Cloud-Based Engine Recalibration via ECU Calibration Settings
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Solution Overview
Problem
Original equipment manufacturers (OEMs) face challenges in accurately predicting engine calibration needs, leading to over or under-ordering of engines with specific calibrations, resulting in inefficiencies, increased costs, and waste due to inability to recalibrate engines post-purchase.
Innovation Solution
A calibration system that includes an electronic control unit (ECU) and a calibration tool allowing OEMs to query an engine's unique identifier, determine and select desired calibration settings from a cloud-based server, and implement these settings, enabling flexible recalibration to meet changing business needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If engines are calibrated with fixed initial settings stored in the electronic control unit, then the engine calibration is stable and reliable, but the engine cannot be recalibrated by customers to meet changing business needs
Solution Approach 1:
The patent implements a dynamic calibration system where the electronic control unit can transition from a static initial calibration state to an updated calibration state. The system allows calibration data to be dynamically updated through wireless communication, enabling the engine to adapt to changing operational requirements while maintaining stable operation. The calibration data is stored in volatile memory, allowing it to be changed without hardware modifications.
Solution Approach 2:
The system changes the calibration parameters from fixed to variable by introducing a mechanism to receive and apply updated calibration data. The electronic control unit can modify engine operating parameters such as fuel injection timing, ignition timing, and air-fuel ratio based on received calibration updates, allowing the engine to adapt to different operational conditions while maintaining reliable operation.
2Ease of manufacture
If customers must predict engine calibration needs in advance, then the engine calibration can be determined before purchase, but this leads to over or under-ordering of engines with specific calibrations
Solution Approach 1:
The system performs preliminary calibration setup during engine manufacturing with default calibration data stored in the electronic control unit. This preliminary calibration allows the engine to operate immediately upon delivery, while the capability for future recalibration is already in place. The initial calibration is sufficient for basic operation, and updated calibrations can be applied later as needs are identified.
Solution Approach 2:
The system enables a feedback loop where actual engine usage and performance data can inform future calibration updates. Instead of requiring advance prediction, the system allows calibration optimization based on real-world operational feedback. Manufacturers can analyze usage patterns and provide targeted calibration updates to improve efficiency and performance based on actual conditions.
3Device complexity
If engine calibration settings are fixed in the electronic control unit, then the calibration implementation is simple and reliable, but the system cannot adapt to market fluctuations or changing business needs
Solution Approach 1:
The patent introduces an intermediary calibration data structure that separates the engine control hardware from the calibration parameters. The electronic control unit contains a calibration data structure that can be updated without modifying the underlying hardware or control logic. This intermediary layer allows flexible calibration changes while maintaining the simplicity and reliability of the original control system.
Solution Approach 2:
The calibration system is segmented into distinct components: the electronic control unit hardware, the calibration data structure, and the calibration application logic. This segmentation allows the calibration data to be independently updated without affecting the control unit hardware or the fundamental control algorithms. The calibration data can be modified, added, or removed as needed while the core system remains unchanged.
Data Source
AI summary
A method for recalibrating an engine includes querying an engine for a unique engine identifier, sending the unique engine identifier to a cloud-based server, determining one or more engine calibration settings available to the engine based on the unique engine identifier sent to the cloud-based server, presenting the one or more engine calibration settings to a user through a user interface so that the user may select a desired engine calibration setting, sending the desired engine calibration setting as selected by the user to an electronic control unit of the engine, and replacing a current engine calibration with the desired engine calibration setting in the electronic control unit of the engine.