ice²: an integrated software to accelerate your ... · 10 ice² - integrated calibration tool...

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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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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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


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Cycle nodes : Weighting of operating points


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Cycle nodes : Validation of cycle discretization

(with engine “photo” data)


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Engine outputs node : domain modeling

Example local of air path domain for different injection parameters sets


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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)


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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


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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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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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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

ice²: an integrated software to accelerate your ... · 10 ice² - integrated calibration tool...

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