Controls and Software Development for Modern Diesel Engines
Dr. Umut Genc Dr. Serkan Impram
Managing Director Team Leader
AVL Turkey AVL Turkey
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AVL Your Global Powertrain Control Engineering Partner
Ann Arbor (USA)
Sdertlje (SWEDEN)
Steyr (AUSTRIA)
Istanbul (TURKEY)
Lake Forest (USA)
Dunton (UK)
Regensburg (GERMANY)
Graz (AUSTRIA)
Budapest (HUNGARY)2
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AVL Turkey
Founded in August 2008 Based in Tax-free Techno Park in Gebze
near Istanbul (40km) Team of 16 electronics and mechanical
engineers Serves Turkish industry both in engineering and test
systems
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AVL Turkey Key Skills
SW & ElectronicsAlgorithm Dev. Function Dev. Software Dev.
MIL/HIL Testing
CalibrationEmissions Aftertreatment Driveability
8 2 2
3
ElectrificationHybrid Vehicles E-Drives BatteriesYour Partner in
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Test SystemsProject Management Service & Maintenance4
Powertrain Controls and Software Development Agenda
Introduction Model-Based Development Process Engine Models
Controls Conclusions
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Powertrain Controls and Software Development Agenda
Introduction Model-Based Development Process Engine Models
Controls Conclusions
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Powertrain Management System A Small Part of a Distributed
Vehicle Control SystemCAN Class B CAN Class C MOST Bus Private
Bus
25 MBaud 500 kBaud
83,3 kBaud
Conventional Wiring
Source: MaybachYour Partner in Powertrain AVL List GmbH
all Electronic Control Units: 767
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Powertrain Management System Example: ECU Requirements
HARD Emissions Fuel Economy Diagnostics
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Powertrain Management System Example: ECU Requirements
SOFT Torque Power Drivability NVH
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Powertrain Management System Example: Gasoline Engine
Configuration
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Powertrain Management System Example: Diesel Engine
Configuration
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Powertrain Management System Example: ECU Requirements
Ignition / Injection calculation Compensate for component aging
and tolerances adaptation algorithms Interface to Powertrain TMS,
ESP, ABS, Cluster, Immobilizer, . CO2 reduction measures
Stop&Start, Battery management, .. Auxiliary functions A/C,
heater control, cooling fan, .. Vehicle safety, monitoring
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Powertrain Management System Example: Generic ECU
ConfigurationClutch Switch Brake Test Switch Manifold Air Flow
Pedal Value Sensor 1/2 Temperature Coolant Throttle Position Fuel
Pressure Manifold Air Pressure Knock Sensors LIN, FlexRay SENT, BSD
Powertrain CAN Vehicle CAN Voltage Ignition (KL15) Voltage Main
Relay (KL87) Voltage Battery (KL30) GROUND Battery (KL31) Sensor
Supply Sensor GroundYour Partner in Powertrain AVL List GmbH AVL
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COREDigital Interface Monitoring UnitSPI
Power Stage (Low SideHigh Side Driver)
Controller Analog Interface (signals multiplexed) Infineon,
FreescaleSPI
Canister Purge Solenoid Variable Intake Manifold Main Relay
Control Waste gate Malfunction Indication Lamp Fuel Pressure
Actuator Piezo DI Injectors Solenoid DI Injectors External Ignition
Drivers (TTL) Internal Ignition Stage Throttle Turbo EGR BOSCH LSU
4.9 NGK ZFAS U1/2 Solenoid Injector
Power Stage (Injection Driver)
Knock Interface Interfaces
SPI
FlexRay Controller
SPI
Ignition Driver
SPI
H-Bridges
CAN
SRAMSPI
Linear Lambda
EEPROM Power UnitSPI SPI
Injection Driver (MPI)
(DEKA 7)
13
Powertrain Management System Software / System complexity
150 I/O (154 pin connector is standard, 196 pins for high-end)
700 system functions 10.000 A4 pages of specification 350.000 lines
of code 20.000 parameters (~250 kbyte) 25% of customer object code
(increasing) Complex and fast real-time behavior Software accounts
for 50-70% of ECU development costs. Software & Electronics
account for ~40% of vehicle cost with 13% of that coming from
software alone.Your Partner in Powertrain AVL List GmbH AVL
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passing on to third parties60%
Tasks distribution50%
40%
30%
20%
More than 80% of code executed in less than 10 ms
10%
0% Ini 10 ms 20 ms 40 ms 100 ms 1000 ms Reset 1 ms 5 ms Seg
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Engine Management System Hardware and Software Architectures
EMS Hardware Architecture Overview, Block diagram Digital Core
Inputs, Outputs Monitoring Unit EMS Software Architecture
Infrastructure Layer Application Layer
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Engine Management System Main Hardware BlocksDigital
CoreMicrocontroller Code Memory, Data Memory, Non-volatile memory
Power Supply and Reset generator Manufacturing Test Interface,
Debug and Emulation Interface Clock Circuitry
Inputs (sensors & signal acquisition) Outputs (actuators,
power stages) Monitoring Unit
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Engine Management System Main Hardware Blocks Microcontroller
State-of-the-Art Microcontrollers are 32-bit Typical performance
values (e.g. Infineon TC1796):32-bit CPU Single precision FPU 2 MB
Embedded Flash 144 kB internal RAM 32-bit Peripheral Control
Processor Up to 129 digital I/O pins 36 + 4 analog input pins 4 x
V2.0B CAN Controller 150 MHz@ -40 125 CYour Partner in Powertrain
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Engine Management System Main Hardware Blocks MemoryThe memory
sub-system can be located directly on the microcontroller (internal
memory, on-chip), connected via a bus system to the microcontroller
(external memory, off-chip), or both.Utilization Original
programming Programmed at manufacturing and/or End-Of-Line Contents
retained over lifetime
Code memory Flash, ROM
Program code storage Parameter storage Constants Initialization
values
Data memory RAM
Program data storage
Generated during program execution Contents lost after power
down
Non-volatile data memory Accumulated data Flash EEPROMAdaptation
values Diagnostic/Error Codes
Programmed at manufacturing and changed during program execution
Contents retained after power down
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Engine Management System Main Hardware Blocks MonitoringTypical
3-level monitoring of ECU
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Engine Management System Hardware and Software ArchitecturesWhat
is an Engine Management System Hardware? EMS Hardware Architecture
Overview, Block diagram Digital Core Inputs, Outputs Monitoring
Unit EMS Software Architecture Infrastructure Layer Application
Layer
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Engine Management System Software Architecture Top
LevelDriver/Operator Demand Powertrain Coordinator Hybrid
Coordinator Brake System
Diagnostic Services
Combustion Engine
Engine Exhaust
Transmission
Electrical Machine
Electrical Store
Alternative Energy
Body/Chassis other Systems
Control of System State
Engine Air (EngGas)
System interfaces
Safety Monitoring
Integration Platform AUTOSAR RTE or customer specific Basic
Software Electronic Control Unit Combustion Engine Engine Exhaust
System Transmission Electric Machine Hybrid Vehicle System
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Powertrain Controls and Software Development Agenda
Introduction Model-Based Development Process Engine Models
Controls Conclusions
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Model-Based Development Process Factors Influencing SW Quality
(bunu gostermeye gerek yok bence)
SW Quality
Process Quality
Project Quality
Work Environment Quality
Run Selection
Data Selection
Result view
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Model-Based Development Process V-CycleV-Cycle development
capabilities in all varieties V-Cycle development capabilities in
all varietiesSYSTEM
Requirement engineering
RPT unit (RPU)
Verification and Validation
ALGORITHM Modeling & simulation
Testing / HIL
(Auto-) CodingSOFTWARE
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Model-Based Development Process Integrated Methods &
ToolsProcess
Phase-Based-View
Methods
Configuration Management
Change Management
Verification & Validation
Requirement s Engineering
Project Management
Coding Guidelines
Architecture & Design
Project Management
Quality Assurance
AUTOSAR
Simulation
Release Management
Tools
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Model-Based Development Process Integrated Methods &
ToolsInternal development customer / target independentLabel
repository
Customer / internal delivery
ModelingMatlab / Simulink Requirements TargetLink
Code Generation
SW Build
.o .s19 .hex
Ascet SEAscet MD Physical model (Floating-point) Implementation
model (Fixed-point)
Code generator Configuration
.cFile
SW BuildMake, Perl,
.a2l .odxTools Compiler,
Project Config.
Compiler Options
MKS source
MKS Integrity
Application Lifecycle Management
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Model-Based Development Process Different Software Tests at
Different Development Stages
MiL Model in the LoopFloating Point Arithmetic
Rapid Prototyping
PC
System test HiL, Car
Implementation: floating -> fixed-point
SiL Software in the LoopImplementation Code Fixed Point
Arithmetic
Integration test
PC
HiL Hardware in the LoopOptimization for target C
Unit test PiL Processor in the LoopImplementation Code Fixed
Point Arithmetic
Target HW
Debugger
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Model-Based Development Process MiL Model in the LoopTest
execution on standard development PC, no real time behavior
necessary Floating point execution of the function under
development Plant model development and adaptation for test
requirements Test script development and execution When all test
criteria are fulfilled SiL, rapid prototyping
Model Based Function DevelopmentASCET, SIMULINK Response
Stimulation
Test Automation
Developer PC
Plant ModelASCET, SIMULINKYour Partner in Powertrain AVL List
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Model-Based Development Process SiL Software in the LoopFixed
point C-code execution on developers PC, no real time behavior
necessary Plant model and test script re-use from MiL tests
Additional test scripts to detect implementation and code
generation failures Tolerance band definition due to accuracy loss
caused by implementation Comparison of test results with MiL test
results
Automatic generated C-Code Hand written C-CodeResponse
Stimulation
Test Automation
Developer PC
Plant ModelASCET, SIMULINKYour Partner in Powertrain AVL List
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Model-Based Development Process HiL Hardware in the LoopFunction
integration on target ECU Plant model executed in real time on HiL
system Test script reuse from MiL / SiL / PiL tests Additional
calibration system necessary Comparison of test results with SiL /
PiL test results and function requirements
Target ECU Test Bench PC Wiring harness Calibration Link HiL
Interface HiL Test Bench
TestAutomation Calibration System INCA, CalDesk HiL System
Control Operator, Control DeskYour Partner in Powertrain AVL List
GmbH
Real time Hardware
Plant Modelrunning in real time
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Powertrain Controls and Software Development Agenda
Introduction Model-Based Development Process Engine Models
Controls Conclusions
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Powertrain Controls and Software Development Mean-Value Engine
Models
Engines are nonlinear systems with multiple inputs and outputs
Mean value models represent system behaviour over a cycle and are
used for controls & software development
1 Wie (k ) = o 180
k 180
w
4
ie
( )d
( k 1)180 i =1
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Powertrain Controls and Software Development Mean-Value Engine
Modelsk 180 4
1 Wie (k ) = 180o
w
ie
( )d
( k 1)180 i =1
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Powertrain Controls and Software Development Mean-Value Engine
Models
Tw Pi Ti Wi P m V
Q Po To T Wo
Work
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Powertrain Controls and Software Development Mean-Value Engine
Models
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Powertrain Controls and Software Development Mean-Value Engine
Models
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Powertrain Controls and Software Development Engine Models AVL
MoBEOEngine Model
Torquedem Engine speed
. m p,T
Engine Model comprises: ECU + sensors & actuators + engine +
exhaust aftertreatment Semi-empirical engine model embedded in
plant model.
Sensors & Actuators
Model ECU
Engine Hardware Model
p,T
Torque NOx, Soot, HC, CO, BSFC, Heat to coolantYour Partner in
Powertrain AVL List GmbH
Engine model is mainly 0dimensional with volumes, restrictions
and special components (e.g. combustion, turbine, catalyst).
Resulting in states and fluxes in software platform
(Matlab/Simulink).
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Powertrain Controls and Software Development Engine Models AVL
MoBEOControls & Diagnostics algorithm design in Matlab /
Simulink Software function tests: - Test case design, automated
execution & evaluation - MiL tests = SW + MoBEO engine &
Exhaust Aftertreatment System simulator Offline pre-calibration
using MoBEO Verification with production SW: - SiL tests =
Production SW + MoBEO Verification in production ECU - HiL tests
with signal stimulator - Calibration on HiL test rig with MoBEO
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Powertrain Controls and Software Development Engine Models AVL
MoBEO
Controlalgorithm
TargetLink
MiL tests ECU Code Generated Customer Code Code
SiL tests
MoBEO
Selected Production SW Applications at AVL: DPF / Air Path
Control & Diagnosis Software DOC / SCR Diagnosis SoftwareYour
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MoBEO = Model Based Engine Optimisation39
Powertrain Controls and Software Development Example: On-board
DiagnosticsAVLs integrated tool chain allows development of OBD
algorithms before hardware is available High-Quality BOOST models
of exhaust components Defined model calibration procedure Simulated
catalyst ageing Real time engine model to simulate engine-out
emissions OBD software development in Simulink Pre-calibration on
modelSCR Model
(c) AVL / DGE 2006 RTI Data CAN Co ntrol ler Setu p [DCU_
st_m]DC U_st_m Com _dmActPSCR Ctl1 ENG_nrpm _m AMB_m f kgps_m SCR
_tcU p_m SCR _tcDwn_m INJ_mgpi_m EXH _phScrU p_m swDosingC ameo swC
am eoOption AB_mf m gpsCameoD em AB_alphaCameoD em SC R_rppm NH
3Dwn CEB_rppm NoxEo EXH _m f kgps_m DC U_st AB_m f mgps_m INJ_mf m
gpi_m AB_mf m gpsAdapt AdBlue ENG_nrpm _m AMB_mf kgps
EXH_phScrUp_m
DCU_st_m [AB_mfmgp s_m] ENG_nrpm_m [AMB_ mfkgps_m] [SCR_ tcUp
_m] [SCR_tcDwn_m] [INJ_mfmg pi_m] [EXH_ phScrUp_m] swDosi ngCame o
swCameo Optio n AB_mfmg psCameoDem AB_a lpha CameoDem SCR_rp
pmNH3Dwn CEB_rppmNoxEo [EXH_mfkg ps_ m] [SCR_rppmNoxUp_ m]
[SCR_rNoxDwn_m] [EXH_mfkgps_m] [EXH_ph ScrUp_m] [SCR_ rppmNH3Dwn]
[SCR_tcUp_m] [SCR_tcDwn_m] [AB_mfmgps_m] -K[AB_mfmgps_m]
[INJ_mfmgpi _m] [ENG_nrpm_m] [AMB_mfkgp s_m]
(NH2)2CO - Urea inj ection (vi a CAN)
SCR _rN H3Dwn SCR _tcU p_m SCR _tcD wn_m AB_m f mgps_m SMF_rN H3
SCR _rppm NoxUp_m SCR _rN oxDwn_m EXH_m f kgps
DAC NH3 gas i njecti on (Anal og Si gnal Out)
Input MPE: DCU \ Gene ral Para meter \ NGK Sonde NGK_sw -CEnable
SCR _rN oxUp_m SCR_rppmN oxUp_m SCR _rNoxD wn_m SCR_rppmNoxD wn_m
SCR _rNoxEO_m SCR_rppmNoxEO_m NGK_st
SCR Strategy op en SCR Li brary SCR_rppmNoxUp_ m Goto18
pmNoxDwn_m SCR_rp Goto19 SCR_rppmNoxEO_m NGK_st Goto15 Goto2 0 open
DCU.mat with MPE
[SCR_ rNo xUp_m] Goto [SCR_rNoxDwn_ m] Goto1
[ENG_nrpm_m]
EN G_nrpm _m
NGK Sonde Aktiva ti on / Recei ve / Send Bootschaft
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Powertrain Controls and Software Development Agenda
Introduction Model-Based Development Process Engine Models
Controls Conclusions
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Powertrain Controls and Software Development Typical Common Rail
Diesel System
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Powertrain Controls and Software Development Controls Torque
Based Structure
TORQUE DEMAND FUELTIMING AMOUNT
AIRBOOST EGR
IDLE GOVERNOR AFTERTREATMENT
Fuel consumption Efficiency Emissions Performance Temperatures
.A Good Control Strategy is Required A Good Control Strategy is
Required
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Powertrain Controls and Software Development Controls Typical
Feedback LoopPID gains usually depend on speed, load and possibly
other parameters Each application may need up to 300 points tuned
This makes the tuning process time consuming
Torque
Error
Speed
Precontrol
Setpoint
PID Controller
System Dynamics
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Powertrain Controls and Software Development Controls Exhaust
Gas Recirculation (EGR)A certain amount of exhaust gas is
recirculated back into the inlet manifold to improve NOx emissions
EGR system could be high pressure or low pressure In modern diesel
engines, EGR is controlled via EGR valve, and throttle valve.
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Powertrain Controls and Software Development Controls EGRTARGET:
Regulate NOx Emissions Regulate EGR Valve position Control EGR
Valve actuator Cascade control Inner loop: position control (PID)
Outer loop: flow control (PID) Challenges Time delay, Multi Input
(e.g. speed, torque demand, fuel & air flow)
Pre-control
Pre-control Engine Dynamics
Setpoint
Controller
Setpoint
Controller
EGR Valve
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Powertrain Controls and Software Development Controls EGRNormal
Operation Conditions Controls to fulfill Emissions requirements Low
fuel consumption Drivability Balancing production tolerances
Balancing deviations over life time Adopting to environment in
Engine Warm/cold Idling, part load, full load Vehicle Ambient
temperature Ambient pressure Fault Operation Conditions Electrical
failures Component failures Leakage Sensor Drift System failures
Oil dilution OBD relevance Non-functional Requirements Performance
Safety/monitoring Error handling & diagnosis Security Quality
Robustness Testability Users' experience Reliability Modifiability
C resources
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Powertrain Controls and Software Development Controls
Performance / Boost ControlHistorically, turbo was utilized for
increased engine performance. Nowadays, turbo is used also for
engine downsizing leading to smaller & lighter engines. This,
in turn, leads to lower fuel consumption & emissions while
maintaining (or increasing) performance.
Turbine: rotates with power from exhaust gas Compressor:
connected to same axis with turbine & compresses air into
cylinders
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Powertrain Controls and Software Development Controls VGT
operation
at high RPM
at low RPM
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Powertrain Controls and Software Development Controls
Performance / Boost ControlBoost controller is similar to EGR
controller
Pre-control
Pre-control
MAP Setpoint
Controller
Setpoint
Controller
VGT Vane Positions
Engine Dynamics
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Powertrain Controls and Software Development Controls Air Path
(EGR & Boost)In most applications, EGR & Boost loops are
assumed to be decoupled and, as such, controlled separately as
shown previously In reality, however, there is strong interaction
between these two loops Multi-Input / Multi-Output (MIMO)
controllers might give improved results !
Air-PathEGR Controller
Ref
+VGT
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Powertrain Controls and Software Development Agenda
Introduction Model-Based Development Process Engine Models
Powertrain Controls Conclusions
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Powertrain Controls and Software Development ConclusionsModern
diesel engines are complex & sophisticated systems Controls
& Software development for such systems requires
well-established engineering processes well-structured
multi-disciplinary teams advanced controls knowledge practical
experience with state-of-the-art control systems handling a vast
array of sensors & actuators good understanding of, and
experience with, real-time systems hardware & software
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Many thanks for your time & attention !For more information:
[email protected]
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