1. Model-Based Calibration Toolbox JumpStart
p
Service:
Common-Rail CI E i With V i bl G
C R il Engine Variable Geometry T b h
t Turbocharger and C l d EGR
d Cooled
orks, Inc.
© 20 The MathWo
009
The MathWorks Consulting

2. Agenda
 Introduction
 Design of experiments
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
© 2009 The Math
 Review
2

3. Course Problem Statement
 Produce optimal calibration tables in speed and torque for
p p q
 best injection timing
 best fuel mass/inj
 best fuel pressure
 best VGT Position
 best EGR position and mass fraction
 Minimize
Mi i i mode-weighted b k specific f l consumption,
d i ht d brake ifi fuel ti
hWorks, Inc.
subject to constraints on
 8-mode weighted NO
© 2009 The Math
 Turbo.
Turbo speed
 averaged peak cylinder pressure
 exhaust AFR by mode
3

4. Test Configuration
I/O of 9.0L Diesel Engine with EGR, VGT
VGT Position Brake Torque
Engine Out NO
EGR Position
Exhaust AFR
SOI Turbo. Speed
Peak Pressure
P kP
hWorks, Inc.
Fuel Pressure
EGR Fraction
© 2009 The Math
RPM Fuel Mass/Inj
4

5. Course P bl
C Problem St t
Statement
t
I/O of 9.0L Diesel Engine with EGR, VGT BSFC
Brake Torque Objective
VGT Position
Engine Out NO
EGR Position
Exhaust AFR
E h t
Constraints
SOI Turbo. Speed
Peak Pressure
Fuel Pressure
EGR Fraction Used to
hWorks, Inc.
Used To Build Build
Optimal Tables Extra
Table
© 2009 The Math
RPM Fuel Mass/Inj
Minimize mode-weighted brake specific fuel consumption
mode weighted consumption,
subject to multiple mode-based output constraints
5

6. Preview of Course Calibration Results*
MAIN SOI Table MAIN Fuel Table EGR Mass Fraction Table
hWorks, Inc.
© 2009 The Math
Fuel Pressure Table VGT Rack Position Table
*Note: this table format assumes a torque-based engine control strategy
6

7. Agenda
 Introduction
 Design of experiments
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
© 2009 The Math
 Review
7

8. Generate Experimental Design
16
hWorks, Inc.
© 2009 The Math
8

9. Agenda
 Introduction
 Design of experiments
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
© 2009 The Math
 Review
R i
9

10. 65 pt V Optimal Data Ready for MBC Import
V-Optimal
hWorks, Inc.
© 2009 The Math
CI_DoE_Data.xls
10

11. Review Data 24
19
hWorks, Inc.
22
20
© 2009 The Math
17 21
23
18
11

12. Agenda
 Introduction
I t d ti
 Design of experiments
g p
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
© 2009 The Math
 Review
12

13. Review Final Model
5
2 6
1
3
hWorks, Inc.
© 2009 The Math
Extrapolation
Will Be Prevented
By Boundary
4 Model In
Optimization
Later
13

14. Review Boundary Model 40
39
hWorks, Inc.
© 2009 The Math
14

15. Export Models For Other Users
4
Model
Description
Input Order
5
hWorks, Inc.
Brake Torque Value
Input Order:
© 2009 The Math
MAINSOI, SPEED, MAINFUEL, FUELPRESS, EGRPOS, VGTPOS
6
Boundary Model Value
Values < 0 are within bounds
15

16. Export Models For Other Users
hWorks, Inc.
© 2009 The Math
Use Your Accurate, Fast Torque Model in:
•Hardware In The Loop Testing (HIL)
•Performance and Fuel Economy Simulation
P f dF lE Si l ti
•Control Design Activity
16

17. Agenda
 Introduction
 Design of experiments
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
© 2009 The Math
 Review
17

18. Load Models of Engine Responses
7  Review your imported
Models in the CAGE
tool
hWorks, Inc.
© 2009 The Math
6
8
18

19. Set Up Tables: Completed Table List
hWorks, Inc.
© 2009 The Math
19

20. Optimization Strategy: Define New Optimization
 Specify 5 optimization
variables - SOI
ariables SOI,
MAINFUEL, EGR
Position, VGT
Position, and Fuel
4 Pressure
5  Specify 2 constraints
for now
hWorks, Inc.
6
© 2009 The Math
20

21. Run Optimization: Sum Optimization
8 9
hWorks, Inc.
10
© 2009 The Math
11
12 21

22. 2
3
4
1
Fill Tables
5
7
6
8
© 2009 The Math
hWorks, Inc.
22

23. Review Calibration Sensitivity In Tradeoff
12
13
hWorks, Inc.
© 2009 The Math
23

24. Export Calibration Tables
2
hWorks, Inc.
© 2009 The Math
1
3 24