Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
2013 GT-SUITE European Conference Frankfurt / Main
Diesel Gasoline Systems
Dr. Björn Lumpp Dr. Mouham Tanimou, Dr. Erica Trapel, Dr. Micha Münzenmay, Dr. Martin McMackin, Eva Bouillon, Klaus Zimmermann
Desktop Simulation and Calibration of Diesel Engine ECU Software using Software-In-The-Loop Methodology
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Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Desktop Simulation and Calibration of engine ECU
Diesel Gasoline Systems
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
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Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Desktop Simulation and Calibration with SiL
Diesel Gasoline Systems
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
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Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Desktop Simulation and Calibration of engine ECU
Diesel Gasoline Systems
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 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
Engine model Detailed engine model - overview
two-stage turbo charger
air intercooler/ interstage cooler
EGR system (λ-controlled)
boost pressure control
throttle valve
D2676LF25 engine (12.4 l, 353kW/480HP, Euro 6)
6 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
Detailliertes Modell
Datengenerierungzum Trainieren derneuronalen Netze
Erstellen derneuronalen Netze
Integration der neuronalen Netze
Vereinfachung des Leitungssystems
generation of training data for neural networks
creation of neural networks
simplification of pipe system
integration of neural networks
Engine model Representation as mean value model
detailed model
7 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
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
9 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
Design of GT Model and import to Simulink
Integrate other libraries and Generate code
for Intecrio
HEX COD
Generate the model for the target system
“Virtual OS”
Execution in INCA Measure & calibrate as with a real ECU
Copy additional files to INCA
.trb
.nno .dat
.xyz
Combine with other modules and configure the OSEK OS
A2L
GT-SUITE & Intecrio Workflow for integrating GT models within INTECRIO
Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Desktop Simulation and Calibration of engine ECU
Diesel Gasoline Systems
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
Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Diesel Gasoline Systems
Desktop simulation of engine ECU-Software
RB OEM Bosch functions OEM functions, to be tested in interconnection with Bosch functions
Bosch ECU-SW will be provided in a virtual environment that can be flexibly used by the OEM to develop its own functions.
Co-Simulation EDC-Software and GT-SUITE Model
Development Environment @OEM
Control Software
OEM Test Stimulation
RB OEM
OEM
RB RB
RB
RB
RB
RB
RB
RB
OEM Test Assessments
Labcar/Bench/Vehicle
OEM Plant Models
Simulink+CoSimulation GT Suite/AmeSim/…
Calibration Data
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Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Diesel Gasoline Systems
Desktop simulation of engine ECU-Software
RB OEM Bosch functions OEM functions, to be tested in interconnection with Bosch functions
Bosch ECU-SW will be provided in a virtual environment that can be flexibly used by the OEM to develop its own functions.
Co-Simulation EDC-Software and GT-SUITE Model
Development Environment @OEM
Control Software
OEM Test Stimulation
RB OEM
OEM
RB RB
RB
RB
RB
RB
RB
RB
OEM Test Assessments
Labcar/Bench/Vehicle
OEM Plant Models
Simulink+CoSimulation GT Suite/AmeSim/…
Calibration Data
12
Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Desktop Simulation and Calibration of engine ECU
Diesel Gasoline Systems
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
Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Diesel Gasoline Systems
Other sources
Automatization via APIs
Signal Generator
VP*) on PC RP **) on PC RP **) on high end HW
RP **) on cost effective HW
Simulink Coder ASCET
ASCMO
Embedded Coder
HE
X
SC
OO
P-IX
A2L
A2L
AR
XM
L
INCODIO
TargetLink Manual C-Code
Obj C
GT-SUITE
INTECRIO Universal prototyping system
Co-Simulation EDC-software and GT-SUITE model
INTECRIO Integration and configuration platform
for prototyping system
Crossbar / RTA-RTE
RTA
-OS
Proprietary Basis SW
*) VP: Virtual Prototyping **) RP: Rapid Prototyping
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Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Diesel Gasoline Systems
Integration workflow for EDC-SW und GT-Model with INTECRIO
SiL-ready Model Model.dat
GT-SUITE Library
C-code
Model.gtm
GT-SUITE GUI
Simulink GUI
Environment & I/O Model
GT-SUITE S-function block + INTECRIO GUI
SiL ECU Testing
EDC-SW (ECU Code)
*.obj *.six
EDC-SW: - pre-compiled Object-files will be used - SCOOP-IX* files are needed
INCA Experiment
dcm
Calibration data
Co-Simulation EDC-software and GT-SUITE Model
X86
*.exe (HEX&A2L)
CODE Integration
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DGS-EC/ECC | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Co-Simulation EDC-software and GT-SUITE model
INTECRIO Virtual Prototyping Environment
Diesel Gasoline Systems
ViP4ECU (Virtual Prototyping for ECU SW development) Virtual prototyping environment for Function Development, Test and Pre-Calibration
Engine Model
Catalyst Model
Pipe Modell
e.g. 0D Matlab or 1D GT-Power
ECU Functionality Functions as object code
func
Models in ASCET or Matlab
func
Function Development
Optimization
Calibration and Testing
Control Export
INCA
System or Submodels
• Granular Access (BC, FC) • Rapid Function Development • SW-Sharing and Bypass
• Function optimization with Matlab optimization functions
• Feels like real vehicle • Handling like on prototype • Control with all INCA library
functions and testing tools • PC-based function verification
• High Accuracy (ECU+Plant) • Fast and Flexible Development • Holistic Engineering • High Development Efficiency • Cost Reduction on Prototypes • IP-Protection
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Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Desktop Simulation and Calibration of engine ECU
Diesel Gasoline Systems
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
18 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
Euro VI
Virtual EDC Logic calculates a dosage with a high conformity to the measurement (error<1%)
NOx concentration after the SCR is perfectly reflected by the GT RT model Satisfactory accuracy of cumulated
tailpipe NOx emissions (error <10%)
Software-in-the-Loop - Application Validation of SiL-Model (EDC dosing logic + GT-SCR) in WHTC
19 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
SCR upstream temperature: EDC signal: -10% GT model: as measured
Dosing rate limited by EDC temperature
Simulation duration: ~ 7 min > 4 x faster than real-time
Euro VI
Temperature error leads to ~ 5 % higher Adblue consumption ~ 75 % higher tailpipe emissions
NH3 level controller compensates for previous limitation
Controller calibration robust with regard to pre-SCR temperature sensor accuracy
Software-in-the-Loop - Application Sensor drift analysis – Temperature upstream SCR
Mouham Tanimou, Bjoern Lumpp | 21.10.2013 | F13-0349 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Desktop Simulation and Calibration of engine ECU
Diesel Gasoline Systems
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
21 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
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
Mouham Tanimou, Bjoern Lumpp | 25.09.2013 | F13-0234 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Diesel Gasoline Systems
Co-Simulation EDC-Software und GT-SUITE Modell
Questions? Thank you!
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23 < > MAN Truck & Bus Tanimou / Lumpp 21.10.2013 Robert Bosch GmbH 2013 GT-SUITE European Conference
Thank you for your attention!
Dr. Björn Lumpp MAN Truck & Bus AG Powertrain Research Process Simulation Vogelweiherstr. 33 90441 Nürnberg
Co-Authoren: MAN Truck & Bus AG Eva Bouillon, Dr. Martin McMackin, Dr. Erica Trapel, Robert Bosch GmbH Dr. Micha Münzenmay, Klaus Zimmermann
Dr. Mouham Tanimou Robert Bosch GmbH Diesel Gasoline Systems Engineering Customer Projects Commercial Vehicles Postfach 30 02 20 70442 Stuttgart