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Accurate simulation model of Electronic Throttle Body (ETB) is important to engine control, system analysis and diagnosis. However, some model parameters could vary significantly due to temperature variation and harsh working environment, therefore are very difficult to calibrate in test. In this paper, an optimization of model parameters with genetic algorithm is implemented to match simulation with open loop step and impulse response test results to achieve a precise ETB model. Closed loop validation test with rapid prototyping tool is accomplished to confirm the accuracy of simulation model. This automatic parameter-refining modeling approach turns out to be an efficient way to achieve the required model accuracy, which utilizes the advantages of multi-software tool chain.

A new hydrogen flow sensor was designed and evaluated based on the concept of hot wire anemometry. This sensor is designed to measure the mass flow rate of hydrogen gas used in (but not limited to) proton exchange fuel cell, PEFC. The conceptual evaluation was initiated by deriving an electro-thermal model of the hot wire required for sensing hydrogen velocity. The modeling is done via a mechatronics software tool, Saber™. This model was validated using air as a medium. Simulated and experimental performance results and safety issues are presented and discussed in this paper. Fail safe methods and effectiveness have been investigated along with hydrogen ignition temperatures with varying hydrogen to air ratio.

In the past few years, the demand for more complex system development and the ever-increasing requirement for improvement in software productivity have amplified the need for graphical programming and automatic generation of controller software. This paper discusses the implementation of graphical code generation in the context of a fully automated calibratable system. Generally, controller parameters coarse tuning is done at the simulation level with a virtual plant and then fine-tuned when the code is downloaded onto the target controller. The tuning process is then based on trial and error approach relying on experienced calibrators to perform this tedious work. We are proposing an innovative concept that will automate the whole process of controller development. This process goes from the control algorithm code generation to the real-time calibration of the controller parameters on the actual target controller.

Resolvers as position and speed sensors are widely used in many areas including the automotive industry, especially in the application of an electric drive for a hybrid electric vehicle. One of the disadvantages of using resolvers is that their complexity usually leads to quality issues during development that requires engineering resources and time to solve, which could be better served in solving the complex system issues of improving the hybrid system functionality. This paper describes the creation of a full resolver system simulation that can be used to prevent development issues, improve the hybrid system DFMEA, and act as a catalyst for solving development issues when they do happen.

We have developed a full virtual engine system prototyping platform with 4-cylinder engine plant model, SH-2A CPU hardware model, and object code level software including OSEK OS. The virtual engine system prototyping platform can run simulation of an engine control system and digital knock detection system including 64-pt FFT computations that provide required high-resolution DSP capability for detection and control. To help the system design, debugging, and evaluation, the virtual system prototyping consists of behavior analyzer which can provide the visualization of useful CPU internal information for control algorithm tuning, RTOS optimization, and CPU architecture development. Thus the co-simulation enables time and cost saving at validation stage as validation can be performed at the design stage before production of actual components.

As the demand for more complex system development and the ever-increasing requirement for improvement in software productivity, the need for graphical programming or Zero-Hand Coding for automatic generation of controller software becomes highly desirable. The graphical programming must not be limited to the algorithm development which consists of the application modules but must be extended to the microcontroller platform, which include the middleware (i.e. operating system, I/O device drivers) and hardware. Automatic code generation is very important for programming the complex microcontroller internal parameters and registers. The combined software tool chain is to generate the final target specific executable code. This approach is very beneficial for system development, reduction of the development cycle and bridges the gap between control and software engineers reducing time, effort and cost of the production software.