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OCSYGENE 6 (*)
L’optimisation mécatronique dans la boucle d’air et d’EGR des moteurs à combustion interne à l’horizon €6
Journée MécatroniqueJournée MécatroniqueENSAM Angers, 6 décembre 2012
Jérôme MIGAUD ([email protected])
(*) Optimisation dans la Conception de SYstèmes embarq ués d’admission de Gaz d’Echappement et d’air pour la Norme Euro 6
OCSYGENE 6 / OCSYGENE 6 / PartnersPartners
TechnicalTechnical Plastic Parts Plastic Parts ManufManuf..Electronic Parts Electronic Parts ManufManuf..OEMsOEMs
Mechatronics Mechatronics
Large CompaniesSmall CompaniesLabs / Univs.
Mechatronics Mechatronics OptimizationOptimizationControlControl
CFD simulations CFD simulations Turbo Turbo ChargersChargersAir Air intakeintake systemssystems
MeasurementMeasurement / / EngineEngine benchbench
OCSYGENE 6 OCSYGENE 6 consortium descriptionconsortium descriptionFUI10, 3 years, 9 partners, 3.2 M €
OCSYGENE E OCSYGENE E EElectrical Actuator lectrical Actuator
OCSYGENE + OCSYGENE + (low (low end end torque increase)torque increase)
OCSYGENE TOCSYGENE T
Engine bench
ENSAM Angers– December – 6 th 2012 - Confidential Refer to protection notice ISO 1 6016
EElectrical Actuator lectrical Actuator
Air & EGR architecture
OCSYGENE TOCSYGENE TTTestingesting
OCSYGENE C : COCSYGENE C : CompositionompositionPlastic module for LP EGR, Plastic module for LP EGR,
Next Euro regulationsNext Euro regulations
MAF Sensor
EGR Inlet Mixer
Comp. IntercoolerThrottle
HP EGR CoolerEGR Valve
Intake Throttle
E-Actuator
General architecture for LP EGRGeneral architecture for LP EGR
ENSAM Angers– December – 6 th 2012 - Confidential Refer to protection notice ISO 1 6016
Air Cleaner
Filter Element
Turbo
Exhaust
Fresh AirInlet
HP EGRValve
EGR Valve
LP EGR Cooler
ExhaustThrottle
Condensate Separator
CondensateDump Valve
EGR Filter
5
OCSYGENE C : a modular & compact approach OCSYGENE C : a modular & compact approach integrating Mechatronicsintegrating Mechatronics
-
ENSAM Angers– December – 6 th 2012 - Confidential Refer to protection notice ISO 1 6016
OCSYGENE C OCSYGENE C –– FromFrom systemsystem toto productproduct designdesign
Système Model
Component Model
Control model
Engine Test
Driving cycles / Duty cycle from OEMsSystem simulationsOEMs specificationsBenchmark activities
ENSAM Angers– December – 6 th 2012 - Confidential Refer to protection notice ISO 1 6016
Position Control Strategy + ECU
Component Model
Organic test bench
Prototyping (HW / SW)
SubSystem Specifications
FromFrom thermodynamicsthermodynamics to to mechatronicsmechatronics
0,6
0
4
8
12
16
20
24
0 50 100 150 200 250
∆ P (mbar)
Measurements
Test interpolation
CFD
CFD interpolation
Valve Force (N) � A compensation chamber has beendesigned to reduce torque requirement
� A prototype has been built and tested� CFD simulation has been made in same
conditions for correlation� Simplified model has been built and
used for mechatronics simulation(Simulink)
ENSAM Angers– December – 6 th 2012 - Confidential Refer to protection notice ISO 1 6016
0,00
0,04
0,08
0,12
0 4 8 12 16
Valve lift (mm)
A (N/mbar) Measurements
CFD
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0 2 4 6 8 10 12 14 16
Valve lift (mm)
C d (-) Measurements
CFD simulation
8
Matlab / Simulink Model
9
ValveTorque Vs
position
TransmissionFriction vs. load
Friction Oscillation vs. position and loadReturn spring torque vs. position
Inertia
MotorResistance & Inductance
Torque constantRegulation constant
Cogging torqueInertia
+Temperature derating
4
3
Position réelle (°)
2
Courant mesuré (V)
1
Courant réel (A)
courant_sim
pos_simCouple charge (N.m)
Courant réel (A)
Courant mesurée (V)
Position réelle (°)
Position mesurée (V)
kch
Gain raideur ressort
Cch
Couple de charge (N.m)
ENSAM Angers – December – 6 th 2012 - © Electricfil – Reproduction & disclosure prohibited without express permission.9
9
SensorResponse curveResponse delay
VehicleBattery voltage
Harness resistanceAmbient T°
Position setpoint
ControlControl loop calculation
Sampling rateParametersElectronics
Resistive losses
12
Temps (s)
11
Energie consommée (J)
10
Couple résistant (N.m)
9
Couple moteur (N.m)
8
Temp. bobine (°)
7
Vi tesse réelle moteur (rad/s)
6
Vitesse estimée (rad/s)
5
Vitesse réelle (rad/s)
4
Posi tion mesurée (V)
montant
descendant
TransportDelay
retard
crestot
vit_sim
Uc
25
Températureextérieure
Tension al imentation (V)
Température ambiante (°C)
Position mesurée (V)
Vi tesse réelle (rad/s)
Vi tesse estimée (rad/s)
Vitesse moteur (rad/s)
Température bobine (°C)
Couple moteur (N.m)
Couple résistant (N.m)
Energie consommée (W.s)
Motoréducteur Ocsygene
Manual Switch
Im réel (A)
Theta réel (°)
Theta consigne (°)
Temps µC
Tension de commande (V)
Commande
Actuator, topology 1 , Gear Ratio Optimization
Mission profile energy vs reduction ratiofor different values of max current
90000
0 to 80° travel time vs reduction ratiofor different values of max current
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0 5 10 15 20 25 30 35 40
Reduction ratio
0-8
0° tr
ave
l tim
e ( s
)
2.5
3
3.5
4
10
Dynamicsneed
Dynamics compliance
+ Total loadMotor
Transmission concept and
reduction ratio
x
Energy
ENSAM Angers – December – 6 th 2012 - © Electricfil – Reproduction & disclosure prohibited without express permission.10
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
0 5 10 15 20 25 30 35 40
Reduction ratio
Tot
al e
nerg
y (
J )
2.5
3
3.5
4
10
� In order to improve transmission efficiency spur ge ar is preferred.
� Increasing reduction ratio is suitable for lower cu rrent consumption and higher torque margin but not for dynamics.
� Energetic approach is the best way for system optim ization and reduction ratio choice.
� Analytical method has been built for transmission o ptimization
Mission profile
reduction ratio
x
Energyconsumption
Position Control Strategy
From Single actuator to EGR Valve
Position control strategy synthesis
Rapid Prototyping
Set-up and Calibration
11 ENSAM Angers– December – 6th 2012 - Confidential Refer to protection notice ISO 16016
Position Control Strategy optimization
0.01
0.015
0.02
0.025
0.03Position de la vanne EGR
2
4x 10
-4Erreur position
0.01
0.015
0.02
0.025
0.03Position de la vanne EGR
2
4x 10
-4Erreur position
~100 deg
12 ENSAM Angers– December – 6th 2012 - Confidential Refer to protection notice ISO 16016
-4
-2
0
0 0.5 1 1.5 2 2.5
-10
-5
0
5
10
Tension
Temps (s)
-4
-2
0
0 0.5 1 1.5 2 2.5
-10
-5
0
5
10
Tension
Temps (s)
Optimization on Response time
ConclusionConclusion
� Thanks to ID4CARS, Regions Pays de la Loire and FUI / OSEO for their Help and financial support to this project
� A network of competencies around Engine knowledge, fluid dynamics and mechatronics activities has been founded.
� In OCSYGENE 6 program, Focus is to meet new challenges in air loop on New Engines to meet next Euro 6 regulation.
ENSAM Angers– December – 6 th 2012 - Confidential Refer to protection notice ISO 1 6016
meet next Euro 6 regulation.
� A methodology has been created to optimized mechatronics concerning packaging, future functions, electrical consumption and cost.
� Durability and engines tests are in progress on prototypes based on concrete work achieved with OCSYGENE 6.
13
Thank You For Your Attention !
ENSAM Angers– December – 6 th 2012 - Confidential Refer to protection notice ISO 1 6016
