Desktop Simulation and Calibration of Diesel Engine ECU Software using Software-In-The- Loop Methodology

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1 2013 GT-SUITE European Conference Frankfurt / Main Desktop Simulation and Calibration of Diesel Engine ECU Software using Software-In-The- Loop Methodology Dr. Björn Lumpp Dr. Mouham Tanimou, Dr. Erica Trapel, Dr. Micha Münzenmay, Dr. Martin McMackin, Eva Bouillon, Klaus Zimmermann 1

2 Desktop Simulation and Calibration of engine ECU Agenda 1 Motivation 2 Plant models in GT-SUITE 3 Simulation of Diesel engine ECU Software 4 Coupling GT-SUITE models and ECU software models in Intecrio 5 Virtual Calibration with Inca 6 Summary & next steps 2

3 Desktop Simulation and Calibration with SiL Motivation and Goals Motivation Increase development efficiency as well as calibration efficiency by cooperative and holistic approaches Better mastering of extremely complex drive systems as well as reduction of calibration effort for those systems Tightened focusing on role based development processes Improvement of software quality by relocation of certain tests on early development stages Goals Increased exchange in the development whilst safeguarding Know-How protection Virtual simulations of engine ECU-Software in combination with industry standard 1D plant models Use of single source for several use cases: function development, pre-calibration, optimization and test Integration of existing infrastructure and tools Imply already implemented code (from different sources e.g. as models, C-Code and/or objects) Modular structure of ECU-SW with access to single modules of control functions 3

4 Desktop Simulation and Calibration of engine ECU Agenda 1 Motivation 2 Plant models in GT-SUITE 3 Simulation of Diesel engine ECU Software 4 Coupling GT-SUITE models and ECU software models in Intecrio 5 Virtual Calibration with Inca 6 Summary & next steps 4

5 Engine model Detailed engine model - overview D2676LF25 engine (12.4 l, 353kW/480HP, Euro 6) two-stage turbo charger air intercooler/ interstage cooler EGR system (λ-controlled) boost pressure control throttle valve MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 5 >

6 Engine model Representation as mean value model detailed Detailliertes model Modell generation of Datengenerierung training data for zum Trainieren der neural networks neuronalen Netze Vereinfachung simplification des of Leitungssystems pipe system Erstellen creation der of neuronalen neural networks Netze Integration integration der of neuronalen neural networks Netze MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 6 >

7 Exhaust aftertreatment model EURO VI application Exhaust aftertreatment model in GT-Power with global reaction kinetics Calibration using synthetic gas measurements Real-time capable without modification MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 7 >

8 GT-SUITE & Intecrio Workflow for integrating GT models within INTECRIO Design of GT Model and import to Simulink Integrate other libraries and Generate code for Intecrio Copy additional files to INCA.dat.xyz.nno.trb Combine with other modules and configure the OSEK OS Generate the model for the target system Virtual OS Execution in INCA Measure & calibrate as with a real ECU A2L HEX COD MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 9 >

9 Desktop Simulation and Calibration of engine ECU Agenda 1 Motivation 2 Plant models in GT-SUITE 3 Simulation of Diesel engine ECU Software 4 Coupling GT-SUITE models and ECU software models in Intecrio 5 Virtual Calibration with Inca 6 Summary & next steps 10

10 Co-Simulation EDC-Software and GT-SUITE Model Desktop simulation of engine ECU-Software Bosch ECU-SW will be provided in a virtual environment that can be flexibly used by the OEM to develop its own functions. Development Calibration Data Control Software OEM Labcar/Bench/Vehicle OEM Plant Models OEM Test Stimulation OEM OEM Test Assessments Simulink+CoSimulation GT Suite/AmeSim/ Bosch functions OEM OEM functions, to be tested in interconnection with Bosch functions 11

11 Co-Simulation EDC-Software and GT-SUITE Model Desktop simulation of engine ECU-Software Bosch ECU-SW will be provided in a virtual environment that can be flexibly used by the OEM to develop its own functions. Development Calibration Data Control Software OEM Labcar/Bench/Vehicle OEM Plant Models OEM Test Stimulation OEM OEM Test Assessments Simulink+CoSimulation GT Suite/AmeSim/ Bosch functions OEM OEM functions, to be tested in interconnection with Bosch functions 12

12 Desktop Simulation and Calibration of engine ECU Agenda 1 Motivation 2 Plant models in GT-SUITE 3 Simulation of Diesel engine ECU Software 4 Coupling GT-SUITE models and ECU software models in Intecrio 5 Virtual Calibration with Inca 6 Summary & next steps 13

13 Co-Simulation EDC-software and GT-SUITE model INTECRIO Universal prototyping system ASCMO GT-SUITE Signal Generator TargetLink Manual C-Code Other sources Embedded Coder Simulink Coder ASCET INCODIO RTA-OS Crossbar / RTA-RTE Proprietary Basis SW INTECRIO Integration and configuration platform for prototyping system Obj C A2L SCOOP-IX AR XML HEX A2L VP *) on PC RP **) on PC RP **) on high end HW RP **) on cost effective HW Automatization via APIs *) VP: Virtual Prototyping **) RP: Rapid Prototyping 14

14 Co-Simulation EDC-software and GT-SUITE Model Integration workflow for EDC-SW und GT-Model with INTECRIO Calibration data Simulink GUI dcm GT-SUITE S-function block + Environment & I/O Model C-code GT-SUITE Library INTECRIO GUI INCA Experiment CODE Integration *.obj EDC-SW (ECU Code) *.six SiL ECU Testing GT-SUITE GUI SiL-ready Model Model.dat X86 *.exe (HEX&A2L) Model.gtm EDC-SW: - pre-compiled Object-files will be used - SCOOP-IX* files are needed 15

15 Co-Simulation EDC-software and GT-SUITE model ViP4ECU (Virtual Prototyping for ECU SW development) Virtual prototyping environment for Function Development, Test and Pre-Calibration ECU Functionality Functions as object code Models in ASCET or Matlab System or Submodels Engine Model func func INTECRIO Virtual Prototyping Environment Function Development Granular Access (BC, FC) Rapid Function Development SW-Sharing and Bypass Optimization Function optimization with Matlab optimization functions Calibration and Testing Feels like real vehicle Handling like on prototype Control with all INCA library functions and testing tools PC-based function verification Pipe Modell Catalyst Model e.g. 0D Matlab or 1D GT-Power Control Export INCA High Accuracy (ECU+Plant) Fast and Flexible Development Holistic Engineering High Development Efficiency Cost Reduction on Prototypes IP-Protection 16 DGS-EC/ECC F Robert Bosch GmbH Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.

16 Desktop Simulation and Calibration of engine ECU Agenda 1 Motivation 2 Plant models in GT-SUITE 3 Simulation of Diesel engine ECU Software 4 Coupling GT-SUITE models and ECU software models in Intecrio 5 Virtual Calibration with Inca 6 Summary & next steps 17

17 Software-in-the-Loop - Application Validation of SiL-Model (EDC dosing logic + GT-SCR) in WHTC Virtual EDC Logic calculates a dosage with a high conformity to the measurement (error<1%) NO x concentration after the SCR is perfectly reflected by the GT RT model Euro VI Satisfactory accuracy of cumulated tailpipe NO x emissions (error <10%) MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 18 >

18 Software-in-the-Loop - Application Sensor drift analysis Temperature upstream SCR SCR upstream temperature: EDC signal: -10% GT model: as measured Simulation duration: ~ 7 min > 4 x faster than real-time Dosing rate limited by EDC temperature NH 3 level controller compensates for previous limitation Euro VI Temperature error leads to ~ 5 % higher Adblue consumption ~ 75 % higher tailpipe emissions Controller calibration robust with regard to pre-scr temperature sensor accuracy MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 19 >

19 Desktop Simulation and Calibration of engine ECU Agenda 1 Motivation 2 Plant models in GT-SUITE 3 Simulation of Diesel engine ECU Software 4 Coupling GT-SUITE models and ECU software models in Intecrio 5 Virtual Calibration with Inca 6 Summary & next steps 20

20 Summary Use of models from engine development leads to a good model availability with high model quality High quality of used plant models allows a highly accurate description of the overall system Extending plant models to include different additional aspects can be done in a very simple way with Simulink EDC functions are directly derived from the original sources Simulation of implemented EDC SW-functions together with the available plant models allows a very early pre-calibration of these EDC functions and optimally supports the front-loading process in the area of ECU-SW verification Outlook Block simulation and automatization of ECU-SW validation as well as calibration using optimization techniques Embedding of additional sub-models (engine, exhaust aftertreatment, powertrain, ) in this environment MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 21 >

21 Co-Simulation EDC-Software und GT-SUITE Modell Thank you! Questions? 22 Mouham Tanimou, Bjoern Lumpp F Robert Bosch GmbH Alle Rechte vorbehalten, auch bzgl. jeder Verfügung,

22 Thank you for your attention! Dr. Mouham Tanimou Robert Bosch GmbH Engineering Customer Projects Commercial Vehicles Postfach Stuttgart Dr. Björn Lumpp MAN Truck & Bus AG Powertrain Research Process Simulation Vogelweiherstr Nürnberg Co-Authoren: MAN Truck & Bus AG Eva Bouillon, Dr. Martin McMackin, Dr. Erica Trapel, Robert Bosch GmbH Dr. Micha Münzenmay, Klaus Zimmermann MAN Truck & Bus Robert Bosch GmbH Tanimou / Lumpp 2013 GT-SUITE European Conference < 23 >