Driving cycle in Europe Cumulated emissions during ECE + EUDC test cycle.

Cycle duration: Length of cycle: Mean cycle speed Max. speed:

0.8

1180 s 11.007 km 33.6 km/h 120 km/h

NOx / HC emissions with 100 Kkm catalyst (dyno aged)

140

0.7

Stage V limit for HC

120

0.6

HC

Stage V limit for NOx

100

HC / NOx emissions (g)

0.5

0.4 60 0.3

NOx
40 0.2

0.1

20

0 1 195 389 583 Time (s) 777 971 1165

ECE (City driving)

+ EUDC (highway)
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SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

Speed (km/h)

80

Exhaust gas measurement : HC, CO, NOX, CO2, O2 ... Constant Volume Sampling system (CVS)
EMISSION CHASSIS DYNO CELL
Exhaust outlet Condenser Air Drier CVS Blower 500 CFM

~ 90% of exhaust goes in atmosphere ~ 10% are analyzed

Ambient Air Bag Sample Line

AMB. AIR BAG

AMB. AIR BAG

AMB. AIR BAG

AMB. AIR BAG

REMOTE SENSOR

TLEV Bag Sample Line

REMOTE CONTROL

TLEV BAG

TLEV BAG

TLEV BAG

TLEV BAG

Flow calculated indirectly versus CO2 rate

Burke E Porter Electrical Cabinet

Peus Drivers Aid

ULEV Bag Sample Line

ULEV BAG

ULEV BAG

ULEV BAG

ULEV BAG

Pierburg CVS
BURKE E PORTER DATA PROCESSOR

BAG Results: gram / phase

Pierburg Pierburg Pierburg Bag Before After Bench Catalyst Catalyst Bench Bench

Designed By Lincoln

3 Ventures 7 flow rates

Dilute Modal

MODAL Results: gram / second ppm / second cumulated gram

Burke E Porter 48" Roll

Before Catalyst Line

Tracer Line

After Catalyst Line EGR Sample Line VENTURE FLOW RATES 1.= .32484 2.= .64156 3.= 1.1124 4.= .95808 5.= 1.43 6.= 1.7381 7.= 2.0496

BURKE E PORTER COMPUTER PEUS COMPUTER

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SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

DRIVABILITY EVALUATION: More or less subjective

One of the ranking used in Siemens Starting (cold / hot) Idle ; Vehicle stopped in neutral Pedal tip-in: Slight, medium, strong Pedal release return to idle Constant Speed
r

Launch (take-off) Idle ; Drive train engaged : Pedal tip-out : Slight or complete release Gear shift Cruise control
5 Medium 6 Moderate Sellable 7 Light 8 Trace Acceptable 9 10 Nothing Average customer Critical customer Specialist

Rating Seen by Defect Evaluation Judgement

2 Very strong

3 All customers Strong

Not acceptable

Improvement required

In general: 5 --> Unsaleable 6 --> Marginal / Sellable 7 --> Acceptable 8 --> Target
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SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

System components description

ECU

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SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

TCO_GND
BK/LB 350mm K4C 20AWG K6B 20AWG

EGR_FB_V
LG/PK 900mm K235 20AWG

EGR_FB A15
2 1

B17
1

TCO
TN/BK 1080mm K002 20AWG

TCO

EGR_FB_GND

TCO_GND, EGR_FB_GND
BK/LB 730mm K4E 20AWG
2 MAP

90 WAY CONNECTOR PIN NUMBERS

WIRING DIAGRAM

3 4

LDPI_SOLENOID
OR 450mm K107

CLOSED=VENT OR LEAK F012

2

THROTTLE ASSEMBLY

A001 K090 PDC 25 TN 450mm K90 20AWG PDC 28

ETC MOTOR

VB_KEY

A041 T040
PDC 26

PDC 24

Z001

Z012 1

PDC 73 PDC 70 DB/PK 450mm C027

A016 C027

OPEN = HIGH PRESS

F012 C025 PDC 69

CRUISE

RAD FAN

A017 C028 PDC 30 PDC 33

MULTIFUNCTION SW (BRAKE LAMPS)

F012 C003 PDC 31

VB_RLY

BRAKE_SW

PEDAL

AC CLUTCH

A014 A014

PDC 34 PDC 35

K051 A142

PDC 38 PDC 36

A014

PDC 60 PDC 61

F012 K031

PDC 59

A041

KEY SWITCH ON IN START ONLY

A021 DB/WT 450mm F12

15A KEY SWITCH ON IN START & RUN

Z01B Z01C Z01A

30A 20A

30A

SI presentation
EGR VALVE GY/YL 900mm K35 20AWG 130mm K4J 20AWG

A33 A11
1

MAP_GND
BK/LB 885mm K4M 18AWG

EGRPWM B52 B16 A75

3

MAP_V

MAP
DG/RD 885mm K1 20AWG

MAP_V, EGR_FB_V
VT/WT 885mm K6A 18AWG PVS_1_V PVS_1 PVS_1_GND

BK/GY 980mm K019 18AWG

IGC_CYL_1_4 B60
OR 450mm J4PA 18AWG
4

PVS_1_V PVS_1
WT 450mm J5PA 18AWG
2

A12 A74 B19

5

IGNITION COIL ASSY

1
IN HARNESS

PVS_1_GND
LG 450mm J6PA 18AWG

PEDAL ASSEMBLY

4
0.47uF

A13
2

PVS_2_3_V
BK PK RD

450mm J1PA 18AWG 450mm J2PA 18AWG 450mm J3PA 18AWG

PVS_2_3_V
6 10

A07
DB/TN 980mm K017 18AWG

PVS_2 PVS_2_GND

PVS_2
8

PVS_3 PVS_2_GND PVS_3_NEG

TO EATX

3
IGC_CYL_2_3 B30 B22
1

2
F012

TPS 2

S
2

PURGE CANISTER
PK/BK 450mm K052 18AWG

CPPWM B55 A67 B23 A38 B46 A14 A31 STE_RLY A35 TPS_1 TPS_V B77 LDPPWM LDP_SWI

TPS_2 TPS_GND

LB 1035mm K222 18AWG

2

WT/DG 450mm K106

BK/LB 1035mm K4N 18AWG

5

TPS 1

OR/DB 1035mm K221 18AWG

1

LG 1035mm K6T 18AWG

3

ETC_POS

DB 1035mm K40 18AWG

4 6

A32 FAN_RLY_2 (PT ONLY) A36

ETC_NEG

DG 1035mm K39 18AWG

LT HDLAMP

ENGINE BLOCK

IP LEFT

IP RIGHT

Z001

Z008

Z010

FAN_RLY_1

A65 A39 PSTE_SWI

PSTE_SW
DB/OR 450mm K10 18AWG
2

FAN RELAY START ENABLE RELAY TO STARTER SOLENOID

NO CONNECTION PDC 71

POIL_SW

ELECTRONIC CYCLE SW (OPEN COLLECTOR)

IGN RUN ONLY

BRK_LEVEL
1

CLU_DOWN

CLU_UP

LO PRESS

A40 A69 A70 B76

DB/OR 450mm C028

BRK_LEVEL CLU_UP CLU_DOWN CRU ACC_RLY A08 A05 B50 A68 A71 B20 A62 B26 A72 A09 A43
DB/YL 450mm K051 18AWG

GY/BK 450mm G9 18AWG

CLOSED=LOW FLUID LG/BK 450mm K119 18AWG YL/RD 450mm T141 18AWG RD/LG 450mm V37 18AWG

A02 A03 A04 B27 B48 B51 B58 A64 B87

OPEN=PEDAL DOWN CLOSED=PEDAL DOWN

ACIN POIL_SWI BLS BRK_SWI KNK KNK_SHD KNK_GND

BR/OR 450mm C20 18AWG GY 1600mm G6 20AWG

GROUND=AC REQUEST CLOSED=LOW OIL PRESS HIGH=BRAKE ON WT/PK 450mm K29 18AWG DB/LG 1185mm K042 20AWG
1 3 1 5

RESISTORS TO GND

BRAKE_SHIFT_INTLK ATX ONLY

HI PRESS

SIM 70 C1 ECU

A/C COMPRESSOR RELAY

PDC 29

OPEN=PEDAL DOWN

KNK

NC PENDING EMC TESTS

BK/LB 1185mm K4B 20AWG

TIA TIA_GND CAM_V MAIN_RLY A34

BK/RD 1100mm K21 18AWG

TIA
1

2 Z012

BK/LB

1100mm K4A 18AWG OR 1130mm K7A 20AWG

3 CAM

VBD

BK/LB 1130mm K4D 20AWG TN/YL 1130mm K44 20AWG OR 1320mm K7C 20AWG BK/LB 1320mm K4L 20AWG A142

MAIN RELAY FUEL PUMP RELAY FUEL PUMP

RAD FAN STARTER A/C CLUTCH

HALL 2 1

A42 B49 A44 B25 VB_RLY

DG/OR 450mm 18AWG BR 450mm K031 18AWG

CAM_GND CAM CRK_V CRK_GND B88 EFP_RLY A66 B21 A45 A10 B79 TRD TPSPWM
PDC 63

CRK

HALL 2

CRK K024 VS_V VS_GND VS B78 A37 N_OUT

START FAN V AC CLUTCH V

GY/BK 1320mm 20AWG OR 1190mm K7B 20AWG BK/LB 1190mm K4F 18AWG WT/OR 1190mm G7A 20AWG

VS

2 3

HALL

[OR: VS from EATX] B47

EATX ONLY

VLS_DOWN

TN/WT 2170mm K141 20AWG

4 3

B53

VLS_DOWN_GND BK/LB

2170mm K4H 20AWG

LAMBDA_DOWN

VBD

B80 B85

LSHPWM_DOWN

BK/OR 1230mm Z2

VB_KEY

FPV
BR/BK 450mm D25 18AWG LG 450mm D20 18AWG PK 450mm D21 18AWG

B18 B57 J1850 SCI_RX SCI_TX A06 A41 A73 B89 B24 B81

VLS_UP VLS_UP_GND LSHPWM_UP

BK/DG 1140mm K041 20AWG

4

BK/LB 1135mm K4K 20AWG

3

LAMBDA_UP OR/RD 1135mm K079

2 1 1

ALTPWM

DG 1120mm K020

ALT FIELD
2

VB_KEY

A61 B84

INJ_CYL_4

LB/BR 685mm K014

INJECTOR 4
2

PWR_GND_1 PWR_GND_2 PWR_GND_3

Z01D

B29 B83
D021 D020 D025 16AWG

INJ_CYL_3 B59 B28

YL/WT 785mm K013

INJECTOR 3
2 1

Example

PWR_GND_4

B90

B82

INJ_CYL_2

TN 885mm K012

INJECTOR 2
2

Battery

Dec 15, 00 AT PT GS
O. Schmid engine control.ppt

NC
A014 Z012

PWR_GND_5

A63
A001 C025

IGN RUN-START A017 A001

RD 450mm 18AWG

A014

VBD
+

B54 A01 20A

A014

INJ_CYL_1

WT/DB 965mm K011

INJECTOR 1
2

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DIAGNOSTIC CONNECTOR

Z012

0.75MM-18AWG

16 5 4 7 6 2

Input Signal example: Coolant temperature acquisition (Absolute acquisition)

Acquisition of Coolant sensor voltage Raw voltage acquisition Every 1ms r V_TCO [04.995V] r 10 bits [0..3FF] [0...1023] Signal Processing --> TCO Conversion table (V or deci ) (C) Every 1second r TCO = IP_TCO__V_TCO r Physical range [-48142.5C] Monitoring r Min/Max voltage for open/short r Intermittent failure Derivative values: r TCO_ST: coolant at start r TCO_REST: coolant at last engine stop.
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ECU

VN (5V) TCO sensor (NTC)

VN (5V)

Main MC ATR35

RTCO

Low pass filter

V_TCO

Converter 10 bits A/D

SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

Pedal Springs

Limit stop

Input Signal example: Pedal acquisition (Ratio metric acquisition)

Acquisition of Pedal voltage Raw voltage acquisition Every 1ms r V_PVS_1 [04.995V] r 10 bits [0..3FF] [0...1023]
PEDAL pot n 1 PVS_1 VA2
(5V)
o

Axis

Pedal sensor
(potentiometer spring inside)

Pedal

ECU VN
(5V)

Main MC ATR35

R1high Rp R1 pot R1low

Pull-down Converter 10 bits A/D

V_PVS_1

Signal Processing --> PV_AV_1 Conversion formula (V) (C) Every 10 ms r PV_AV_1 = [ V_PVS_1 C_offset ] * C_slope r Physical range [0%100%] Monitoring r Min/Max voltage for open/short r Rationality between pot1 and pot2

Pedal output (V)

4.7 V

V_PVS_1
3.3 V

V_PVS_2

0.3 V

Default values in case of failures

(0 for instance)

0%

OPERATING ANGLE
o

100 %

(25 for instance)

Pedal Closed

Wide Open
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SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

Digital input & Engine synchronization CRK and CAM

Geometry r Typical Crank target wheel in Siemens:
60-2 teeth (1 tooth = 6CRK)
r

4 Cylinder
T_SEG n-4 T_SEG n T_SEG n-3

T_SEG = segment time = 720 deg / number of cylinder

(180CRK for 4 cyl, 120CRK for V6)

Preferred cam target wheel: half moon = 360CRK Purpose T_SEG n-2 T_SEG n-1 r Engine speed calculation (rpm): based on T_SEG r Injection phasing (SOI) r Ignition spark (IGA) and Dwell time (TD) phasing Delay between elec & mecha + 6 r One can back-up the other in case of sensor or 5V failure
r
Tooth number CRANK electrical signal CAMSHAFT electrical signal TDC4 360 Injection cyl 1 (A) Intake valve open 486 Intake valve open Intake valve open Injection cyl 4 (C) 1 15 45 61 75 105 121

CRANK Mechanical signal CRANK Electrical signal time or crankshaft degree tooth number n 1 n 2

TDC1 Crankshaft -84 Cyl n 1 (A) Cyl n 3 (B) 0 126

TDC3 180

TDC2 540 720

Injection cyl 3 (B) Intake valve open

Cyl n 4 (C)

Injection cyl 4 (C)

Cyl n 2 (D)

Injection cyl 2 (D)

Intake valve open

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SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

Synchronization at engine start: Different cases versus engine resting position

-84 0 15 90 180 360 450 540 720

CRANK elec

8 valid teeth

LV_RUN_ENG

LV_SYNC

TDC 1

TDC 3

TDC 4

TDC 2

TDC 1

TDC 3

CAM elec
TIPR

Cyl n 1 (A)

Injection cyl 1 (A)

start of preinjection BK1 TIPR

end of preinjection BK1

start of sequential BK1

ti_1

ti_1

Injection cyl 1 (A)

ti_2

Injecti

ti_2

Cyl n 3 (B)

Injection cyl 3 (B)

TIPR

Injection cyl 3 (B)

end of preinjection BK2 start of sequential BK2

ti_1

Injecti

Cyl n 4 (C)

Injection cyl 4 (C)

start of preinjection BK2 TIPR

Injecti

ti_2

Cyl n 2 (D)

Injection cyl 2 (D)

exhaust

intake Injecti

-84

0 15

90

180

360

450

540

720

CRANK elec

8 valid teeth

LV_RUN_ENG

LV_SYNC

TDC 1

TDC 3

TDC 4

TDC 2

TDC 1

TDC 3

CAM elec
start of preinjection BK1 tipr end of preinjection BK1 start of sequential BK1 ti_1

Cyl n 1 (A)

Injection cyl 1 (A)

tipr

Injecti

ti_2

Cyl n 3 (B)
tipr

Injection cyl 3 (B)

start of sequential BK2 end of preinjection BK2 ti_1

Injecti

Cyl n 4 (C)

Injection cyl 4 (C)

start of preinjection BK2 tipr

Injecti

ti_2

Cyl n 2 (D)

Injection cyl 2 (D)

exhaust

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SI presentation

Dec 15, 00

AT PT GS
O. Schmid engine control.ppt

Actual example : start-up

TDC 1 - 4 TDC 1 IV 1 EV 1 IV 2 EV 2 IV 3 EV 3 IV4 EV4

Injector Cyl1
( Powerstage )

Intake valve
( from Startbox)

2000 1800

Camshaft signal Crankshaft signal

CRK CAM

engine speed in rpm

1600 1400 1200 1000 800 600 400 200 0 0,1

File: H170200b

engine speed

rpm calculated out of Crankshaft Signal

0,5 0,6 0,7

0,2

0,3

0,4

Zeit in s
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Dec 15, 00 AT PT GS
O. Schmid engine control.ppt

SI presentation