Fuel optimization using

Lambda sensor input from exhaust for best

combustion and catalyst efficiency

Fuel pressure related correction (Hysterics) and

OEM Fuel gauge linearity


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Calibration Strategy for Alternative Fuels (CNG / LPG)

DFCO (Deceleration Fuel Cut off) logic optimization for

better F.E and resume logic to prevent jerks during

driveability.

High Idle/ Fly up rpm control with fuel & spark cutoff.

Injection and Ignition map correction based on Engine

Coolant, Air Temperature, Battery Voltage etc.

MAP based Ignition Timing Control w.r.t RPM, Load &

Coolant Temp.

Cold Start and warm up Strategy (Separate MAP withinput from Lambda sensor and coolant temperature for

switch over)

OBD / EOBD Threshold limit set and verification test


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SELECTION OF LOCATION FOR CLIMATE TEST TRIPS:

Cold Temperature Option 1: (-10 ~ -15 0C) LEH in Himalayas, appox. 18000 ft

Option 2: (0 ~ 2

0

C) ROHTANG appox. 14000 ft

Hot Temperature in Plain areas (40 ~ 48 0C) in JAISALMER in Rajasthan

Altitude Test OOTY in South India, appox. 7500 ft, 25~ 30 0C & Humidity @ 80%

Verification of thermal stability (Cooling Performance of engine, A.C etc..)

Fine tuning of calibration during test trips

Evaluation of calibration along with OEM experts

FACILITIES:

Locations for test trips according to OEM requests / agreed procedures

Chassis Dynamometer, Public Roads, VRDE, AVL Test Track (HQ Graz)

Location for Calibration and Verification Tests


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Work content : Calibration requirements according to legislation / OEM

Calibration strategy for development of OBD / EOBD functionality

Emission related component (Air flow, EGR, O2 sensor, EGAS etc.) Fault memory management (MIL / DTC errors)

Generic Scan Tool adaptation on OEM service tester

Facilities :

Engine test bed

Emission chassis dynamometer

Road testing

Target specification :

Definition of customer OBD / EOBD strategy (if required)

Specification of MIL thresholds limits for error

Paperwork for OBD / EOBD certification requirements

Calibration: OBD / EOBD , Diagnostics


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Verification of the existing calibration regarding

Emissions, Fuel Consumption Targets (Engine / Vehicle)

Driveability and Controllers functionalities check

Diagnosis, OBD / EOBD , DTC errors etc

Cold start behaviour

Noise and NVH

Driving Evaluation along with OEM and Optimisation

Pre-Master Data Set updation, after final evaluation by

customer for FINAL DATA SET release.

Notes: Pre-production series vehicles must be available for 4 - 8 weeks

Calibration Fine Tuning on Pre- Production Vehicles


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AVL Advantages

OverviewOverview


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Work Content :

Emission, driveability checks on endurance fleet

Support during regular emission tests of fleet vehicles

Registration and statistical evaluation of fleet vehicle results

(e.g. fault memory, failures, emissions, DTC etc)

Correction in Pre-Dataset for OBD / EOBD

Notes:

Mileage accumulation generally performed by OEM

Fleet Testing / Vehicle Validation Tests


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Possible work share for homologation:

Emission demonstration test at AVL / OEM prior to

homologation

FTP Test on engine test bed at AVL / Support at agency

Fuel consumption test at AVL / Support for FC test at

agency

Full homologation entirely by AVL

Notes:

Homologation work share to be defined at project start

Homologation / Certification


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Definition of end-of-line tests and procedures (Flashing, VIN, IQA etc)

Trouble shooting in production ramp up phase regarding

Specific check and Analysis of vehicles / variant

Vehicle / Variant Specific Coding

Diagnostic Codes (MIL & DTC Errors)

Updation and Verification of Master Data set

Production Ramp-Up Support


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AVL Advantages

OverviewOverview


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Calibration:Calibration:

110 + Engineers (Including 22 at AVL affiliates110 + Engineers (Including 22 at AVL affiliates e.g.e.g.

ITC in IndiaITC in India, STC in China, STC in China))

Calibration Methodology:Calibration Methodology:

14 Engineers (Including 2 at AVL affiliates)14 Engineers (Including 2 at AVL affiliates)

TheThe LocationalLocational AdvantageAdvantage -- ITCITC

Staff undergone long term training at AVL headquartersStaff undergone long term training at AVL headquarters

Near by Real hNear by Real hotot and cand cold weatherold weather conditions etc..conditions etc..

High altitudeHigh altitude calibration under real conditionscalibration under real conditions

Tailor made toughest city driving cycle can beTailor made toughest city driving cycle can be mademade

AVL Graz & Affiliates are committed to strategic partnershipAVL Graz & Affiliates are committed to strategic partnership

AVL Global Network for Calibration


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AVL Calibration Strengths and Profile

Highly motivated team working with state-of-the-art and future technologies, using latest

development tools and methodologies

High experience through a significant number of

SOP projects

Own calibration process and procedures with

possibility to adopt customer specificprocedures

Customers located world-wide, contact with

various cultures

Experience with all established ECU suppliers

Application Centre HQ Graz


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Application Centre-HQ Graz

Thank YouThank You for Yourfor Your

kind Attentionkind Attention !!!!

Contact ITC Calibration TeamContact ITC Calibration Team

H.S.SOHIH.S.SOHI

phone: +91/124/4090300phone: +91/124/[email protected]@avl.com

AVL-ITC, Gurgaon

Documents

Up Coming Requirements in Calibration for Alternative Fuels