ICE²: an integrated software to accelerate your calibration

ICE²: an integrated software to
accelerate your calibration process
Generating excellence
D2T calibration expertise
Calibration - Diesel Engines
Calibration – Engine tuning
Model Based Simulation on test bench
Pollutant Optimization / consumption / noise
Particulate Filter
Performances
Cold Start
Regulation (Boost Pressure, EGR)
EOBD, electrical and functional diagnostic, safety
Hot, cold, altitude conditions
Drivability
2
D2T calibration expertise
Calibration - Gasoline Engines
Our Strengths
Calibration work on engine and on vehicle
Dedicated engineers for calibration work:
3
Basic calibration (air load, torque structure, power optimization)
Startability at various temperatures
Drivability
Knock detection and regulation,
OBD (catalyst diagnosis, misfire detection)
Safety (torque and components monitoring)
Lambda regulation and emissions optimization for Euro 6
standard.
Calibration work:
On engine (at D2T Testing Centre)
On vehicle (i.e at RENAULT Sport facilities)
MBC approach
Model based calibration
Market requires more and more efficient calibration
methodologies for engines to meet industrial needs :
Meet simultaneously regulation and customer requirements
Shorten test duration and accelerate optimization phase
Use test data for several applications of the same engine
Take into account robustness
Take into account interaction between ICE and its surrounding
4
MBC approach
Model based calibration
Why do we need a MBC approach ?
Emissions regulation and engine performance’s seek, leads to a
higher complexity of calibration work
Diesel engines combustion parameters to be tuned increased
strongly with multiple injection strategies and advanced air
path (TGV HP/LP, EGR HP/LP, Air throttle, etc)
Gasoline engines complexity as well have become more
complex with direct fuel injection, VVA systems (VVT, VVL),
turbocharger and EGR
Analytical models cannot represent complex phenomena (i.e
NOx, PM emissions), and thus calibration with simulation is today
still a long path challenge
Experimental testing needed
5
MBC approach
Model based calibration
Experiments, but at what price ?
A standard sweep approach is not
compatible
8 factors with 4 different levels makes a
total of 65536 experiments
Need of models based on experimental
results to limit the number of test
Fitting polynomial models depending on 8
factors require around 100 experiments
DOE/MBC approach is completely adapted
to solve the optimization problem
6
MBC approach
Work Flow (1/2)
Work flow for cycle calibration of
MBC local approach example
Cycle analysis
Selection of pertinent operating
point
Domain definition
Experiment definition
7
MBC approach
Work Flow (2/2)
Work flow for cycle calibration of
MBC local approach
Testing
Modeling
Optimization
Smoothing of maps
8
MBC approach
Methodologies
So, calibration methodologies are now based on DoE approaches
But different methods to do it
Local Approach
Mixed Approach
Global Approach
Local models
Local models
Global models
Optimization and
Local optimization +
Direct optimization
Direct optimization of
maps building
smoothing
of maps
maps
Model of engine
responses
Need of a tool to summarize and integrate all methods and data
9
ICE² - integrated calibration tool
Overview
Model based calibration tool :
ICE² (Integrated Calibration
Environment for Internal Combustion
Engine
Design of Experiment, Modeling, and
Optimization tool in a same software
Possibility of a cycle based calibration
Engine calibration oriented
Innovative map smoothing tool
Direct map optimization
Many features coming soon with
further releases (after treatment
efficiency, etc)
10
ICE² - integrated calibration tool
ICE² goal
What for ? In order to…
Be more efficient
Reduce, rationalize and enhance the experimental phases
Capitalize know-how of IFPEN/D2T in terms of advanced
methodologies and innovative algorithms
How ?
Assisted by computer for all or part of the calibration tasks
For whom ?
Calibration technicians and engineers
11
ICE² - integrated calibration tool
ICE² main features and innovations
Study of normalized cycles on speed/load operating points
Discretization (divide) into operation areas (strategies) then into operating points
Time and energy weighting of operating points
Management of driving cycle with hot and cold start
Experimental approach using model-based calibration
Tests design in a non-hypercubic domain is managed
Statistical modeling of engine responses, including kriging techniques
Constrained optimization settings, with robustness analysis
Maps deformation
Maps smoothing and direct optimization techniques
Calculation of a map smoothing index
Simultaneous optimization of hot and cold maps actuator engine actuator
Estimation of emissions on driving cycle
Consistency with automation system, ECU interface and post processing
12
ICE² - integrated calibration tool
Organization: Application Explorer
All data are in 3 main nodes into the project
Theoretical or experimental data
Raw or digital data
CYCLES node
• For driving cycle analysis
Engine Outputs node
• For validated data from engine
test bench
Maps node
• For smoothing maps and optimization
13
ICE² - integrated calibration tool
Organization: Editors and views
The editors and displays
can be organized as tabs
can interact if they are from the
same data into the main Engine
Outputs node
can be displayed together
14
ICE² - integrated calibration tool
Organization: Additional views zone
Synthesis panel
Allows the user to place the progress of project tasks
• form of Workflow
For exportable form of image file via File menu / Export
• for insertion into a report or a presentation
15
ICE² - integrated calibration tool
ICE² work flow
Cycles node : Importation of cycle trace
16
ICE² - integrated calibration tool
ICE² work flow
Cycles node : Distribution of operating points into operating
areas
constant engine control mode
17
ICE² - integrated calibration tool
ICE² work flow
Cycle nodes : Weighting of operating points
18
ICE² - integrated calibration tool
ICE² work flow
Cycle nodes : Validation of cycle discretization
(with engine “photo” data)
19
ICE² - integrated calibration tool
ICE² work flow
Engine outputs node : domain modeling
Example local of air path domain for different injection parameters sets
20
ICE² - integrated calibration tool
ICE² work flow
Engine outputs node : design of experiment into the domain
D-optimal design or space filling
Example 6 parameters space filling DoE (pairwise projection)
21
ICE² - integrated calibration tool
ICE² work flow
Engine outputs node : response modeling
Use of polynomial or kriging models
o Modeling statistical results
22
o Graphical determination of model
quality
ICE² - integrated calibration tool
ICE² work flow
Engine outputs node : local optimization (for local approach)
Minimization of one objective with respect to constraints on other
engine responses or factors (domain)
Take into account dispersion of factors
23
ICE² - integrated calibration tool
ICE² work flow
Maps node : smoothing between local optima to obtain final maps
(local approach)
smoothing principle
smoothing results
global regularity index
(on each control map)
cumulative results
24
ICE² - integrated calibration tool
ICE² work flow
Maps node : direct optimization of maps (mixed approach)
1.
2.
3.
4.
parameterization of control maps (bilinear or Lolimot)
definition of objective and constraints
optimization process
analysis of results
3D comparative view of initial and final control maps
25
Instantaneous and cumulated emissions
ICE² - integrated calibration tool
Local approach overview
From the initial calibration settings and
results to the final optimized ones
Normalized
Cycle
Optima integration
and map
smoothing
al
op
tim
i za
tio
ns
Cycle discretization
and weighting into N
operating points (OP)
New maps
validation
Optimization, and
robustness (on NxOP)
N
l oc
Domain definition (on
NxOP)
Modeling (on NxOP)
Test plan (on NxOP)
Testing
26
ICE² - integrated calibration tool
Mixed approach overview
From the initial calibration settings and
results to the final optimized ones
pt
ob imiz
jec ati
tiv on
es wi
th
sL
sa
ch
oa
pr
ap
al
oc
Test plan (on NxOP)
Dir
ec
tm
ap
o
es
oc
pr
Domain definition (on
NxOP)
me
Sa
Cycle discretization
and weighting into N
operating points (OP)
Testing
27
New maps
validation
cy
cle
Normalized
Cycle
Cycle driven
optimization,
smoothing and
robustness at the
same time
Modeling (on NxOP)
Conclusion
Engine calibration oriented
Fully integrated tool and easy to use
Standard and kriging modeling techniques
Maps smoothing tool and visualizations
Direct map optimization (cycle driven)
D2T-IFPEN know-how inside
Further innovative developments and improvements on
going…
The right tool to accelerate your calibration
process and ensure meeting quickly today’s
and tomorrow’s new requirements
28