Engine Control Unit Calibration via Simulated Altitude and Temperature
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Solution Overview
Problem
Existing engine control systems face challenges in accurately predicting and controlling engine performance under difficult-to-simulate conditions such as high altitudes and elevated temperatures, due to the cost and time required for collecting empirical data, which limits their ability to provide appropriate engine control.
Innovation Solution
A method and system that involves operating a test internal combustion engine at various speeds and torques while simulating altitude and temperature conditions, using sensors and intake air control devices to measure and store engine performance information, which is then used to program the engine control unit, allowing for more accurate calibration and prediction of engine performance under these conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If empirical data is collected from actual internal combustion engine systems operating under various conditions, then the model can accurately predict engine performance, but data collection becomes difficult, costly, and time-consuming for certain conditions
Solution Approach 1:
The patent applies preliminary action by pre-programming the control unit with calibration parameters and models before actual engine operation. Empirical data is collected and processed in advance during the calibration phase, creating lookup tables and calibration maps that are stored in the control unit's memory. This allows the control unit to quickly reference pre-computed data during real-time operation without needing to collect and process data on-the-fly, thereby resolving the contradiction between prediction accuracy and data collection time.
2Measurement precision
If empirical data is collected from actual internal combustion engine systems operating under various conditions, then the model can accurately predict engine performance, but the cost of data collection increases
Solution Approach 1:
The calibration process performs preliminary actions by collecting and processing empirical data during a dedicated calibration phase before production. Test engines are operated under various simulated conditions to gather data, which is then used to create calibration parameters and models. This upfront investment in calibration reduces the need for expensive field testing and data collection during actual production and operation, thereby resolving the contradiction between prediction accuracy and manufacturing cost.
3Reliability
If the control unit uses models with calibration parameters to predict engine performance, then appropriate control can be achieved, but the control unit requires complex programming and calibration
Solution Approach 1:
The patent applies segmentation by dividing the control unit's functionality into distinct modules: empirical model modules that contain theoretical engine behavior models, calibration parameter modules that store empirically-derived correction factors, and lookup tables that map operating conditions to optimal control parameters. This modular segmentation allows each component to be developed and calibrated independently, reducing overall system complexity while maintaining high control accuracy through the integration of these specialized modules.
4Measurement precision
If the control unit is programmed with detailed calibration parameters, then engine performance prediction improves, but the programming process becomes more complex
Solution Approach 1:
The calibration process performs preliminary actions by automatically generating and organizing calibration parameters, lookup tables, and model data during a dedicated programming phase. Empirical data collected during calibration is processed through algorithms that automatically create the necessary data structures and parameter sets. This automated preliminary programming reduces manual intervention and simplifies the overall programming process, allowing detailed calibration data to be incorporated without proportionally increasing programming complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables more accurate calibration and control of internal combustion engine control units, improving their performance prediction and control, especially during acceleration events at high altitudes and elevated temperatures, by providing detailed calibration parameters and training data for the engine model.
Implementation Method 1
elevating a temperature of the flow of air to simulate ambient temperature variations of the test internal combustion engine
Data Source
AI summary
A method for programming an internal combustion engine control unit includes operating a test internal combustion engine at a first speed and a first torque while simulating a condition of the test internal combustion engine by restricting a flow of air to the test internal combustion engine to simulate altitude variations of the test internal combustion engine or elevating a temperature of the flow of air to simulate ambient temperature variations of the test internal combustion engine. The method also includes measuring engine performance information while operating the test internal combustion engine at the first speed and first torque and while simulating the condition of the test internal combustion engine, and programming the internal combustion engine control unit by storing the measured engine performance information in a memory associated with the internal combustion engine control unit.