Use of mechatronics and automotive microelectronics for future vehicles

Research programme: New tools of mechatronics and vehicle electronics for future automobiles
Start date: 1/2011
Leader of the research programme: Doc. Ing. Petr Kocourek, CSc.
Objectives (incl. outputs, results, milestones and specification of user groups):
Goal: Assessing and selecting the concept of predictive and adaptive control engine-drivetrain or powertrain-vehicle, applying non-linear system approach and model-based control. Creating virtual engine/vehicle model and testing control unit by means of Hardware-in-the-Loop (HiL) technology. Transfer to real engine specimen. Involving X-by-Wire and electric equipment diagnostics into vehicle networks. Developing the tools for optimization of microelectronic systems usable for vehicles. Developing the RT systems based on the results of experimental-simulation optimization of controlled objects.
Outputs:
Vt1 Set of sensors and data acquisition units for measurements at ICEs, electric motors and powertrains, providing data for direct evaluation of calibration parameters for selected simulation codes, and evaluation codes for this purpose 12/2012
Vt2 Function model of a predictive and adaptive controller for engine/drivetrain or powertrain/vehicle based on multi-layer structure with different time-scales (up to reaction to information from road infrastructure) and suitable for non-linear systems, tested at engine specimen – function model 12/2013
Vt2 Testing equipment for vehicle networks, X-by-Wire systems and the diagnostics of electric accessories – function models, 12/2013
Results:
V1 Putting the laboratories of mechatronics and microelectronics into pilot operation 7/2012
V2 Demonstration and 3 publication of selected procedures applying experimental-simulation methods for optimization 12/2012
V3 Validated research technologies transformed into authorized software (1 item) for all potential users 12/2012.
V4 1 patent or protected model of control systems IV/2013
V5 3 publications on software tools (2 items) for advanced control of engines and vehicles 12/2013
Milestones:
M1 Putting the laboratories of mechatronics and microelectronics into pilot operation 7/2012
M2 System of control algorithms and measurement procedures acquiring the directly inaccessible unsteady quantities in the form of authorized software (1 item) 12/2012
M3 Demonstration and 3 publications of selected procedures applying experimental-simulation methods for optimization 12/2012
M4 Predictive and adaptive controller algorithm for engine/drivetrain 12/2012
M5 Function specimen of X-by-Wire system 12/2013
Specification of user groups:
Contractors of the CVSM from testing and certification fields, powertrain OEM manufacturers and suppliers of accessories having their own R&D activities, and engineering service/R&D companies. Key methodological approaches, key challenges, key equipment:
Methodological approaches: The outcomes stimulate the use of sophisticated combined methods of time-consuming optimization based on the virtual reality (simulation) and its continuous calibration by experiments. The high-reliable predictivity consists in this combined approach, which at the other side accelerates the development by testing virtual variants only. It must react to very fast progress in
engine and transmission concepts, electric components, available fuels and flexible control systems. New standards of vehicle distributed systems based on TDMA will enhance the cooperation between vehicle systems but they are more sensitive to communication problems. The required reliability can be reached by simulation and testing the response to different failures at all protocol layers. This process is decisive to implementation of X-by-Wire technologies (Steer-by-Wire, Brake-by- Wire, Park-by-Wire, etc.). The investigation of network reliability is addressed by this activity together with the detection of the failure in electric equipment and the prediction of future possible failures.
Formulation of algorithms for direct and indirect approach. Data acquisition in LabView environment. Calibration of code parameters using optimization. Finding inaccessible values by iterative co-simulation associated with experiments. Key challenges: Continuous calibration of simulation codes by inverse algorithms coupled to experiments. Determination of inaccessible values (unsteady temperatures, variable gas compositions, unsteady flow-rates in movable parts of machines, etc.) by iterative co-simulation aimed at the best fit of simulation results to measured ones. Predictive and adaptive control of an engine/powertrain based on non-linear system hierarchy and interaction with transport infrastructure. Vehicle control and power networks/buses, X-by-Wire systems, predictive diagnostics of vehicle electric systems.
Key equipment:
K1 Dynamometers for 2 different sizes of engines (single cylinder test engine, SI or CI engines for passenger cars, CI or gas SI engines for light-duty trucks a heavy duty trucks), completed by measurement equipment for both high and low frequency data, namely pressure, temperature, flowrates and torque sensors, exhaust gas analyzers, PM analyzers, dilution tunnels, experimental equipment for exhaust gas aftertreatment and fuel injection equipment testing including fuel blending for liquids and gases.
K2 Equipment for vehicle powertrain testing based on chassis dynamometer for PC/LD vehicles, connected to engine testing equipment (dilution tunnel, ...).
K3 Equipment for mechanical transmissions testing with loading/motoring, torque and speed measurements.
K4 Equipment for testing electric transmissions and drives with energy accumulation (loading/motoring, measurements of electric quantities, torques, speeds).
K5 Equipment for measurements and production of microelectronic tailored units and for development/testing of vehicle network systems for X-by-Wire technologies.
K6 Equipment for rapid prototyping of control systems with flexible gate fields.
K7 Simulation facility with a powerful multi-processor server, terminals and database equipment.
Associations to other programmes:
Directly linked to the programmes 1, 2 and 3. Although these tight links exist the RP4 is managed
independently to create good conditions for the following contractual research.