Transcript B2 Preliminary Info

M274 Engine Hot Test Controller
NI Powertrain Controls Group Application
of cRIO ECS to Production Hot Test
The Challenge
• Take control of a new production 4-cylinder GDI
engine for purposes of assembly line hot test
• Supplied with a crate engine in San Antonio
• No access to production ECU or fueling
calibrations
• 8 weeks to get engine running for Nissan visit
• Provide TCP/IP interface to KUKA XCT,
communicating all relevant controls and
indicators
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cRIO ECS Solution
• M274 engine controller was the first use of PCG ECS software on
a cRIO target, using the high performance cRIO-9082 controller.
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Layered approach of LabVIEW RT and FPGA software for engine control
applications
• Hardware Layer: RT / FPGA devices drivers for modular I/O
• Engine Layer: RT software connecting I/O channels to control algorithms
• Control Layer: Collection of engine control algorithms independent of Hardware
and Engine layers
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San Antonio Engine Installation
• The M274 engine was installed on a portable engine startstand for drag-racing engine builds.
• Start-stand allowed us to quickly setup cooling, fuel and
basic electrical systems.
• The prototype cRIO ECS was mounted on a panel next to the
engine.
• A custom exhaust system was fabricated with oxygen sensor
ports
• Customized pulley and belt arranged for missing A/C and
alternator
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San Antonio Engine Installation
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Reverse Engineering Process
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Our line of work often involves reverse-engineering
of electro-mechanical systems in order to operate
them for research projects
We rang-out the ECU connectors and compared
against the provided simplified schematic
ECU connectors were removed and replaced with
Circular Plastic Connectors (CPC)
Brief datasheets and pinouts were provided for
sensors and actuators
Engine manual with some sensor calibrations was
provided
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Reverse Engineering Process
• Highlights:
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Engine-synchronous fuel-pump pulse timing
was manipulated around the 720 degree
cycle until finding the “sweet spot” range
which affects pressure.
Fuel pump pulse-width table was calibrated
based on pressure setpoint and estimated
flow rate
Cam signals monitored while experimentally
identifying VVT travel and default positions
Various valves were energized while
running engine to determine open/closed
states
Fuel Pump Pulse Current
Piezo Injector Current/Voltage
(Charge Phase)
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NI Compact RIO Generic System Diagram
RT Processor
FPGA
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I/O Module
I/O Module
I/O Module
I/O Module
I/O Module
I/O Module
Ethernet
User-defined I/O
configuration
I/O Module
User Interface Link:
FPGA-based “driver” code for
modules (ie EPT)
I/O Module
Engine control
software and
calibration points
LabVIEW FPGA and Modular I/O
NI 9751 Direct Injector Driver Module
NI 9752 Automotive AD Combo Module
NI 9753 Differential Digital I/O Module
NI 9754 Engine-Synchronous TTL Output Module
NI 9757 O2 Sensor Module
NI 9758 Port Fuel Injector Driver Module
NI 9759 Electronic Throttle Driver Module
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FPGA-Based Engine Position Tracking
Tracks angular position of crankshaft to a nominal 0.1 degrees
• Supports most common trigger patterns in the industry
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N-M (example: 60-2)
Plus 1 (example: 6+1)
Encoder (example 360 count optical encoder)
Chrysler 36-4
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LabVIEW RT Control Algorithms
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Calibration
• Software Calibration Management (SCM) Toolkit
(previously known as CalVIEW) was used to
instrument the RT application for parameter interface
and calibration
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Communications
• LabVIEW-based TCP/IP functions were added to
communicate all relevant controls and indicators with
KUKA XCT test cell supervisor software
• XCT supervises the test cell and engine control
setpoints
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Conclusion
• A successful steady-state setpoint engine controller was prototyped
quickly using NI Powertrain Controls cRIO ECS Platform
• Modular C-Series I/O was implemented to select exactly the I/O types
required by the target engine
• LabVIEW RT and LabVIEW FPGA were used to provide real-time
algorithm processing and microsecond control of I/O processes
• The LabVIEW RT and FPGA software can be ported to other RT/FPGA
targets
• TCP/IP interface to KUKA XCT was implemented, however, a variety of
communications protocols can be implemented via NI hardware and
software (RS232/485, CAN, LIN, etc)
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