GM Powertrain Europe Engineering Center

Powertrain Electronic Control Units: development, models, analysis and tests

according to General Motors

Alessandra Neri Hardware Electrical Architecture Development Engineer

GM vision and brands General Motors Vision: Design, Build and Sell the World’s Best Vehicles

Jiefang

GM Powertrain 2005-2013

• GM 104 years-old• GMPT/Torino 8 years-old• Average age 35, 25% under 30• 20% are women

GMPT-E Italy activities

Diesel Engine EngineeringDiesel Engine design & testingComputer Aided Engineering (CAE) & SimulationExhaust AftertreatmentTurbocharging

Controls EngineeringDiesel Control (HW&SW)Engine Management System ComponentsGM is the only auto maker with complete software and systemsexpertise in control of Gasoline & Diesel engines and transmissions

Diesel Hybrid EngineeringEngine system configuration modelling & optimizationDiesel Hybrid verification

GLOBAL RESP IN TORINO

GLOBAL RESP IN TORINO

GLOBAL RESP IN TORINO

GMPT-E Italy Figures

• €30 million initial Investment• 624 office places• 15 Test Cells

• 12 Laboratories• Workshops • Chassis Dyno

€20 million new investment (2011-2014)50% of IP developed by GM Powertrain in Europe comes from Torino

GMPT-E Italy Diesel Portfolio2.5-2.8L 2.0L CDTI

1.0L CDTI 2.2L CDTI 1.3L CDTI

1.7L CDTI

Controller D1Plus:

Opel InsigniaOpel Astra

Opel CorsaChevrolet Beat

Chevrolet Colorado

Chevrolet Orlando

New 1.6-liter diesel engine MDE

7

Engine Control System Development

Control System Architecture

Requirement Definition

Algorithm and Software 

Design

HW and SW test

Control System 

Validation

Controller D1Plus

Diesel controls developmentOur Teams

8

Electronic EngineeringElectrical architecture and interfacerequirements Worst case and variation analisysController hardware engineeringTarget software build

Control system tools and testingHIL set up Tools developmentTest automationsHIL testing

Algorithm and softwareModel based approachAdvanced signal processing and robust controlRapid prototyopingAutomatic code generation

11

24

1012

13

15

16

17

1819

20

2123

2526

3 32

33

9

2

1

5 6

4

22

to the vehicle

7 8

14

29

28

30

31

34

27

35

36

EURO5 typical architecture

9

1. Tank2. Electric Fuel-feeding Pump3. Fuel Filter Assembly4. Damper Volume5. High Pressure Pump6. Fuel metering Valve7. Rail8. Rail Pressure Sensor9. Solenoid Injectors10. Air Filter11. Air Flow Meter (+Air Temperature Sensor)12. Compressor13. Intercooler14. Electronic Throttle Body15. Electronic EGR Valve16. EGR Cooler with pneumatic on/off by-pass valve 17. Intake Manifold Pressure + Temperature Sensor18. Crankshaft Position Sensor19. Camshaft Position Sensor20. Coolant Temperature Sensor21. Oil Minimum pressure switch 22. Oil Level Sensor switch23. Metallic/Ceramic Low Voltage Glow Plugs 24. Variable Geometry Turbine25. VGT Vacuum Modulator26. VGT position feedback27. Lambda Sensor28. Main Cat29. Diesel Particulate Filter30. Temperature Sensor31. DPF Relative to Ambient Pressure Sensor32. Pedal Assembly33. ECU34. Electronic Variable swirl actuator35. Temperature Sensor36. Pre Cat

PRIMARY MICRO

SECONDARYMICRO

ANALOGINPUTS ADC

POWERSUPPLY

HS/LSDRIVERS

BARO

INJBANKS

COMPLEXOUTPUTS

HBRIDGES

COMM

SENSORS

BATTERY

DISCRETEINPUTS

RELAYSACTUATORS

DCMOTORS

FUELINJECTORS

INJHEATERS

GPIO

PULSE/FREQINPUTS EMIOS

ETPU

CORE

ADC TEST

SYS VOLT

SENSORS

SWITCHES

ECM: block diagram

COMM

SPI comm

ECU System voltage/temperature ranges

Q&A