MORPHEE AuSy and ICE² tool

MORPHEE AuSy
and ICE² tool
Boost your calibration : from Office to Test bed solutions
Generating excellence
D2T Test bed customers
A worldwide reference
2
D2T product and services
Context and organization
•  Onsite service to
accompany our
customer on
their projects.
•  Service around
powertrain
development,
calibration and
validation.
At office
At test bed
MORPHEE
•  Turn key project
in the field of
powertrain and
attached
components.
3
•  Advanced tools
and equipments
for Powertrain
development and
testing.
D2T MORPHEE Test beds
25 years of automation and innovation
§ 
1989 è MORPHEE is created and installed on D2T test center
First real-time test beds automation system under Windows 3.1
§ 
1994 è 500 test beds installed on all kind of test beds – Windows 95
OSIRIS combustion analyzer is created and installed on D2T test center
D2T dynamometers range launch
§ 
2001 è 1,000 test bed installed on all kind of test beds - Windows NT
§ 
2007 è 2,000 test beds installed - Windows XP
First automation system including real time simulation and calibration
First automation system EtherCAT compatible
D2T launch MORPHEE Host solution for large test center management
§ 
2012 è 2,500 test beds installed worldwide – Windows 7
D2T MIO acquisition system launch
MORPHEE test beds today:
ó ~ 10,000 users
ó ~ 2,000,000 hours per year of test cell operation
4
D2T calibration expertise
Calibra'on -­‐ All types of Engines Calibration – Diesel-Gasoline-Gas
ü  2 test centers : Dynamic test beds and 4x4 Chassy Dyno
ü  Basic calibration (air load, torque structure)
ü  Model Based Calibration with ICE² tool for Pollutant /
Optimization / consumption / noise /performance
ü  Model Based Simulation on test bench with MORPHEE
Dynamic Simulation
ü  Knock detection and regulation with MORPHEE real time
controllers
ü  Particulate Filter testing and control
ü  Control (Boost Pressure, EGR)
ü  Hot, cold start, altitude conditions
ü  Driveability
ü  EOBD, electrical and functional diagnostic, safety
5
ICE²: MBC approach
Model based calibration tool
§  Market requires more and more efficient calibration
methodologies for engines to meet industrial needs :
ü  Meet simultaneously regulation and
customer requirements
ü  Shorten test duration and accelerate
optimization phase
ü  Use test data for several applications of
the same engine
ü  Take into account interaction between
ICE and the vehicle configuration
ü  Take into account robustness and
dispersions
6
Calibration context with ACS
The procedure is driven by the ACS
Test Cell context
§  Calibration
context
• 
• 
• 
• 
• 
• 
• 
• 
At Test bed
At Test bed
At Office
Cycle analysis
Selection of pertinent operating
point
Domain definition
Experiment definition
Data analysis
Modeling
Optimization
Smoothing of maps
• Indi
• Dcom
• Ethercat
• CAN
ACS*
ICE
MACSI driver
Or
Other tool
Or in House tool
• 
• 
• 
Modeling
Optimization
Maps
*Automatic Calibration System
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• Experiment
definition
• DOE Testing
• DOE Screening
• Decision process
• CAN Std
• CAN CCP
•  Fast ECU Access
• MCD3
• MCD3 Com
Calibration context : without ACS
ICE², MORPHEE with Real 'me controller/model §  Test
Cell context
Calibration
context
At test bed
At office
• 
• 
• 
• 
• 
• 
• 
Cycle analysis
Selection of pertinent operating
point
Domain definition
Experiment definition
Modeling
Optimization
Smoothing of maps
• Indi
• Dcom
• Ethercat
• CAN
Automapping
ICE
• DOE Testing
• DOE Screening
• Decision process
Real time Simulink
Controller/Model
• Engine controllers (SA, enrichment)
• Online DoE/Modelling/Optimization
• CAN Std
• Vehicle simulation (MDS)
• CAN CCP
• etc
•  Fast ECU Access
• MCD3
• MCD3 Com
MORPHEE is at the center of the test and manage it in Real Time !
8
D2T Calibration context
ICE² , MORPHEE with Real 'me controller/model §  Calibration context
At test bed
At office
• 
• 
• 
• 
• 
• 
• 
Cycle analysis
Selection of pertinent operating
point
Domain definition
Experiment definition
Modeling
Optimization
Smoothing of maps
• Indi
• Dcom
• Ethercat
• CAN
Automapping
ICE
• DOE Testing
• DOE Screening
• Decision process
Real time Simulink
Controller/Model
• Engine controllers (SA, enrichment)
• Online DoE/Modelling/Optimization
• CAN Std
• Vehicle simulation (MDS)
• CAN CCP
• etc
•  Fast ECU Access
• MCD3
• MCD3 Com
MORPHEE is at the center of the test and manage it in Real Time !
9
ICE²: MBC approach
Model based calibration tool
§  Why do we need ICE² MBC approach ?
ü  Emissions regulation and engine
performance’s seek, leads to a higher
complexity of calibration work
ü Diesel engines combustion
parameters to be tuned increased
strongly with multiple injection
strategies and advanced air path
ü Gasoline engines complexity as
well have become more complex
with direct fuel injection, VVA
systems, turbocharger and EGR
è Experimental testing needed and ICE² approach simplify your
optimization problem while maintaining acceptable testing cost
10
ICE² presentation
Model based calibration tool
§  Parameters and engine responses
Spark
Advance
Start of
Injection
VVTi
position
Optimum
?
Efficency
?
ICE
Emmissions
T°
VVTe
position
Inj Pressure
Knock
AFR
Fuel
• density
• LHR
• % O2
• Ind Oct
• …
11
Turbo speed
…
ICE²: MBC approach
Model based calibration tool
§  ICE² technical advantages
ü  Include cutting edge calibration
methodologies
ü  Be safely guided among the process, and
free to use your favorite method
ü  Engine calibration oriented
ü  Adapted to your needs
ü  Fully integrated tool and easy
to use
ü  Make Model Based Calibration
accessible to non specialist
ü  High accuracy kriging modeling
techniques
ü  Generate accurate models easily and
rapidly
ü  Maps smoothing and
optimization tool
ü  Get the best of your engine (fuel
consumption/emissions/ durability)
ü  OS 64 bits optimized, multicore, multi-threaded
ü  Optimized, and Fast even on off-the shelf
laptops
è The right tool to accelerate your calibration process and ensure
meeting quickly today’s and tomorrow’s new requirements
12
Calibration methodologies
Model based Calibration with “Local approach”…
And cycle results prediction with ICE²
From the initial calibration settings and
Advantages
of cycle
estimation:
Cycle definition
results
Engine tests
on cycleto the final smoothed ones
Validation
and targets
Valid ?on a defined cycle
Predict engine results
Selection of Operating points
Limit the number
of calibration
Choice and
weighting of iterations by anticipating cumulated results offline
(OP) and control
Smoothing of maps
operating points (OP)
mode strategies
Up to 25% gain
in engine test duration compared with iterative calibration
ICE²
No
xOP
Gain in efficiency with re-using your data
Local
Domain
definition
xOP
Engine tests of DoE
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Local optimum
Several cycle applications with same data
Possibility to test different engine Control Mode strategy offline
xOP
up to 25% gain in post processing
duration
Design of
Experiments
MORPHEE
xOP
modeling of engine
responses
ICE² presentation
Speed up your calibration process
>  Structuring: the workflow leads the work
according to the calibration process
>  Flexible: multiple cutting edge calibration
approaches inside including cycle prediction
capabilities
>  Integrated: gather all important data and save
results generated within the project
>  User-friendly: data oriented interface providing
guidance to the calibration engineer
>  Advanced: providing innovative algorithms such
as fast high accuracy modeling and optimization
>  Independent: no need of third party application
or toolbox
>  Open: reuse models in other application like
Simulink/Excel or in real time in MORPHEE AuSy
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D2T Calibration context
ICE², MORPHEE with Real 'me controller/model §  Calibration context
At test bed
At office
• 
• 
• 
• 
• 
• 
• 
Cycle analysis
Selection of pertinent operating
point
Domain definition
Experiment definition
Modeling
Optimization
Smoothing of maps
• Indi
• Dcom
• Ethercat
• CAN
Automapping
ICE
• DOE Testing
• DOE Screening
• Decision process
Real time Simulink
Controller/Model
• Engine controllers (SA, enrichment)
• Online DoE/Modelling/Optimization
• CAN Std
• Vehicle simulation (MDS)
• CAN CCP
• etc
•  Fast ECU Access
• MCD3
• MCD3 Com
MORPHEE is at the center of the test and manage it in Real Time !
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Focus on AUTOMAPPING
MORPHEE easy procedure writer
§  Simple and efficient tools (actions) to describe a test:
« Table »: sweep set-points from a defined table ó adapted to DoE
« Loop »: sweep set-points for one channel from defined begin, end and step
« Breakpoints »: sweep breakpoints of an existing ECU look up table
« 2D Loop »: sweep set-points from a 2 dimensional table
« Set »: single value set-points
« Condition»: play or not the indented sub actions
« Method »: Call a MORPHEE method: access to all the power of MORPHEE
and its algorithms for data logging
Only 7 actions to program any test sequence!
Focus on AUTOMAPPING
Managing limits and stabilities
§  For each action of the test sequence:
ü  The user can activate or deactivate limits
ü  Define stabilities
ü  Select the type of action in case of limit violation
Reaction in case of limit violation:
Ø  Next step,
Ø  Exit current action,
Ø  User defined (MORPHEE method).
Focus on AUTOMAPPING
Follow-up of tests
§  Once a test sequence is completed:
ü  The user sees it while the test is running through a dedicated monitor
ü  Some functions can be modified on-line (values of set-points, test orientation...)
ü  Each set-points actions is traced in MORPHEE logbook
Orientation of the test
Cursors
showing
ongoing
actions
Limits status
Follow-up of
specific channels
Colors indicating
the status of the
points (done, in
progress,
following)
Focus on AUTOMAPPING
Follow-up of tests
§  Each action has its own view with on-line access:
§  Activation/deactivation of programmed points TABLE
ü  Set-points values
LOOP 2D & BREAKPOINTS
METHOD
LOOP
IF
SET
Focus on AUTOMAPPING
Tools
§  Simple and efficient tools :
ü  Total freedom on procedure and its complexity thanks to MORPHEE methods
embedded (like trigger modeling, controllers de/activation etc)
ü  Unlimited number of levels of indentation
ü  Easy straight forward test procedure writing and reading
ü  Reaction in case of limit violation to ensure a safe and successful data
collection for DOE, sweeps, engine mapping, etc
ü  Stability criteria reduce to minimum time spent per experiment and maximum
test bed occupancy
Now in standard and free in MORPHEE package
D2T Calibration context
ICE², Automapping & Real 'me controller/model §  Calibration context
At test bed
At office
• 
• 
• 
• 
• 
• 
• 
Cycle analysis
Selection of pertinent operating
point
Domain definition
Experiment definition
Modeling
Optimization
Smoothing of maps
• Indi
• Dcom
• Ethercat
• CAN
Automapping
ICE
• DOE Testing
• DOE Screening
• Decision process
Real time Simulink
Controller/Model
• Engine controllers (SA, enrichment)
• Online DoE/Modelling/Optimization
• CAN Std
• Vehicle simulation (MDS)
• CAN CCP
• etc
•  Fast ECU Access
• MCD3
• MCD3 Com
MORPHEE is at the center of the test and manage it in Real Time !
21
Focus on RT embedded Simulink Controller Unlimited possibili'es
RT functions can be developed under Matlab Simulink and are running in
real time into MORPHEE automation system up to 2 kHz
§  RT Simulink Controller examples on Gasoline Fuel path :
ü  MFB 50% or Pmax angle target with SA control (Spark Advance)
ü  Knock limit with SA control for engine protection
ü  AFR with injection timing control
ü  AFR enrichment for engine protection
è Controllers can run in RT continuously during procedure such as :
engine mapping, full load, or DoE, … and triggered/stopped from any
procedure such as Automapping
Focus on RT Controller Example of Ethanol fuel use for Full load calibra'on §  Torque specification :
ü  Torque specification reached or not depending on fuel used
§  Automatic combustion phasing :
ü  Impact of the fuel on the MFB50 (CA50)
§  Automatic combustion enrinchment :
ü  AFR adjusted for limited T°exhaust and engine protection and impact on BSFC
MFB50 (Osiris)
Richness 5Gas
BMEP
24
BSFC
SP95
Ex
Exx
Exxx
Exxxx
E100
SP95
Ex
Exx
Exxx
Exxxx
E100
Richness
[-]
BMEP[bar]
BSFC
[g/kWh]
MFB50
[°V]
SP95
Ex SP95
ExxEx
Exx
Exxx
Exxx
Exxxx
Exxxx
E100
E100
1.00
500
500 1000
1000 1500
1500 2000
2000 2500
2500 3000
3000 3500
3500 4000
4000 4500
4500 5000
5000 5500
55006000
6000
Engine
Speed
[rd/min]
REGIME
[rd/min]
240
500
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
REGIME [rd/min]
Engine Speed [rd/min]
è Maximize you test bed running time in automated mode
Customer’s project (values removed)
Focus on RT Model
Real time simulation with MORPHEE
§  MORPHEE Dynamic Simulation at test bed : ready made
embeded models for vehicle simulation
MORPHEE 2
Gear box ratio, clutch
Real Time Model 3
Vehicle Model
Real Time Model 1
Vehicle
Velocity
3
5
2
4
6
GBMgt
Vehicle Velocity
Demand
MORPHEE PARAMETERS
Test Bed
Controler
1
SIMULINK
DRIVER
Brake
Engine
Speed
Demand
GearBoxMgt Model
Throttle
Demand
SIMULINK
SIMULINK
VEHICLE
Real Time Model 2
Driver Model
Vehicle
DRIVER
GearBox Mgt
Mass
P
Gear shifting times
Gear Box ratios
I
K1, K2, K3 coeff.
D
Engine speed for
gear shifting
...
...
Pedals rules
ROAD
PROFILE
Throttle
Demand
...
Engine
Speed
Demand
Engine
Speed
Measured
AC DYNO
Engine
Torque
Measured
ECU
Actuators
Driveline
ü  Simulate chassy dyno at test bed and
reduce your calibration cost
ü  Validate ICE² new optimal maps
results without delay
ü  Improve the analysis of new
calibration thanks to better
repeatability
Sensors
ENGINE
Example : road load simulation
ü  Reduce calibration iterations
Conclusion D2T solution
D2T solution advantages:
§  ICE² offers the best of model based calibration for a standalone usage
§  Flexible, simple, and independent solution: create your desired
procedure and controllers. MORPHEE is still the only master of the test
§  Only one PC is running the test bed: best possible Real Time solution,
and avoid the need of duplicated communications
§  Cost effective solution: Automapping driver is included in MORPHEE
package
Thanks
D2T - 11 rue Denis Papin - F-78190 Trappes - Tel. : +33 (0)1 30 13 07 07 - Fax :+33 (0)1 30 13 07 10