1. Generating Optimal Engine Calibrations Using
Model-Based Calibration Toolbox
hWorks, Inc.
© 2009 The Math

2. Topics
 Green Economy Marketplace Drivers
 Response to Marketplace Drivers
 Model-Based Calibration Process Overview
 Example CI and SI Engine Calibration Problems
hWorks, Inc.
 Customer Application Examples
© 2009 The Math
 Live Demonstration of Optimal CI Engine Calibration
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3. Marketplace Drivers
The Green Economy Dictates Stringent Performance, Emissions,
and Fuel Economy Requirements:
 Engineers R
E i Respond b Addi M
d by Adding Many E i A t t
Engine Actuators
hWorks, Inc.
 Engineering Resources are Scarce and Expensive
© 2009 The Math
3

4. Response to Marketplace Drivers
The Green Economy Dictates Stringent Performance, Emissions,
and Fuel Economy Requirements:
 Engineers R
E i Respond b Addi M
d by Adding Many E i A t t
Engine Actuators
 Increased Understanding via Accurate Statistical Models
 Make Numerical Calibration Optimization Accessible
p
hWorks, Inc.
 Engineering Resources are Scarce and Expensive
© 2009 The Math
 Design of Experiments Tools To Reduce Testing
 Off-Shelf Software, Promoting Core Business Focus
 Facilitate Systematic Repeatable Process
Systematic,
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5. Model Based
Model-Based Calibration Process Overview
hWorks, Inc.
© 2009 The Math
5

6. Example CI Engine Calibration Problem
 Test Configuration
hWorks, Inc.
© 2009 The Math
6

7. Example CI Engine Calibration Problem
 Optimization Problem Setup
hWorks, Inc.
© 2009 The Math
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8. Example CI Engine Calibration Problem
 Optimal Calibration Results
MAIN SOI Table MAIN Fuel Table
F l T bl EGR M
Mass F ti T bl
Fraction Table
hWorks, Inc.
© 2009 The Math
Fuel Pressure Table VGT Rack Position Table
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9. Example SI Engine Calibration Problem
 Test Configuration
hWorks, Inc.
© 2009 The Math
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10. Example SI Engine Calibration Problem
 Optimization Problem Setup: Stoich. Region
hWorks, Inc.
© 2009 The Math
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11. Example SI Engine Calibration Problem
 Optimal Calibration Results
hWorks, Inc.
© 2009 The Math
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12. Customer Application Examples: Ford
Key Point:
 Process to develop optimal
multi-inject diesel calibration
using Model-Based Calibration
hWorks, Inc.
© 2009 The Math
From: “Using Model-Based Calibration Toolbox Multimodels for Cycle-Optimized Diesel
Calibration
Calibration”, MathWorks Automotive Conference 2008 Joshua Styron Ford Motor
2008, Styron,
Company
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13. Customer Application Examples: Toyota
Key Points:
 Full-Factorial Testing
No Longer Feasible for
optimal results
 Model-Based
hWorks, Inc.
Calibration Process
Required and
© 2009 The Math
Developed
From: “Steady-State Engine Modeling for Calibration: A Productivity and Quality
Study
Study”, MathWorks Automotive Conference 2007 Toyota/A&D/IAV
2007,
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14. Customer Application Examples: John Deere
pp p
hWorks, Inc.
© 2009 The Math
“Analytical Engine Calibration at JohnDeere”
Jason Schneider, John Deere Power Sys.
2007 SAE Commercial Vehicle Eng Conf.
Panel on Analytical Calibration
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15. Customer Application E
C t A li ti Examples: GM H ld
l Holden
Key Points:
 Significant reduction in
g
test points compared
with ‘one parameter at
a time’ or factorial test
methods
hWorks, Inc.
 Model re-use: MBC
models are engine test-
test
© 2009 The Math
bed simulator
From: “Cold Engine Emissions Optimization Using Model
Based Calibration”, MathWorks Automotive Conference 2007, Dr. Clive Tindle, GM Holden
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16. Customer Application Examples: Literature
pp p
 Model-Based Calibration Toolbox
http://www.mathworks.com/products/mbc
 MathWorks Automotive Conference Papers
 Ford: http://www.mathworks.com/industries/auto/macde2008
 Toyota / GM Holden: http://www mathworks com/industries/auto/mac2007
http://www.mathworks.com/industries/auto/mac2007
 Model-Based Calibration Toolbox Related SAE Papers and Presentations
http://www.mathworks.com/industries/auto/technicalliterature.html
http://www mathworks com/industries/auto/technicalliterature html
SAE COMVEC Panel on Analytical Calibration
hWorks, Inc.

 SAE 2008-01-1366: “A Model Based Calibration Process for Robust Optimal Cam Position
Selection Under all Engine Operating Conditions” – GM Holden
© 2009 The Math
 SAE 2009-01-0246: “Objective Determination of Minimum Engine Mapping Requirements for
Optimal SI DIVCP Engine Calibration” – The MathWorks, Inc.
 SAE 2005-01-3833: Improving Base Engine Calibrations for Diesel Vehicles through the
use of DoE and Optimization Techniques – Mahle Powertrain
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17. Contact Info
Pete Maloney
The MathWorks Consulting
Novi,
Novi Michigan USA
hWorks, Inc.
248-596-7928
pmaloney@mathworks.com
pmaloney@mathworks com
© 2009 The Math
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18. Live Demonstration
Optimal CI Engine Calibration Development
hWorks, Inc.
© 2009 The Math
18

19. Set U T t Pl
S t Up Test-Plan
hWorks, Inc.
© 2009 The Math
19

20. Design Experiment for Each Torque/Speed Mode
hWorks, Inc.
© 2009 The Math
•Script or GUI
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21. Export Experiment to .CSV or Direct to Dyno
CSV
hWorks, Inc.
© 2009 The Math
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22. Import and Review Dyno Data From .XLS or Direct
hWorks, Inc.
© 2009 The Math
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23. Set Up Local Model to Hybrid RBF for Each Mode
Point
hWorks, Inc.
© 2009 The Math
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24. Fit Hybrid RBF Models at Each Mode Operating Point
hWorks, Inc.
© 2009 The Math
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25. Remove Outliers, Review Fits by Model and Mode
hWorks, Inc.
© 2009 The Math
•View Mode Operating Points
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26. Make Boundary Models By Mode Operating Point
y y p g
hWorks, Inc.
© 2009 The Math
*Key Differentiating Product Feature
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27. Visually Review Models For Overfitting
hWorks, Inc.
© 2009 The Math
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28. Export Models To MATLAB and SimuLink for Other Users
hWorks, Inc.
© 2009 The Math
*Key Differentiating Product Feature – Re-Use
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29. Models C
M d l Complete
l t
hWorks, Inc.
© 2009 The Math
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30. Auto Export
Auto-Export Models to CAGE Optimization Tool
hWorks, Inc.
© 2009 The Math
•Starting-Point Optimization Setup and Tables
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31. Add Constraints to Optimization Setup
hWorks, Inc.
© 2009 The Math
31

32. Run Optimization by Mode and Review Results
hWorks, Inc.
© 2009 The Math
32

33. Set Up Cycle Weighted Optimization and Intialize From
Cycle-Weighted
Earlier Mode-point Optimization
hWorks, Inc.
© 2009 The Math
33

34. Run Cycle Weighted Optimization and Review Results
Cycle-Weighted
hWorks, Inc.
© 2009 The Math
34

35. Fill Calibration Tables With Optimal Results
hWorks, Inc.
© 2009 The Math
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36. Export Calibration Tables to INCA .dcm
hWorks, Inc.
© 2009 The Math
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