CaliAV. Guided-Calibration for INCA Concept Overview. By Nithin Nath ETAS/STI

Transcription

1 CaliAV Guided-Calibration for INCA Concept Overview By Nithin Nath ETAS/STI 1 CaliAV Product Concept Overview Nithin Nath (ETAS-STI) Sept 2013 ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

2 About the Presenter Nithin Nath Regional Product Manager Measurement, Calibration & Diagnostic solutions for the Indian market. Lead calibrator at Robert Bosch India and Continental Automotive India. System Program Manager Handling Calibration, System, ECU software and hardware teams at Continental Automotive India. 11years of experience as an engine/vehicle Calibrator, having worked on a variety of turnkey diesel platforms for Indian and European customers. 2

3 Guided Calibration for INCA The Classic & Automated approach The Classic manual calibration method using INCA 3

4 Guided Calibration for INCA The Classic & Automated approach Automated Calibration with INCA 4

5 Guided Calibration for INCA What would you like to have?.. as calibration engineer Easily automate day-to-day repetitive tasks.. as manager of a calibration department Deploy best-practice across teams Increase calibration project efficiency.. as executive manager for automotive electronics Ensure consistent quality results Documented procedures and documented calibration results 5

6 ETAS MCD Solutions to optimize the calibration process Introduction Continuous engine control complexity increase Consumption and emission requirements ~12 labels The One-Million-Labels Challenge!! Effort Number of calibrations Number of degrees of freedom for powertrain optimization ~10 labels Increased variants ~19 labels ~8 labels ~5 labels 100% Globalization, distributed teams 0% Engine control complexity 2010 New, complex functions 6 6

7 Guided Calibration Calibration Process Vehicle Level Calibration - Typical Team Calibrators Calibrator Workstation Calibration Lead/Pilot Vehicle Environment 7

8 Guided Calibration Calibration Process with a use-case An explanation for a typical use-case would bring in more clarity Function calibration for Diesel engine (at vehicle level) Smoke Limitation Calibration in dynamic environment (transient dyno/vehicle) is a basic process for any vehicle calibration, more important in diesel powertrain domain it is normally performed with online-smoke measurement and the ideology behind is to control smoke levels to be within acceptable zone with minimal trade-off on performance 8

9 CaliAV - Guided Calibration for INCA Calibration Process Vehicle Calibration function Dynamic smoke limitation calibration Vehicle Environment Torque Maps Test Vehicle Calibrator Workstation Calibration Pilot makes rough notes to define a concept 9

10 CaliAV - Guided Calibration for INCA Calibration Process Vehicle Calibration function Dynamic smoke limitation calibration Calibrator Workstation Calibration Pilot defines the Test Procedure in proper format 10

11 CaliAV - Guided Calibration for INCA Calibration Process Vehicle Calibration function Dynamic smoke limitation calibration Calibrator Workstation Vehicle Environment Test Vehicle 11

12 CaliAV - Guided Calibration for INCA Calibration Process in summary Vehicle Calibration function Dynamic smoke limitation calibration Workstation Calibration Pilot ~30 hrs ~5 hrs Calibrators ~300 hrs Calibration activity on vehicle Total time ~ 335hrs Vehicle Environment 12

13 CaliAV - Guided Calibration for INCA Calibration Process in summary Vehicle Calibration function Dynamic smoke limitation calibration Workstation Calibration Pilot ~30 hrs + ~5 hrs ~5 hrs + ~5 hrs Calibrators ~300 hrs + ~100 hrs Calibration activity on vehicle Proto-build Advanced/Serial-build Vehicle Environment Total Effort goes up by additional 110hrs for new vehicle build!!!! 13

14 CaliAV - Guided Calibration for INCA Calibration Process in summary Considering ever increasing variants in a product, the effort increases by a major multitude The requirement of additional manpower and overall effort is considerable and will also encounter extended project timelines Attrition rate and subsequent loss of expertise can further impact the project time-line negatively Graphic representation shows the major set-back in not being able to estimate the new lead-times for delivery 14

15 CaliAV - Guided Calibration for INCA Calibration Process in summary Vehicle Calibration function Dynamic smoke limitation calibration Workstation Calibration Pilot ~? hrs + ~? hrs ~? hrs + ~? hrs Calibrators ~200 hrs + ~? hrs Calibration activity on vehicle Proto-build Advanced/Serial-build Vehicle Environment 15

16 CaliAV - Guided Calibration for INCA Calibration Process The CaliAV way. from calibrators for calibrators! 17

17 CaliAV - Guided Calibration for INCA Calibration Process Vehicle Calibration function Dynamic smoke limitation calibration with CaliAV Vehicle Environment Torque Maps Test Vehicle Calibrator Workstation Calibration Pilot makes rough notes to define a concept 18

18 CaliAV - Guided Calibration for INCA Calibration Process Vehicle Calibration function Dynamic smoke limitation calibration with CaliAV Calibrator Workstation Calibration Pilot defines the Test script on CaliAV 19

19 CaliAV - Guided Calibration for INCA Calibration Process Vehicle Calibration function Dynamic smoke limitation calibration with CaliAV Calibrator Workstation Vehicle Environment Test Vehicle 20

20 CaliAV - Guided Calibration for INCA Calibration Process in summary Vehicle Calibration function Dynamic smoke limitation calibration with CaliAV Calibration Pilot Workstation ~20 hrs 0 hrs Calibrators ~200 hrs Total time ~ 220hrs Vehicle Environment 21

21 CaliAV - Guided Calibration for INCA Calibration Process in summary Vehicle Calibration function Dynamic smoke limitation calibration with CaliAV Workstation Calibration Pilot Virtually same script!!! ~20 hrs hrs 0hrs + 0 hrs Calibrators ~200 hrs + ~70 hrs Calibration activity on vehicle Proto-build Advanced/Serial-build Vehicle Environment Total Effort goes up by additional 70hrs only for new vehicle build!!!! 22

22 CaliAV - Guided Calibration for INCA Calibration Process in summary Guided Calibration reduces calibration effort by roughly 70% for this use case! 23

23 Efficient best-practice measurement & calibration automation Reasons to consider CaliAV What skills do I need? What skills do I need to create automation? Can calibration engineers capture their knowledge into automation? Is my core-expertise in developing automation tools? How good is the connectivity to INCA? Does my approach integrate with INCA? Does it support all INCA-AddOns? Can I access all measurement devices? Does my automation support all ECU access paths Are my investments protected? Can I re-use automation algorithms across domains? How easy can I maintain my automation knowledge How well is it documented for 24

24 Efficient best-practice measurement & calibration automation CaliAV is INCA! Integrated with INCA Access to INCA Database No double maintenance of project and process Automation is always connected to the right software All Measurement Devices & ECU accesses support Access to all measurement devices connected to INCA Access to all INCA protocols and ECU devices (CCP, XCP, ETK) Support of all Hardware AddOns (ES910, ES1000, ES720) All Add-Ons supported INCA ODX-Link.. Automating diagnostics INCA-VLINK. Automating Software-in-the-loop for test and optimization INCA-SIP.Automating Model-in-the-loop with Simulink INCA-EIP. Automating Virtual & Rapid Prototyping for test and validation INCA-MCE Automating fast ECU access 25

25 Efficient best-practice measurement & calibration automation From Experts For Experts Easy-to-use visual design environment High productivity with typical components required for measurement and calibration No expert API-programming required Excellent documentation as a simple by-product Many Tutorials to support a quick learning curve Ready-to-use processes 26

26 Efficient best-practice measurement & calibration automation From Experts For Experts Easy-to-use visual design environment High productivity with typical components required for measurement and calibration No expert API-programming required Excellent documentation as a simple by-product Many Tutorials to support a quick learning curve Ready-to-use processes 27

27 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Generate calibration maps and curves from data, Interpolate/extrapolate missing breakpoints Modify map-sizes 28

28 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Application-Triggers Monitor conditions during calibration work, react on temperature on increase, component protection 29

29 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Application-Triggers Read & Write DCM files 30

30 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Application-Triggers Read & Write DCM files Working with Measurement files Read an INCA measurement file Select signals to read (Engine speed) Filter on changes in the accelerator pedal that s all it needs to identify all load changes in a recording 31

31 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Application-Triggers Read & Write DCM files Working with Measurement files Signal Analysis Control Performance Analysis Just pass online data, or recordings, to this method, and you get all information.... How long did it take to reach my set point?.. What s the overshoot?.. And, and 32

32 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Application-Triggers Read & Write DCM files Working with Measurement files Signal Analysis Control Performance Analysis Fast-Fourier Transformations..with one click 33

33 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Application-Triggers Read & Write DCM files Working with Measurement files Signal Analysis Control Performance Analysis Fast-Fourier Transformations Parallel controllers Parallel controllers in CaliAV allow to control boundary conditions during calibration tasks (keep temperature at a set level, maintain pressure within defined boundaries) 34

34 Efficient best-practice measurement & calibration automation Ready-to-use for Measurement, Calibration, Diagnostic Curve & Map Manipulation Application-Triggers Read & Write DCM files Working with Measurement files Signal Analysis Control Performance Analysis Fast-Fourier Transformations Parallel controllers Stimuli Generator Mathematical, Measurement files, Excel Just these two blocks suffice to increase the rail pressure over a period of 170 seconds from 30 to

35 CaliAV - Guided Calibration for INCA Real-World Examples Low-idle speed control Online optimization for variable camshaft Online optimization for variable valve lift control On- and offline optimization for transitional correction Anti surge control Exhaust recirculation and boost pressure control Engine smoothness control Drive Cycle Simulation Catalytic converter diagnostic System analysis of exhaust recirculation valve Drivability analysis and base calibration load alteration Monitoring of start-stop function Automatic calibration & validation of thresholds for sensor diagnostics 36

36 CaliAV Add-Ons Toolboxes provide special-purpose methods for modeling calibration procedures and offline data analysis. Toolbox for Design Support the development and test of control functions Generation of stimuli for modeling and testing of control functions Interactive graphical editor for designing characteristics and maps Toolbox for Optimization Ready-to-use blocks with polynomial, least squares and simplex optimization algorithms Generation of drive cycles Generic PID controller Toolbox for Analysis Filtering and synchronization of MDF measurement data Fast-Fourier Transformation Various blocks for measurement data visualization 37

37 CaliAV Add-Ons CaliAV Compiler Generation of stand-alone executable scripts Approved and tested sequences can be compiled and distributed to users without a CaliAV license Sequences can be distributed to partners without compromising intellectual property With a compiler, everyone doesn t need to have CaliAV! INCA PC User 1 (no CaliAV) CaliAV PC Process script Process executable file INCA PC User 2 (no CaliAV) 38

38 Efficient best-practice measurement & calibration automation Summary From calibrators for calibrators! Easy creation and adaption of work procedures by calibration experts Improved calibration quality Reduction of manual calibration errors Validation of work results Effortless repeatability Reproducible results for each control function, each variant Seamless Automation Automation of ECU and test systems (Vehicle, HIL, SIL) Reduced vehicle-usage Planning of calibration tasks in the office Efficient usage of the time a vehicle is at hand Process Documentation Improved skill-up phase for new calibrators Global best-practice for all ECU/Software releases / functions 39 39

39 CaliAV product naming change.. in Q4 2013, the latest version of CaliAV will be released as INCA-FLOW 40

40 Efficient Calibration Success Story Automated Calibration: Component adaptation Initial Situation Every six to eight weeks at the test benches the injectors have to be exchanged during the base calibration of heavy duty engines. After the exchange a series of base adaptations have to be done. The calibration engineer has to attend the complete procedure (~6 hours) together with the test bench operator. Facts and Figures Solution Initial effort at ETAS: Customer: 3 mw 3 mw The required process, the calculation methods for maps & curves and the determination of the ideal sequences of operating points were captured within INCA-FLOW in an automation sequence. Customer savings: Labor cost 65 % Test bench cost 35 % Time for adaptation: 35 % mw = men weeks INCA-FLOW guides now the test bench operator through the complete process. He runs the adaptation procedure in 4 hours by himself without support from the calibration engineer. 41

41 Efficient Calibration Success Story Automated Calibration: Road approval certification Initial Situation The quality procedure at an OEM of heavy duty vehicles requires a road approval certification after development phase before the vehicle is allowed to drive on public roads. Intense documentation certifies, that all tests has been passed successfully. It could happen, that tests had been overseen or were executed with incorrect presets. Initial effort at ETAS: Customer: Facts and Figures 6 mw 3 mw Customer savings: Labor cost 80 % Time for test & docum. 15 % Customer benefit: Quality mw = men weeks 0 failure Solution INCA-FLOW automates now the complete test series. It ensures that every test is executed with the corrects presets and generates automatically the complete needed documentation in parallel. The certification process itself is documented in INCA-FLOW and can be easily extended, if needed. The Road approval certification is now performed almost unattended and it is ensured, that the execution is complete and correct. 42

42 Drehzahl [[1/min]] Efficient Calibration Success Story Automated Calibration: Repeatability Initial Situation A passenger car OEM wants to drive always the same driving profile at the altitude test trip. This is necessary because the calibration engineers needs repeatable measurements for analysis of various calibration datasets time [s] Facts and Figures Initial effort at ETAS: 2 mw Customer: 0,5 mw Customer savings: Solution INCA-Flow was used in connection with INCA to define a automated driving profile. The script for the automated driving profile can be used for every test-trip in future and the customer will always have comparable measurements for analysis of different calibration datasets. Customer benefit: - Quality improvements - Standardization mw = men week 43

43 Efficient Calibration Success Story Automated Calibration: Know how transfer and protection Initial Situation A European Tier-1 supplier had to setup up calibration services in India for local customers. The high labor costs in Europe prevented him of providing the service out of his home base or by European calibration engineers on site. Initial effort at ETAS: Customer: Facts and Figures 2 mm 3 mm Customer savings: Labor cost 70 % Travel expenses 50 % Training cost 50 % Customer benefit: know how protection 100% mm = men months In India there weren t enough sufficient skilled calibration engineers available. Customer was afraid of losing his know how. Solution INCA-FLOW has been used to capture the expertise of the skilled calibration engineers for the local organization and also to secure their know how on the other side. The local personal is now able to execute the calibration process easily without knowing the details of the calibration and calculation methods behind. Quality, timing and cost of the calibration met the expected levels from customer. In addition, the graphical documentation of the calibration procedures helps quickly to ramp-up the skills of new hired personal in India. 44

44 Efficient Calibration Success Story Automated Calibration: Best Practize Initial Situation A passenger car OEM wants to secure a consistent driving experiences for their customers across all car lines and models. The increasing number of variants require significant calibration effort for drivability and it is almost impossible to ensure consistent quality results across the multiple calibration teams involved. Initial effort at ETAS: Customer: Facts and Figures 3 mm 4 mm Customer savings: Labor cost 15 % Customer benefit: Quality improvements Standardization Continuous improvement process mm = men months Solution A team has been established to set the standard. INCA-FLOW is now used to capture the best-practice and provide this standard procedures for the major drivability calibration tasks. Identical procedures can be used now for roller test bench and on road calibration. The procedures are now centrally managed and a continuous improvement process was established to achieve excellence. Calibration engineers can customize the key parameters of the drivability procedures to their vehicle configuration and can easily repeat best-practice with consistent quality results. Their feedback contributes to a continuous improvement. 45

45 Efficient Calibration Success Story Automated Calibration: Efficient function calibration Initial Situation A OEM uses a double-loop control for the lambda management of its recent gasoline engines. The validation is done at the chassis dyno, followed by a long lasting robustness tests. The calibration including verification for robustness required highly skilled engineers and chassis dyno for ~ 4 weeks. Initial effort at ETAS: Customer: Facts and Figures 3 mm 2 mm Customer savings: Labor cost 30 % Chassis dyno cost 30 % Customer benefit: Quality improvements Documentation mm = men months Solution INCA-FLOW has been used to create an automated calibration and validation procedures for base calibration and robustness verification. This standard procedure guarantees identical quality results independent of individual expertise and saves ten days of test bench usage. The graphical specification in INCA-FLOW provides a good documentation, supporting changes for future enhancements. 46

46 Efficient Calibration Success Story Automated Calibration: Efficient diagnosis Initial Situation An engineering service provider was hired by an OEM to calibrate and validate OBD calibration. The project schedule was very tight and test vehicles had only been available during a short phase before SOP. Initial effort at ETAS: Customer: Facts and Figures 5 mm 4 mm Customer savings: Labor cost 15 % Vehicle cost 15 % Customer benefit: Shorter timing with upfront calibr. Efficient use of test vehicles mm = men months Solution INCA-FLOW procedures were designed upfront. Some procedures did only require data-sets, based on a model, to validate diagnosis function. Later, when vehicles were available, the ES720 drive recorder & INCA FLOW was used to adopt the catalyst diagnostic thresholds automatically on the road and to generate report. Model based upfront calibration is now possible without test vehicles. Vehicles can be used more efficient by performing time-consuming tasks automatically and unattended by a calibration engineer. 47

47 Efficient Calibration Success Story Automated Calibration: Efficient testing Initial Situation A Tier-1 suppliers requires intense testing of ECU software and calibration prior to release for SOP. Engineers are tied up with tedious manual repetition of standard procedure for testing (i.e level 2 safety tests for specific drive maneuvers). Initial effort at ETAS: Customer: Facts and Figures 4 mw 1 mw Customer savings: Testing time 50 % reduce a 2 people exercise to a 1 person task Customer benefit: Better resource usage Huge efforts in time and personnel are required to ensure that tests are executed under identical conditions, generate repetable results and adhere ISO26262 requirements. Solution INCA-FLOW automates the test procedures (i.e accelerates the test vehicle in defined patterns and monitor level 2 documentation). The graphical procedure description, including test logs and measurement data automatically deliver documentation for ISO The number of test repetitions due to erroneous configurations or mistakes during test execution could be reduced to zero. The customer test team size could be reduced, and the engineers are available for additional customer value activities. mw = men weeks 48

48 Efficient Calibration Success Story Automated Calibration: Efficient testing Initial Situation Calibration of NSC regeneration function requires driving a vehicle on the road. For each operation condition (load/speed) it must be avoided that passenger experience engine speed oscillations during regeneration. Lengthy calibration work with 2 person teams to calibrate & validate all conditions Initial effort at ETAS: Customer: Facts and Figures 3 mw 1 mw Customer savings: reduce a 2 people exercise to a 1 person task Customer benefit: only a non-expert is necessary for calibration Solution INCA-FLOW automatically detects each operating condition that requires modification. NSC regeneration is triggered, engine speed behavior monitored and if necessary improved. The progress of the calibration is displayed and operation conditions which had not been considered so far, are visualized. The complete process is automated and simply a driver is required. The complete process is automated and it requires just a driver. The calibration engineer validates the final results. mw = men weeks 49

49 Guided Calibration for INCA with INCA-FLOW Thank you for your attention Please visit for more information And ETAS YouTube page Contact 50