This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Simulation-Based Engine Calibration: Tools, Techniques, and Applications
ISSN: 0148-7191, e-ISSN: 2688-3627
Published March 08, 2004 by SAE International in United States
Annotation ability available
Calibration of engine management systems requires considerable engineering resources during the development of modern engines. Traditional calibration methods use a combination of engine dynamometer and vehicle testing, but pressure to reduce powertrain development cost and time is driving development of more advanced calibration techniques. In addition, future engines will feature new technology, such as variable valve actuation, that is necessary to improve fuel economy, performance, and emissions. This introduces a greater level of system complexity and greatly increases test requirements to achieve successful calibrations.
To address these problems, new simulation tools and procedures have been developed within Delphi to rapidly generate optimized calibration maps. The objective of the work is to reduce calibration effort while fully realizing the potential benefit from advanced engine technology. The procedure utilizes GT Power engine simulation software and engine models validated through limited dynamometer testing.
A front end to GT Power was written to automatically call GT Power executables and produce the calibration dataset. Several methods were used to accelerate the simulation process. Calibrations are optimized using an additional software tool that includes a weighted-optimization scheme. User-defined constraints may be applied during optimization for cam phaser position, combustion dilute limits, exhaust temperature or any other variable defined in the engine model. The overall procedure includes vehicle simulation using ADVISOR to estimate fuel economy and emissions for the drive cycle.
This paper describes the simulation tools and procedures, and presents calibration results for a modern V6 engine equipped with two-step VVA and intake cam phasing. Preferred two-step switching schedules and cam phaser position maps are presented.
CitationRask, E. and Sellnau, M., "Simulation-Based Engine Calibration: Tools, Techniques, and Applications," SAE Technical Paper 2004-01-1264, 2004, https://doi.org/10.4271/2004-01-1264.
- Seabrook, J. et al. “Applications of Advanced Modeling Methods in Engine Development,” Paper No. C606/028/2002 IMECHE 2002
- Raynaud, Y. et al. “Application of Adaptive Online DOE Techniques for Engine ECU Calibration,” 2002 IMECHE Conference on Statistics and Analytical Methods in Automotive Engineering
- Stuhler, H. et al. “Automated Model-Based GDI Engine Calibration Adaptive Online DOE Approach,” SAE Paper 2002-01-0708 2002
- Roepke, K. Fischer, M. “Efficient Layout and Calibration of Variable Valve Trains,” SAE Paper 2001-0668 2001
- Ward, M.C. et al. “Bayesian Statistics in Engine Mapping,” Paper No. C606/020/2002, IMECH E 2002
- Accelerated Powertrain Calibration with DOE, AVL FOCUS Magazine 30 31 May 2003
- Butler, K. “Virtual Partner; Automotive Powertrain Calibration Finally Becomes a Virtual Reality” Engine Technology International 2 03 2003
- Haines, S. N. M. et al. “The Application of an Automatic Calibration Optimization Tool to Direct-Injection Diesels” Statistics for Engine Optimization Professional Engineering Publishing Ltd London 2000
- Stinstra, E. et al. “Design Optimization: Some Pitfalls and Their Remedies,” Centre for Quantitative Methods Eindhoven, Netherlands
- Lowe, D. et al. “Validation of Neural Networks in Automotive Engine Calibration,” Artificial Neural Networks 7-9 July 1997 Conference Publication No. 440, IEE 1997
- Mitterer, A. Zuber-Goos, F. “Model-Based Optimisation - a New Approach Towards Increasing Efficiency in Control-Unit Calibration,” 2000
- Meyer, S. Greff, A. “New Calibration Methods and Control Systems with Artificial Neural Networks,” SAE Paper 2002-01-1147 2002
- i-SIGHT Version 6, Engenious Software Manual 2001
- Burk, R. Jacquelin, F. Wakeman, R. “Using Co-Simulation Methods to Establish Variable Valve Actuation Hardware Specifications and Control Strategies,” Paper No. 2001-ICE-427 37-3 2001 American Society of Mechanical Engineers 2001
- Jacquelin, F. Burk, R. Wakeman, R. “Cam Phaser Actuation Rate Performance Impact on Fuel Consumption and NOx Emissions Over the FTP-75 Drive Cycle,” SAE Paper 2003-01-0023 2003
- Burk, R. et al. “A Contribution to Predictive Engine Calibration based on Vehicle Drive Cycle Performance,” SAE Paper 2003-01-0225
- WAVE Users Manual, Ricardo Consulting Engineers 2002
- Edwards, S.P. et al. “The Role of Statistics in the Engine Development Process,” Statistics for Engine Optimization Professional Engineering Publications, Ltd London 2000
- Osborne, R. “Concurrent WAVE/Matlab Simulink Simulation Applied to HSDI Diesel ECU Calibration,” Proceedings of the Fourth Ricardo Software International User Conference Detroit March 1999
- Osborne, R.P. “Total Vehicle System CAE Modeling Applied to Electronically Controlled Diesel Engine ECU Calibration,” Paper C587/004/2000, IMechE 2000
- MATLAB Version 6 Users Manual The Math Works, Inc. 2001
- GT Power Software, Version 5.2 Gamma Technologies, Inc Westmont, Illinois June 2002
- ADVISOR 3.2, National Renewable Energy Laboratory, Advanced Vehicle Simulator Program 2002
- Sellnau, M. Rask, E. “Two-Step Variable Valve Actuation for Fuel Economy, Performance and Emissions,” SAE Paper 2003-01-0029 2003
- Microsoft Visual Basic for Windows 2000 Microsoft Corporation 2002
- Microsoft Excel for Windows 2000 Microsoft Corporation 2002