Generating excellence
ICE²: an integrated software to accelerate your calibration process
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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
Driveability
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Our Strengths
Dedicated engineers for calibration work:
Basic calibration (air load, torque structure, power optimization)
Startability at various temperatures
Driveability
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 (at D2T Testing facilities):
On engine
On vehicle
D2T calibration expertise Calibration - Gasoline Engines
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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 ICE² and its surrounding
MBC approach Model based calibration
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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
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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
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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
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MBC approach Work Flow (2/2)
Work flow for cycle calibration of
MBC local approach
Testing
Modeling
Optimization
Smoothing of maps
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MBC approach Methodologies
So, calibration methodologies are now based on DoE approaches
But different methods to do it
Local Approach Mixed Approach Global Approach
Model of engine
responses Local models Local models Global models
Optimization and
maps building
Local optimization +
smoothing
Direct optimization
of maps
Direct optimization of
maps
Need of a tool to summarize and integrate all methods and data
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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)
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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
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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
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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
ICE² - integrated calibration tool Organization: Application Explorer
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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
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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
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Cycles node : Importation of cycle trace
ICE² - integrated calibration tool ICE² work flow
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Cycles node : Distribution of operating points into operating areas
constant engine control mode
ICE² - integrated calibration tool ICE² work flow
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Cycle nodes : Weighting of operating points
ICE² - integrated calibration tool ICE² work flow
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Cycle nodes : Validation of cycle discretization
(with engine “photo” data)
ICE² - integrated calibration tool ICE² work flow
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Engine outputs node : domain modeling
Example local of air path domain for different injection parameters sets
ICE² - integrated calibration tool ICE² work flow
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Engine outputs node : design of experiment into the domain
D-optimal design or space filling
Example 6 parameters space filling DoE (pairwise projection)
ICE² - integrated calibration tool ICE² work flow
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Engine outputs node : response modeling
Use of polynomial or kriging models
o Modeling statistical results
o Graphical determination of model
quality
ICE² - integrated calibration tool ICE² work flow
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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
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ICE² - integrated calibration tool ICE² work flow
smoothing principle
smoothing results
global regularity index
(on each control map)
cumulative results
Maps node : smoothing between local optima to obtain final maps
(local approach)
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ICE² - integrated calibration tool ICE² work flow
Maps node : direct optimization of maps (mixed approach)
1. parameterization of control maps (bilinear or Lolimot)
2. definition of objective and constraints
3. optimization process
4. analysis of results
3D comparative view of initial and final control maps
Instantaneous and cumulated emissions
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ICE² - integrated calibration tool Local approach overview
Normalized
Cycle
From the initial calibration settings and
results to the final optimized ones
Cycle discretization
and weighting into N
operating points (OP)
Domain definition (on
NxOP)
Test plan (on NxOP)
Testing
Modeling (on NxOP)
Optimization, and
robustness (on NxOP)
Optima integration
and map
smoothing
New maps
validation
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ICE² - integrated calibration tool Mixed approach overview
Normalized
Cycle
From the initial calibration settings and
results to the final optimized ones
Cycle discretization
and weighting into N
operating points (OP)
Domain definition (on
NxOP)
Test plan (on NxOP)
Testing
Modeling (on NxOP)
Cycle driven
optimization,
smoothing and
robustness at the
same time
New maps
validation
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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
D2T - 11 rue Denis Papin - F-78190 Trappes - Tel. : +33 (0)1 30 13 07 07 - Fax :+33 (0)1 30 13 07 10
Thanks for your attention