Desktop Simulation and Calibration of Diesel Engine ECU Software

Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.

2013 GT-SUITE European Conference Frankfurt / Main

Diesel Gasoline Systems

Dr. Björn Lumpp Dr. Mouham Tanimou, Dr. Erica Trapel, Dr. Micha Münzenmay, Dr. Martin McMackin, Eva Bouillon, Klaus Zimmermann

Desktop Simulation and Calibration of Diesel Engine ECU Software using Software-In-The-Loop Methodology

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Desktop Simulation and Calibration of engine ECU


Agenda

1 Motivation

2 Plant models in GT-SUITE

3 Simulation of Diesel engine ECU Software

4 Coupling GT-SUITE models and ECU software models in Intecrio

5 Virtual Calibration with Inca

6 Summary & next steps

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Desktop Simulation and Calibration with SiL


Motivation and Goals Motivation • Increase development efficiency as well as

calibration efficiency by cooperative and holistic approaches

• Better mastering of extremely complex drive systems as well as reduction of calibration effort for those systems

• Tightened focusing on role based development processes

• Improvement of software quality by relocation of certain tests on early development stages

Goals • Increased exchange in the development whilst

safeguarding Know-How protection

• Virtual simulations of engine ECU-Software in combination with industry standard 1D plant models

• Use of single source for several use cases: function development, pre-calibration, optimization and test

• Integration of existing infrastructure and tools

• Imply already implemented code (from different sources e.g. as models, C-Code and/or objects)

• Modular structure of ECU-SW with access to single modules of control functions

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Agenda

1 Motivation






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5 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference

Engine model Detailed engine model - overview

two-stage turbo charger

air intercooler/ interstage cooler

EGR system (λ-controlled)

boost pressure control

throttle valve

D2676LF25 engine (12.4 l, 353kW/480HP, Euro 6)


Detailliertes Modell

Datengenerierungzum Trainieren derneuronalen Netze

Erstellen derneuronalen Netze

Integration der neuronalen Netze

Vereinfachung des Leitungssystems

generation of training data for neural networks

creation of neural networks

simplification of pipe system

integration of neural networks

Engine model Representation as mean value model

detailed model


Exhaust aftertreatment model EURO VI application

Exhaust aftertreatment model in GT-Power with global reaction kinetics Calibration using synthetic gas measurements Real-time capable without modification


Design of GT Model and import to Simulink

Integrate other libraries and Generate code

for Intecrio

HEX COD

Generate the model for the target system

“Virtual OS”

Execution in INCA Measure & calibrate as with a real ECU

Copy additional files to INCA

.trb

.nno .dat

.xyz

Combine with other modules and configure the OSEK OS

A2L

GT-SUITE & Intecrio Workflow for integrating GT models within INTECRIO




Agenda

1 Motivation






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Desktop simulation of engine ECU-Software

RB OEM Bosch functions OEM functions, to be tested in interconnection with Bosch functions

Bosch ECU-SW will be provided in a virtual environment that can be flexibly used by the OEM to develop its own functions.

Co-Simulation EDC-Software and GT-SUITE Model

Development Environment @OEM

Control Software

OEM Test Stimulation

RB OEM

OEM

RB RB

RB

RB

RB

RB

RB

RB

OEM Test Assessments

Labcar/Bench/Vehicle

OEM Plant Models

Simulink+CoSimulation GT Suite/AmeSim/…

Calibration Data

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Desktop simulation of engine ECU-Software

RB OEM Bosch functions OEM functions, to be tested in interconnection with Bosch functions

Bosch ECU-SW will be provided in a virtual environment that can be flexibly used by the OEM to develop its own functions.

Co-Simulation EDC-Software and GT-SUITE Model

Development Environment @OEM

Control Software

OEM Test Stimulation

RB OEM

OEM

RB RB

RB

RB

RB

RB

RB

RB

OEM Test Assessments

Labcar/Bench/Vehicle

OEM Plant Models

Simulink+CoSimulation GT Suite/AmeSim/…

Calibration Data

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Agenda

1 Motivation






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Other sources

Automatization via APIs

Signal Generator

VP*) on PC RP **) on PC RP **) on high end HW

RP **) on cost effective HW

Simulink Coder ASCET

ASCMO

Embedded Coder

HE

X

SC

OO

P-IX

A2L

A2L

AR

XM

L

INCODIO

TargetLink Manual C-Code

Obj C

GT-SUITE

INTECRIO Universal prototyping system

Co-Simulation EDC-software and GT-SUITE model

INTECRIO Integration and configuration platform

for prototyping system

Crossbar / RTA-RTE

RTA

-OS

Proprietary Basis SW

*) VP: Virtual Prototyping **) RP: Rapid Prototyping

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Integration workflow for EDC-SW und GT-Model with INTECRIO

SiL-ready Model Model.dat

GT-SUITE Library

C-code

Model.gtm

GT-SUITE GUI

Simulink GUI

Environment & I/O Model

GT-SUITE S-function block + INTECRIO GUI

SiL ECU Testing

EDC-SW (ECU Code)

*.obj *.six

EDC-SW: - pre-compiled Object-files will be used - SCOOP-IX* files are needed

INCA Experiment

dcm

Calibration data

Co-Simulation EDC-software and GT-SUITE Model

X86

*.exe (HEX&A2L)

CODE Integration

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DGS-EC/ECC | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.

Co-Simulation EDC-software and GT-SUITE model

INTECRIO Virtual Prototyping Environment


ViP4ECU (Virtual Prototyping for ECU SW development) Virtual prototyping environment for Function Development, Test and Pre-Calibration

Engine Model

Catalyst Model

Pipe Modell

e.g. 0D Matlab or 1D GT-Power

ECU Functionality Functions as object code

func

Models in ASCET or Matlab

func

Function Development

Optimization

Calibration and Testing

Control Export

INCA

System or Submodels

• Granular Access (BC, FC) • Rapid Function Development • SW-Sharing and Bypass

• Function optimization with Matlab optimization functions

• Feels like real vehicle • Handling like on prototype • Control with all INCA library

functions and testing tools • PC-based function verification

• High Accuracy (ECU+Plant) • Fast and Flexible Development • Holistic Engineering • High Development Efficiency • Cost Reduction on Prototypes • IP-Protection

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Agenda

1 Motivation






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Euro VI

Virtual EDC Logic calculates a dosage with a high conformity to the measurement (error<1%)

NOx concentration after the SCR is perfectly reflected by the GT RT model Satisfactory accuracy of cumulated

tailpipe NOx emissions (error <10%)

Software-in-the-Loop - Application Validation of SiL-Model (EDC dosing logic + GT-SCR) in WHTC


SCR upstream temperature: EDC signal: -10% GT model: as measured

Dosing rate limited by EDC temperature

Simulation duration: ~ 7 min > 4 x faster than real-time

Euro VI

Temperature error leads to ~ 5 % higher Adblue consumption ~ 75 % higher tailpipe emissions

NH3 level controller compensates for previous limitation

Controller calibration robust with regard to pre-SCR temperature sensor accuracy

Software-in-the-Loop - Application Sensor drift analysis – Temperature upstream SCR




Agenda

1 Motivation






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Summary

Use of models from engine development leads to a good model availability with high model quality High quality of used plant models allows a highly accurate description of the

overall system Extending plant models to include different additional aspects can be done in a

very simple way with Simulink EDC functions are directly derived from the original sources Simulation of implemented EDC SW-functions together with the available plant

models allows a very early pre-calibration of these EDC functions and optimally supports the front-loading process in the area of ECU-SW verification

Outlook

Block simulation and automatization of ECU-SW validation as well as calibration using optimization techniques

Embedding of additional sub-models (engine, exhaust aftertreatment, powertrain, …) in this environment



Co-Simulation EDC-Software und GT-SUITE Modell

Questions? Thank you!

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Thank you for your attention!

Dr. Björn Lumpp MAN Truck & Bus AG Powertrain Research Process Simulation Vogelweiherstr. 33 90441 Nürnberg

Co-Authoren: MAN Truck & Bus AG Eva Bouillon, Dr. Martin McMackin, Dr. Erica Trapel, Robert Bosch GmbH Dr. Micha Münzenmay, Klaus Zimmermann

Dr. Mouham Tanimou Robert Bosch GmbH Diesel Gasoline Systems Engineering Customer Projects Commercial Vehicles Postfach 30 02 20 70442 Stuttgart

Documents

Desktop Simulation and Calibration of Diesel Engine ECU Software