The document describes using a model-based calibration toolbox to optimize the calibration of a turbocharged engine with variable cam phasing and intake valve lift. It involves designing experiments to collect engine performance data, building models from the data, and using the models to produce optimized calibration tables that maximize torque while satisfying constraints. The process results in optimal settings for spark timing, cam angles, air-fuel ratio, intake valve lift, and turbocharger vane position across the engine's operating range.

1. Model Based
Model-Based Calibration Toolbox JumpStart
Service
SI Turbocharged Engine With Dual-Independent Variable Cam-Phasing
and Continuously Variable Intake Valve Lift
orks, Inc.
© 20 The MathWo
009
The MathWorks Consulting

2. Course Problem Statement
 Given a 2.2L turbocharged 4-valve DOHC spark ignition engine with
dual-independent
dual independent variable cam phasing and continuously variable
intake valve lift control
 Maximize Torque across the speed/load range of the engine subject to
the following constraints:
 Turbocharger speed less than 160,000 RPM
 Engine-out exhaust temperature less than 840C
 AFR constrained to stoichiometry in a user-specified speed/load region
hWorks, Inc.
 Produce corresponding optimal calibration tables in speed and load for
 Best spark timing
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 Best intake cam advance angle
 Best exhaust cam retard angle
 Best AFR
 Best feed-forward intake valve lift position
 Best feed-forward variable geometry turbocharger vane position percent
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3. Preview of Course Calibration Results
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Spark Advance
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4. Preview of Course Calibration Results
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Intake Cam Advance
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5. Preview of Course Calibration Results
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Exhaust Cam Retard
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6. Preview of Course Calibration Results
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Intake Valve Lift
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7. Preview of Course Calibration Results
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VGT Vane Open Fraction
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8. Preview of Course Calibration Results
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Air/Fuel Ratio
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9. Test Configuration
I/O of Turbocharged 2.2L DOHC Engine with
Dual-Independent Continuously Variable Cam Phasing (DIVCP)
and Continuously Variable Intake Valve Lift (CVIVL)
Intake VCP Brake Torque
Exhaust VCP
Spark Advance
Turbocharger Speed
RPM Intake Manifold Pressure
AFR
Exhaust Temperature
Intake Valve Lift
VGT Vane Fraction Load
L d
hWorks, Inc.
Closed Loop
Closed-Loop
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Load Command Load Controller
Temperature-Limited
AFR and Spark Control
AFR Command
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10. Model Configuration
I/O of Turbocharged 2.2L DOHC Engine Model with
Dual-Independent Continuously Variable Cam Phasing
and Continuously Variable Intake Valve Lift
Table RPM Brake Torque Objective
Breakpoints
Load Exhaust Temperature Constraints
Intake VCP Turbocharger Speed
VGT Open Fraction Optimal Tables
Exhaust VCP
Intake Valve Lift
AFR
Intake Manifold Pressure
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Spark Advance
Optimal Tables Auxiliary Table
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Maximize Torque subject to exhaust temperature, turbocharger speed,
and user-specified AFR Constraints
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11. MBC Toolbox Calibration Process
DOE Design Data Collection Data Modeling
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Calibration Implementation
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12. Agenda
 Introduction
 Design of experiments
 Loading and sorting data
 Building models of engine responses
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 Producing optimized calibrations
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 Review
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13. Review Merged Experiment
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14. Temperature Limited
Temperature-Limited AFR and Spark Control Method
840C
Exhaust Temp
Spark Retard Limit Line 12 : Fast Search
Limit Found To Most Retard
3 Sweep to Knock Limit
AFR Desired DoE
AFR
Spark at Desired AFR
2
23 : Slow Sweep
1 To Knock-Limit
x Start
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Spark Advance DegBTDC
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15. Agenda
 Introduction
 Design of experiments
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
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 Review
R i
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16. Merged 210pt Space Fill Data Ready for MBC Import
Space-Fill
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SI_DIVCP_CVIVL_Turbo_I4_Merged_Data.xls
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17. Load 210pt Merged Space Fill Data
Space-Fill
1 2
3
6
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4
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5
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18. Agenda
 Introduction
I t d ti
 Design of experiments
g p
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
© 2009 The Math
 Review
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19. 1
2
3
5
Finish Model
7
4
6
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hWorks, Inc.
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20. Review Boundary Model
25
24
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21. Review Final Model
2
6
1 3
4
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Extrapolation
Will Be Prevented
5 By Boundary
Model In
Optimization
Picture Courtesy US AutoParts Later
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22. 6
Review Validation Fits
7
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hWorks, Inc.
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23. Export Models For Other Users
4
Model Description
5
Input Order
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Input Order: Brake Torque Value
Spark, Speed Load, ICP, ECP,
Spark Speed, Load ICP ECP AFR
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6
Boundary Model Value
Values < 0 are within bounds
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24. Export Models For Other Users
hWorks, Inc.
Use Your Accurate, Fast
Torque Model in HIL
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Simulation Model
(See HIL_Model.mdl)
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25. Agenda
 Introduction
 Design of experiments
 Loading and sorting data
 Building models of engine responses
hWorks, Inc.
 Producing optimized calibrations
© 2009 The Math
 Review
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26. 8-Step Process for Producing Optimized Calibrations
1. Import models of engine responses
p g p
2. Set up function-models
3. Set up tables and tradeoffs
4. Set up optimization and operating points
5. Run operating-point optimizations
6. Set
S t up, initialize, and run sum optimization
i iti li d ti i ti
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7. Review calibration sensitivity
8.
8 Review and export tables
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9. Validate calibration with measurements
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27. Import Models of Engine Responses
 Models are exported
1 directly from the MBC
model browser
 Load
SI_DIVCP_CVIVL_AllModels_Complete
in MBC Model Browser
 Start CAGE tool by
2 entering >>cage at
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MATLAB prompt
3  Click “Import items from
Import
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another project” icon
4 6
5
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28. Set Up Tables and Tradeoffs
1
2
4
3
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9 6 7
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CTRL-V
5
CTRL-C
8
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29. Set Up Optimization and Operating Points
1
2
3
4
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5 6
8
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7
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30. Set Up Initialize and Run Sum Optimization
Up, Initialize,
1
2
3
5 6
4
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8
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9 7
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31. Set Up Initialize and Run Sum Optimization
Up, Initialize,
2
1
9
10
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3
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7
4 5
6
8
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32. Review Calibration Sensitivity
2
1
3
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33. Review and Export Tables
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hWorks, Inc.
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34. Review and Export Tables
1
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2
3
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35. Validate Calibration With Measurements
2
3
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1 4
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