Automated ECU Calibration via Remote Actuator Control
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Solution Overview
Problem
Current ECU calibration processes are inefficient due to manual control of vehicle parameters, leading to increased development time, cost, and human error, with a need for automated and standardized calibration solutions.
Innovation Solution
A remote cloud-based system that automates ECU calibration using a networked setup comprising a remote computer, central server, local computer, dynamometer, and actuators, allowing for automated control of vehicle parameters through scripted instructions and actuators, reducing manual intervention and enhancing reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control of vehicle parameters is used during calibration, then human operators can adjust parameters, but development time increases and human error occurs
Solution Approach 1:
The patent replaces manual mechanical control of vehicle parameters with an automated control system that uses a processing unit to send control signals to actuators. This substitution eliminates human error in parameter control while maintaining the ability to adjust parameters during calibration, thereby improving reliability without significantly increasing development time.
Solution Approach 2:
The calibration system performs self-verification through automated measurement and comparison of calibration results against target values. The processing unit automatically determines whether calibration meets requirements without human intervention, reducing both development time and human error while maintaining calibration accuracy.
2Measurement precision
If manual control of vehicle parameters is used during calibration, then operators can control throttle, clutch, gear and brake, but accuracy and reproducibility decrease
Solution Approach 1:
The patent replaces manual operator control of throttle, clutch, gear, and brake with an automated control system. The processing unit sends precise control signals to actuators that manipulate these parameters, eliminating human error and improving measurement accuracy. This automation also reduces operator control effort while maintaining ease of operation through automated sequences.
Solution Approach 2:
The system implements automated feedback loops where sensors measure actual parameter values during calibration, and the processing unit compares these measurements against target values. This feedback mechanism ensures high measurement accuracy and reproducibility by automatically adjusting control signals to achieve desired calibration points.
3Adaptability or versatility
If automated calibration instructions are uploaded through central server, then calibration process is standardized, but system complexity increases
Solution Approach 1:
The patent implements a centralized server that stores and distributes calibration instructions to multiple client systems. This universal platform allows the same standardized calibration procedures to be applied across different vehicles and locations, improving adaptability and standardization. The modular architecture separates the calibration logic from the hardware, reducing overall system complexity while maintaining versatility.
Solution Approach 2:
The central server acts as an intermediary between calibration instruction authors and execution systems. It standardizes calibration procedures by providing a common platform for creating, storing, and distributing calibration instructions, thereby simplifying the overall system structure through centralized management rather than distributed complexity.
4Ease of manufacture
If expert calibration engineer visits customer location, then calibration can be performed, but time and cost increase
Solution Approach 1:
The patent replaces the need for expert calibration engineers to physically travel to customer locations with a remote calibration system. The automated control system executes calibration instructions locally at the customer site, eliminating travel time and reducing on-site expertise requirements while maintaining calibration quality through standardized automated procedures.
Solution Approach 2:
The central server creates and distributes copies of standardized calibration instructions to multiple client systems. This allows the same expert-level calibration procedures to be replicated and executed automatically at any customer location without requiring the physical presence of expert engineers, thereby reducing time and cost while maintaining calibration accessibility.
Data Source
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AI summary
The system (100) is provided to calibrate the ECU (204) of the vehicle (208). The system (100) comprises a remote computer (102), a central server (106), a local computer (110) and setup (200) comprising at least a dynamo meter (210), and at least one actuator (220). The dynamo meter (210) and the actuator (220) are interfaced and operated with the local computer (110). The central server (106) is connected to the local computer (110) by a second networking means (108), and a remote computer (102) is connected to the central server (106) by a first networking means (104). The remote computer (102), uploads instructions to the central server (106), executes the instructions through the local computer (110) to operate the dynamo meter (210) and the actuator (220), and calibrates the ECU (204) of the vehicle (208). The instructions are downloaded to the local computer (110) by the second networking means (108).