Definition of a Methodology Promoting the Use of 1D Thermo-Fluid Dynamic Analysis for the Reduction of the Experimental Effort in Engine Base Calibration

Nola, Francesco de; Giardiello, Giovanni; Gimelli, Alfredo; Molteni, Andrea; Muccillo, Massimiliano; lng, Roberto Tortora

doi:10.4271/2019-24-0013

Cited by 4 publications

(8 citation statements)

References 18 publications

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“…This work addresses the possibility of applying a 0D-1D physic-based valvetrain model for the reduction of the experimental tests of the basic calibration process with the procedure described in [5]. In this procedure the use of 1D-0D engine models requires the imposition of valve lifts.…”

Section: Resultsmentioning

confidence: 99%

“…The choice of the values of the calibration parameters is part of a much longer process named engine base calibration process [1][2][3][4][5][6][7][8], and is carried out with suitably developed software [1,4], which require an intense experimental campaign as described in [2][3]. In fact, at each single operating point, the software calibrates the functions, by comparing the experimental quantity and the quantity estimated by the function, reducing the error by changing the calibration parameters.…”

Section: Wherementioning

confidence: 99%

“…In the past the authors have used two different approaches to try to decrease the experimental tests: the use of neural networks (NN) to extend the experimental campaigns has proven effective, leading to a reduction from 40 to 60% of the experimental tests without affecting the calibration performance [2][3]. The second approach is the use of 1D simulation models of the engine to be used as a virtual test bench in order to obtain all the experimental quantities necessary for the calibration of the functions [2,5]. This approach has shown good results, but has also highlighted some simplifications made to the model, which, if implemented, can lead to an improvement of the process.…”

Section: Wherementioning

confidence: 99%

“…This approach has shown good results, but has also highlighted some simplifications made to the model, which, if implemented, can lead to an improvement of the process. The model was validated [2,5] with a multi-variable multi-objective validation process [10][11][12][13], choosing 5 calibration parameters (3 relating to turbulent combustion, 1 relating to the heat exchange of the cylinder walls and 1 relating to pressure drops in the intake system) and 6 quantities evaluated by the model to reduce the error compared to the same experimental quantities in 16 different experimental conditions. Furthermore, the throttle model and the friction model were validated using other 15 experimental conditions, for a total of 31 operating conditions [5].…”

Section: Wherementioning

confidence: 99%

“…shows the schematization of the engine model used in the second approach. It is a two-cylinder gasoline engine, 900 cm 2 of total displacement, with indirect injection, equipped with turbocharger and VVA distribution system; more details are reported in[2,5,9].…”

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confidence: 99%

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Engine Valvetrain Lift Prediction Using a Physic-based Model for The Electronic Control Unit Calibration

Giardiello

Gimelli

Nola³

2020

E3S Web Conf.

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The electronic control has an increasingly important role in the evolution of the internal combustion engine (ICE) and the vehicle. Research in the automotive sector, in this historical period, is dictated by three main guidelines: reducing polluting emissions and fuel consumption while maintaining high performance. The Electronic Control Unit (ECU) has made it possible, complicating the engine both in terms of architecture and in terms of strategies, controlling, through simplified functions, physical phenomena in an ever more precise way. The ECU functions are experimentally calibrated, reducing the error between the quantity estimated by the function and the experimental quantity over the entire operating range of the engine, developing extensive experimental campaigns. The calibration process of the ECU functions is one of the longest and most expensive processes in the development of a new vehicle. Some lines of research have been explored to reduce the experimental tests to be carried out on the test bench. The use of neural networks (NN) has proven to be effective, leading to a reduction in experimental tests from 40 to 60%. Another methodology consists in the use of 1D/0D Thermo-fluid dynamic models of the ICE. These models are used as virtual test benches and through them it is possible to carry out the experimental campaigns necessary for the calibration of the control unit functions. At the real test bench, only the few experimental tests necessary for the validation of the model must be carried out. One of the simplifications that is usually made in the 1D/0D ICE models consists in assigning a single intake and exhaust valve lift, without taking into account the effect of the engine speed on the valve lift in early intake valve closure (EIVC) mode for engines equipped with VVA. This phenomenon has a not negligible effect on engine performance, especially at high engine speeds. In the case of engine models equipped with VVA, the valve lift cannot be imposed, since it is unique for each closing angle at each engine speed. Indeed, in order to assign the correct valve lift for a given engine speed and EIVC, numerous experimental tests should be carried out, making vain the beneficial effects of the method. In this work, the authors propose the use of a 0D/1D CFD model of the entire electro-hydraulic valvetrain VVA module, coupled with 1D lumped mass for reproducing the linear displacements of the intake valve, and for simulating the interactions between flow and mechanical systems of the solenoid hydro-mechanical valve. Thus, model simulations allow to predict the valve lift in all the necessary conditions in the experimental campaigns for the calibration of the control unit functions. Starting from geometric valvetrain data, the model has been validated with a parametric analysis of some variables on which there was greater uncertainty, by comparing the valve lift obtained by the model with the experimental ones in certain engine speeds. Subsequently, the authors have obtained the valve lifts in conditions not used for model validation, comparing them with their respective experimental lifts. The model has proven to be sensitive to the effect of the variation of the engine speed, reproducing the valve lift with a low error. In this way it is possible to reduce the experimental effort aimed to the calibration process considering that the virtual experimental campaign has proven to be reliable.

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Section: Resultsmentioning

confidence: 99%

Section: Wherementioning

confidence: 99%

Section: Wherementioning

confidence: 99%

Section: Wherementioning

confidence: 99%

mentioning

confidence: 99%

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Engine Valvetrain Lift Prediction Using a Physic-based Model for The Electronic Control Unit Calibration

Giardiello

Gimelli

Nola³

2020

E3S Web Conf.

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Crank Mechanism Friction Modeling for Control-Oriented Applications

Brancati

Muccillo

Tufano

2020

Mechanisms and Machine Science

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Purpose of the study is to improve the base calibration process of engine Electronic Control Unit (ECU) through the use of 0D-1D CFD engine models coupled to a physics-based model of the engine frictions. Once reliably calibrated, the overall engine model can be used to reduce the experimental effort of the base calibration process. In this paper a specific methodology based on the vector optimization approach is also proposed in order to reliably calibrate the numerical friction model. This methodology was applied to an engine crank mechanism model adopting specific friction sub models, generated using a multibody approach. The vector optimization problem was solved using experimental engine friction data measured in 13 operating conditions: the comparison between numerical results and experimental data highlights how the proposed modelling approach can be effectively adopted to simulate the friction losses, since the average error is about 5%. Therefore, coupling reliably calibrated friction models to 0D-1D CFD engine models could be useful to improve the estimation of the main engine quantities to be used in the base calibration process.

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Kinetic behavior evaluation of electromagnetic valve train subject to exhaust gas force

Fan

Dai

et al. 2020

Applied Thermal Engineering

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Definition of a Methodology Promoting the Use of 1D Thermo-Fluid Dynamic Analysis for the Reduction of the Experimental Effort in Engine Base Calibration

Cited by 4 publications

References 18 publications

Engine Valvetrain Lift Prediction Using a Physic-based Model for The Electronic Control Unit Calibration

Engine Valvetrain Lift Prediction Using a Physic-based Model for The Electronic Control Unit Calibration

Crank Mechanism Friction Modeling for Control-Oriented Applications

Kinetic behavior evaluation of electromagnetic valve train subject to exhaust gas force

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