Development of sensor less PMSM field-oriented motor control for HVAC E-compressors applications, for platform and customer projects.

• Calibration of: motor model, delta / star configurations, speed control, current control, rotor speed and position observer based on sliding mode controller, SVM module.
• Calibration of new features such as:
  • Advance phase angle for motor efficiency improvement (MTPA).
  • Cold start improvement for new compressor refrigerant, thermodynamics response, overall HVAC efficiency.
• Issues investigation and resolution on motor Dactem bench and compressor Ipetronik bench.

• SW debugging and calibration for electric vehicles: diagnostic tuning based on faults severity

• Marketing agent in various sectors: semiprecious stones & jewelleries, industrial ceramics manufacturing, hotels-restaurants

• Development of Predictive Energy Optimization (PEO) algorithm for Plug-in Hybrids
  • Rules-based control strategy design and calibration.
  • Overview: during the initial research phase various approaches were analysed for PEO strategy design (Dynamic Programming, rules-based, Equivalent Consumption Minimization Strategy). In this phase the PEO strategy was integrated in the Vehicle Supervisory Controller (VSC) Simulink model within the complete vehicle simulation environment and the performance of the designed strategies was analysed over various drive cycles.
  • Those analysis led to the choice of a rule-based strategy as best trade-off between model fidelity and memory allocation.
  • Strategy highlights: based on route-ahead information (>200km: Long e-Horizon) and a simplified HEV vehicle model, the strategy calculates a journey energy demand profile and a speed threshold below which EV mode is enabled, with the objective to minimize fuel consumption over the whole journey and fully utilize battery energy, while also coping with route deviations from the planned one (journey energy recalculation based on new e-Horizon information).
  • Rapid prototyping environment setup and operation, including: MABx, BOSCH NDS on iPad programmed for Long Horizon (>200km), WiFi-to-CAN converter (Avisaro Box), CAN, Control Desk NG.
  • Overview: auto-coding, issues resolution for real time MABx operation (eHorizon resolution, CAN traffic, Avisaro lags, multiple tasks overrun).
  • Note: this technology can be used in various applications, such as chassis or aftertreatment control, for strategies optimization based on route-ahead information.
    • Integration into ECU via CAN Gateway on dSpace MABx.
    • Testing of prototype vehicle and debugging
    • Support for production code generation and integration in ECU
    • Testing on production vehicle and debugging
    • CAE analysis of vehicle tests results and correlation with Simulink simulations results: the algorithm provides Fuel economy benefits compared with classic no-eHorizon strategy (CDCS: Charge Deplete Charge Sustain).
• Development of Short Horizon Predictive Energy Optimization algorithm for Hybrids 
  • Analysis of control strategy specific features - such as ADAS devices (radar, camera)
  • Analysis of control strategy specific performances, such as:
    • coasting in cruise control (speed limit tracking against slope or traffic variations)
    • coasting in deceleration (e.g. roundabout approach)
    • coasting in country-road assist (speed limits change)
• Strategy overview: based on 8km route-ahead information (Short eHorizon) and a simplified model of an HEV vehicle fitted with ADAS devices (camera, radar), the strategy determines opportunities to request energy-efficient modes (coasting, regenerative braking) with the objective to minimize fuel consumption .
  
  • Rapid prototyping environment setup and operation, including MABx, BOSCH NDS on iPad programmed for Short Horizon (8km), WiFi-to-CAN converter (Avisaro Box), CAN, Control Desk NG.
  • Integration into ECU via CAN Gateway on dSpace MABx.
  • Testing of prototype vehicle and debugging
  • CAE analysis of vehicle tests results and correlation with Carmaker simulations results and with competitors vehicles test results.
  • CAE analysis overview:
    • ADASRP routes generated from GPS trace and exported to IPG CarMaker.
    • Designed Matlab scripts to automatically correct issues on CarMaker road files imported from ADASRP routes.  This allowed replicating in CarMaker any route run during real driving tests for correlations analysis.
    • Statistical analysis over large test data sets to gather insights on strategy capabilities to identify coasting opportunities of different kinds and to cope with traffic.

Testing and Validation of ECU strategies for EURO6 customer program, in particular for aftertreatment strategies and diagnostic.

• Updated Simulink models based on Software Change Requests received from the customer
• Autocoding, flashing into ECU, code build, ECU functions testing in laboratory
• FMEA, requirements update and documentation

• Feasibility study of a helium leakage detection system for pneumatic reservoirs.
  • System model built from the scratch based on first principles (air/gas mixture, energy conservation, mass transfer, ideal gas law, thermodynamics).
  • Analysis of reservoir output valve pressure sensitivity to various system parameters, such as valves diameters, pipelines turns, volumes, pump power, helium leakage
  • Calibration of systems parameters in order to maximize pressure response sensitivity to helium leakage, to make this detectable via pressure measurement.
• Analysis and optimization of various trucks performances, such as startability, fuel consumption, engine and transmission durability.
  • Data-driven analysis and recommendations for improving the existing vehicle model to include impact on startability of cold start and tyres&clutch slip.
  • Analysis and recommendations for the existing trucks configurations: selected and sized key driveline components for improving startability, while keeping good performance of fuel economy and engine durability.
  • Drive cycles and startability tests simulations.

• On site customer support for EURO6  after-treatment controls algorithms calibration

• DPF regeneration control design and test on dynamometer
  • Soot observer design based on: (1) DPF backpressure vs. Exhaust flow map, (2) soot and ash model, (3) Kalman filter combining (1) and (2) according to their estimated accuracy.
  • State machine supervisory strategy design based on engine operating point, DPF soot loading and temperature, mileage.
  • Actuators control (post injection timing and quantity, EGR valve): PID, blending filters for bump-less state transition, anti wind-up, feed-forward corrections.
  • Strategy optimization based on fuel economy, drivability, DPF thermal security.
  • Software-in-the-loop strategy validation comprising plant model, DPF regeneration controller, DPF backpressure sensor and DPF temperature sensors.
  • Strategy calibration on dynamometer at customer site (Japan): soot model calibration, supervisory calibration, actuators control calibration, controlled regenerations at various conditions. On-site technology transfer
• Three stages turbo diesel engine modelling and air path control  
  • Parameterization of the Mean Value Engine Model (MVEM) based on customer data
  • Innovative parameterization of Turbine and Compressor Efficiencies
  • Calibration of the air path MIMO controller
  • Validation of Plant model and Control strategy.
• Two stages T/C diesel engine model parameterization and SCR control
  • 2 stage T/C MVEM parameterization based on customer data
  • Extensive engineering judgment to cope with incomplete data
  • Steady State and transient MVEM validation
  • Software-in-the-loop strategy validation comprising engine model, exhaust pipe model, DOC model, DPF model, SCR model, urea dosing controller, temperature sensors, NOx sensor.
  • Drive cycle validation tests.
  • Validation results presented to Japanese customer
• Other assignments focussed on systems analysis and simulation for: diesel engines and aftertreatment, OBD, hybrids and conventional vehicles.

• HW electronics engineer ? audio amplifiers simulations and testing