Engine Calibration Models for Real-Time Virtual Optimization
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Solution Overview
Problem
Current methods for optimizing internal combustion engines face challenges in efficiently moving development tasks from real to virtual test stands and achieving real-time complete system simulation, especially under non-standard environment conditions, while also reducing development time and costs.
Innovation Solution
A method and device for model-based optimization of internal combustion engines that involves detecting key parameters using physical and empirical models, simulating the engine's behavior with these models, and adjusting control units based on machine-specific setting parameters to optimize performance and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If model-based optimization methods are used to reduce development time and costs, then productivity improves, but measurement precision and reliability may deteriorate due to reduced extensive measurements
Solution Approach 1:
The patent applies preliminary action by performing extensive measurements and creating comprehensive empirical models during the initial model creation phase. These pre-established models capture complex relationships between parameters, allowing rapid virtual optimization without needing extensive measurements during each optimization iteration. The model is prepared in advance to handle transient processes and non-steady-state operations.
Solution Approach 2:
The patent uses copying by creating virtual copies of the technical device through detailed empirical models that replicate real device behavior. These digital twins allow optimization to be performed in the virtual domain rather than requiring physical prototypes and extensive real-world measurements. The empirical models copy the complex relationships and behaviors of the actual device, enabling accurate virtual testing and optimization.
2Productivity
If real-time transient operation simulation is implemented, then productivity improves through faster optimization cycles, but use of energy and computational power increases
Solution Approach 1:
The patent applies segmentation by dividing the complex optimization problem into separate empirical models for different parameters and operating conditions. Each empirical model handles specific aspects of device behavior, allowing the computational task to be distributed and managed in smaller, more efficient units. This segmentation enables real-time performance by avoiding the need to compute all parameters simultaneously from first principles.
Solution Approach 2:
The patent uses parameter changes by transforming the computational approach from solving complex differential equations in real-time to using pre-computed empirical relationships. The empirical models are created offline with extensive computational resources, then used online with simple parameter substitutions. This changes the parameters of the computational method from high-intensity real-time calculation to low-intensity parameter evaluation, enabling real-time performance.
3Loss of time
If model-based optimization is used to reduce extensive measurements, then loss of time improves, but measurement precision may worsen due to reliance on empirical models
Solution Approach 1:
The patent applies preliminary action by performing comprehensive measurements and creating detailed empirical models during the initial setup phase. These pre-established models capture complex relationships between parameters through extensive offline measurements, allowing rapid virtual optimization without needing extensive measurements during each optimization iteration. The measurement work is done in advance when time is available, enabling fast subsequent optimization cycles.
Solution Approach 2:
The patent uses copying by creating virtual copies of the technical device through detailed empirical models that replicate real device behavior. These digital twins allow optimization to be performed in the virtual domain rather than requiring physical prototypes and extensive real-world measurements. The empirical models copy the complex relationships and behaviors of the actual device, enabling accurate virtual testing and optimization with minimal physical measurements.
4Adaptability or versatility
If complete system optimization with transient operation is implemented, then adaptability improves for handling various operating conditions, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the complex optimization problem into separate empirical models for different parameters and operating conditions. Each empirical model handles specific aspects of device behavior, allowing the system to manage complexity through modular organization. This segmentation enables the system to handle various operating conditions by selecting and combining appropriate model segments rather than requiring a single monolithic complex model.
Solution Approach 2:
The patent uses universality by creating empirical models that can handle multiple operating conditions and transient processes through a unified framework. The empirical models are designed to be versatile, accommodating different operating scenarios (steady-state and non-steady-state) without requiring separate specialized models for each condition. This multi-functional approach manages complexity by providing a single adaptable modeling framework rather than multiple condition-specific models.
Data Source
AI summary
The disclosure concerns a method for model-based optimization, especially calibration, of a technical device, especially an internal combustion engine. The method may involve the following steps: detection of at least a first parameter in relation to the technical device being optimized which characterizes a physical quantity; first determination of at least one second parameter in relation to the technical device being optimized by at least a first physical model which characterizes at least one known physical relationship and for which the at least one first parameter is an input parameter; second determination of at least one third parameter by at least one first empirical model based on measurements on a plurality of already-known technical devices of the same kind, especially internal combustion engines, and for which at least the at least one second parameter is an input parameter, wherein the at least one third parameter is suited to characterizing the technical device being optimized and/or to providing a basis for making a change in the technical device being optimized, especially to adjusting a control unit of the technical device being optimized; and outputting the at least one third parameter.


