Gasoline Engine Calibration Engineering Academy     New!

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I.D.# ACAD10Printable Description
Duration: 5 Days
  Delivered in
September 25-29, 2017 (8:30 a.m. - 4:30 p.m. ) - Pontiac, Michigan    
October 16-20, 2017 (8:30 a.m. - 4:30 p.m. ) - Pontiac, Michigan    
November 6-10, 2017 (8:30 a.m. - 4:30 p.m. ) - Pontiac, Michigan    

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Tuning the many electronic variables to ensure that a vehicle's engine performs according to its mission profile ultimately relies upon a competent calibrator. Because proper calibration is a critical aspect of customer satisfaction and emissions certification, skilled calibrators are in high demand in the auto industry. This Academy is designed to provide a foundation for those interested in entering the field of calibration engineering through hands-on exercises and detailed instruction on the base principles of calibration.

Starting with an introduction to calibration and calibration tools, the course covers a range of topics that provide learners with an understanding of general calibration work flow, project management aspects of calibration, developing calibration processes and manuals, establishing calibration project schedules, and incorporating calibration testing. The relationship between software strategy and calibration strategy is also emphasized along with how to read Simulink block diagrams in order to know the software algorithms being calibrated. Various examples of engine control strategies are provided with an explanation of how these strategies would be calibrated.

This Academy is intended to be interactive and hands-on so learners are challenged each day with calibration projects utilizing engine start stands and basic calibration software. Projects range from electronic throttle control calibration to on-engine idle control, spark, and fuel tuning. Throughout each project, learners address target system requirements, details of the software strategy that will be calibrated, how to formulate the calibration process to meet the requirements, and how to run tests that verify requirements were met.

Learning Objectives
By attending this seminar you will be able to:

  • Read and interpret software strategy from Simulink models
  • Establish calibration initial values by understanding software strategy and system physics
  • Demonstrate generalized calibration techniques by real time calibration of electronic throttles and gasoline PFI engines
  • Relate system requirements to calibration targets
  • Demonstrate fundamentals of calibration techniques for PID feedback controls
  • Describe base requirements to start an engine from sensors, encoders, fuel delivery, spark timing, and air control
  • Calibrate model-based fueling strategy and implement Min Gov RPM control
  • Identify uses of real-time adapt strategies and calibrate feedback Pre Cat O2 controller
  • Implement calibrations for transient fueling and discuss advanced calibration topics for future learning

Who Should Attend
This Academy is intended for anyone not familiar with the operational theories or functional principles of calibration. It is recommended for mechanical or electrical engineers who are new to the field of calibration engineering, and managers new to calibration positions who need an understanding of general calibration workflow. Attendees should have a basic knowledge of gasoline engine hardware. Suggested attendees: Mechanical Engineers, Electrical Engineers, Experienced and/or Advanced Technicians with no experience in calibrations.

Topical Outline

DAY ONE Basics of Calibration & PID Tuning on ETC

  • Course Introduction
  • Explanation of difference between strategy, models, and calibration
  • Types of calibration parameters – constants, enumerations, tables, maps
  • Calibration tools data management
  • Cal management – partial cal, cal comparison, transfer upgrade
  • PID controls explanation
  • ETC strategy review and build files
  • ETC Tuning Project
    • Flashing, display, calibration, logging
    • Sensor characterization actuator overrides
    • Throttle control tuning (P, I, and D gains)
    • Setpoint Management and Control Improvements
    • FeedForward Calculation
    • Basic sensor fault detection

DAY TWO Engine Fundamentals & Crank State

  • Engine control basics – fuel, air, and spark
  • Engine walk through – sensors and actuators
  • Encoder basics, angle based outputs, synchronization, TDC offset
  • Engine state machine
  • Crank state strategies and calibrations
  • Cold start crank calibrations
  • Crank State Calibration Project
    • How to use wideband O2
    • Effect of spark advance
    • Cold start calibration procedures
    • Crank flare calibration procedures
  • Run state strategies and calibrations
  • Model based fuel strategy
  • Sensor characterization

DAY THREE Run State & Minimum Governor

  • Calibration review of run state strategy
  • Run State Calibration Project
    • Sensor characterization
    • Crank to run transition
    • Fuel compensation tuning and modelling errors
  • Minimum governor explanation and requirements
  • Minimum governor model and calibration review
  • Minimum Governor Project
    • Pedal input testing
    • Minimum governor gain tuning
    • Pedal tip-ins and WOT accelerations
    • Minimum governor disturbance rejection
    • Idle entry smoothing

DAY FOUR Airflow Estimation & O2 Control

  • Model based estimation – speed density
  • Real time model adapting techniques
  • Speed Density Calibration Project
    • VE map tuning
    • MAF based adaptation
    • Other adapt strategy examples
  • Feedback O2 control and fuel perturbation for catalysts
  • Linear vs. ramp/jump O2 control strategy
  • O2 Control Project
    • Steady state control tuning
    • Fuel flow compensation adapting
    • Response to disturbances and transients
    • Fuel perturbation calibration
    • Fuel perturbation biasing
    • Fuel flow compensation adapting

DAY FIVE Transient Fueling & Advanced Topics

  • Transient fueling requirements and intake manifold puddling
  • Delta TPS vs Tau-X strategies
  • Transient Fuel Project
    • Using Delta TPS
    • Demonstrate improvement in throttle and O2 response
  • Emissions Calibrations - EGR, purge, misfire, and post O2 control
  • Calibration equipment for steady-state and vehicle based calibrations
  • Advanced calibration - knock, torque based, VGT, VVT
  • Calibration process and timeline for production release

Instructor(s): Jason Tartt

Jason Tartt is the technical lead for LHPU, responsible for controls and course development training. He has worked as a controls and calibration engineer for Mercury Marine, MotoTron, and Woodward, Inc., specializing in knock, governing, coldstart, and vehicle drivability on diesel, gasoline, and natural gas applications.

Jason received his Bachelor of Science in Mechanical Engineering from Washington University in St. Louis and his Master of Science in Mechanical Engineering from University of Wisconsin at Madison. In his spare time, Jason enjoys training for triathlons.

Fees: $3995.00 ; SAE Members: $3196.00 - $3596.00

4.0 CEUs
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

To register, click Register button at the top of this page and submit the online form, or contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at CustomerService@sae.org.