World Top 10 April 2013

Two very different approaches to the electric car in the two top spots

Revenge of the Pure Electric Car 


Models

April confirmed that pure electrics are on the rebound, with Tesla's Model S removing the Chevrolet Volt from the second place YTD and BEV share increasing to 61% of the market, up 3% from last month.

The rest of the chart is stable, the Renault Zoe exchanged positions with the Mitsu I-Miev family and the tenth place now belongs to the Chery QQ3 EV, highlighting the significance of the chinese market on the world stage.

PlModelsYTD
1Nissan Leaf12.289
2Tesla Model S7.097
3Chevrolet Volt (1)6.760
4Toyota Prius PHEV5.401
5Mitsubishi Outlander PHEV4.304
6Renault Zoe2.481
7Mitsubishi I-Miev (2)2.462
8Renault Kangoo ZE2.110
9Ford C-Max Energi1.577
10Chery QQ3 EV (e)1.050


Manufacturers

In the Manufacturers ranking, Nissan is number one with 24% share, up 4% from last month, followed by Mitsubishi at 15% share, which was been hampered by batteries issues.

Tesla is now #3, leaving Chevrolet in fourth and in the line of fire of Renault, already #4 in April and looking to reduce distances from the american brand.

Toyota was surpassed this month by Renault and has to watch his back, because Ford is coming strong and if the Fusion continues to grow its sales, we might see Ford in #6 before the end of the year.

Behind these major players, figures become a bit sketchy as one doesn't know for sure how the chinese brands are behaving, but taking in account confirmed numbers, Chery is #8, BYD is stable in #9, Smart is benefiting from placing the Fortwo ED in the production line to climb to tenth place.


PlBrandsYTD
1Nissan12.289
2Mitsubishi7.485
3Tesla7.107
4Chevrolet6.760
5Renault6.119
6Toyota5.713
7Ford2.922
8Chery (e)1.050
9BYD934
10Smart531


(1) - Includes Holden Volt, Opel and Vauxhall Ampera;
(2) - Includes Citröen C-Zero and Peugeot iOn.
(e) - Estimate


Categories

Dividing the plug-in sales by the conventional segments used for gas cars, it is possible to see how each segment leader stands in the global EV chart:

A (City Cars) - Mitsubishi I-Miev (#7)

B (Superminis) - Renault Zoe (#6)

C (Compact) - Nissan Leaf (#1)

D (Midsize) - Ford Fusion Energi (#11)

E/F (Full-size) - Tesla Model S (#2)

SUV - Mitsubishi Outlander Plug-In (#5)

MPV - Ford C-Max Energi (#9)

LCV - Renault Kangoo ZE (#8)

Sports Cars -  Tesla Roadster (#29)

Besides the outstanding (#2) global position of the E/F leader, there's also something to be said about the poor result of the D-segment leader, only eleventh, although it could climb a few positions in the near future.

The same can't be said about the poor result (#29) of the Sports Cars leader, the Tesla Roadster, which is already out of production and should be replaced in the #1 spot by one of two low production hypercars: Porsche 918 or McLaren P1.

Europe April 2013

These two are grabbing the headlines in Europe
The Duel 

There's a hard fight between the Nissan Leaf and the Renault Zoe for the #1 spot in Europe, with several changes in positions and few units separating them. Right now the Nissan Leaf has more 194 units than the Zoe and with both expecting to increase sales in the next months, it looks that things will continue to be interesting between these two.

Behind them, the Kangoo ZE is a comfortable third,  followed by the Prius Plug-In and the Renault Twizy.

Speaking of Twizy, it's important to register that it ended last year in number one, so a drop to fifth and just 7% share is a matter of concern. It wasn't the only one to drop positions though, as last year's number two, the Opel Ampera, also dropped to #6 YTD and #8 in April.

Are these two heading for extinction?
Further down the ranking there are also drops, like the Citröen C-Zero down four positions to #10 YTD and #15 in April...Coincidence or not, its sibling Peugeot iOn was 14th in April, it makes us wander if these two franco-japanese EV's aren't on their last breaths, right?

For any drop, there's always someone rising, besides the two on top, there are other models climbing the sales chart, like the Smart Fortwo ED, up five places to #7, or the Volvo V60 Plug-In coming out of nowhere (#22) to a respectable eighth place, an important position considering that this is the most expensive model here.

By brands, Renault increases by 6% the share it had last year to 43%, followed by Nissan with 20% share (Up from 12% last year) and Toyota with 13%.

PlEuropeAprilYTD%
1Nissan Leaf8802.67520
2Renault Zoe8462.48119
3Renault Kangoo ZE5322.11016
4Toyota Prius Plug-In (e)2471.65913
5Renault Twizy2868887
6Opel Ampera827836
7Smart Fortwo ED (e)925594
8Volvo V60 Plug-In394443
9Mitsubishi I-Miev1283723
10Citröen C-Zero63633
11Bolloré Blue Car512092
12Peugeot iOn81771
13Chevrolet Volt311591
14Renault Fluence ZE281041
15Mia Electric12961

(e) - Estimate

HTML5 blooper reel

I find bloopers infinitely amusing — mind you I’m talking about those that come on a reel, not those that happen for real. Missed deadlines, cost over-runs, IP disputes — these are the bloopers we all could do without.

Helping customers avoid bloopers is what we do — so to speak. Except it seems, when we put them in front of the camera. <grin>

Seriously though, no customers were hurt in the making of this video.



This compilation of bloopers from the HTML5 series highlights the professionalism of QNX customers, partners, and employees as well as their good nature.
 

Replacing door speakers on the Volvo S40

While giving one of my friends a lift to the railway station on my old trusty Volvo S40, he somehow punched a hole through the speaker on the passenger side. I took it to the garage and they told me that it would take about £100 to replace the speakers and cover, plus the service. That was several months ago. I tried some DIY repair work on the speakers by putting super glue but that was a bad idea and it did not turn out well. The sound was terrible. In the end , I used the balancing knob on the music system to shut off the left speakers. It was irritating but I was not going to shell out almost £100 for one speaker. 

Anyway, one day while surfing eBay I chanced upon someone selling used speakers and covers from a S40 and without thinking much, I just bought them - all for £17.50.

I then went to YouTube looking for a tutorial video, I was sure there was bound to be at least one and I was right. 


It took me less than 10 minutes to replace the speakers with the new (old) ones and save myself around £80. 


New speaker in

Pop the cover on

The old speakers and cover

It is so great to finally listen to music with all the speakers on. 

ECU Fuel Trim - use in Diagnostics

Fuel trim is technology used to keep the fuelling control operating correctly over vehicle lifetime, in order to comply with emissions regulations. Trim values are accessible via scan tools and this knowledge can help your diagnostic procedures.

What does it do?
Short-term fuel trim (STFT) and long-term fuel trim (LTFT) are expressed as a percentage, Positive fuel trim percentages indicate that the ECU is attempting to richen the fuel mixture, to compensate for a lean condition. Negative fuel trim percentages indicate the opposite. Fuel trim values are generated and stored with respect to engine operating condition – generally speed or load.

Why do you need it?
As vehicles operate over their lifetime, and accumulate mileage. The engine system components accumulate operating hours, and thus experience wear and tear. With respect to the fuelling control system – air flow meters can become dirty and contaminated, and this has an effect on their initial calibration and response characteristic. Oxygen sensors can also become contaminated and this impacts on their accuracy and reliability of the signal. The fuel injection wet system also suffers from long term fatigue effects – injectors can clog, thus affecting their spray pattern, and ability to provide a homogenous charge for combustion. Fuel pressure regulators lose their calibration and accuracy due to the continuous operation mode. Add to these factors, general engine wear, due to loading and thermal effects and it’s clear that over a long period of time, the accuracy and capability of the engine control system, with respect to correct fuelling, becomes compromised. In the past, this gradual loss of accuracy for fuel metering would have been accepted – just wear and tear. However, due to ever tightening emissions regulations, this is no longer accepted! The engine control system must maintain emissions within prescribed limits over vehicle life, and if it can’t (perhaps due to component failure) then the system must inform the driver that his vehicle has exceeded critical limits. So that’s why we need fuel trim – to monitor and compensate the closed loop emission control system, over a long term period (the life of the car).

Adaptive Learning
Fuel trim values are the result of an adaptive learning strategy within the ECU, this monitors the effectiveness of the control system during engine operation. For example, a gasoline engine ECU system will determine deviations from stoichiometry in the exhaust gas content over time. The information is stored in non-volatile memory and used to adjust or offset the fuelling value from the original stored fuel map value, to the required value, taking into account wear and tear factors. This is known as a long term trim value – it is learned by the ECU and it is not lost when the battery is disconnected, it generally can only be reset by a technician with a scan tool. 

In addition, there are short term trim values, these are offset values based on short term effects, in response to temporary changes. Typically, for a gasoline engine, the short term trim values are a result of the closed loop lambda control system, comprising of the pre-catalyst oxygen sensor signal, that helps maintain fuelling at the stoichiometric point. Short and long term fuel trim correction values work together to maintain the correct, required lambda value. The short term trim will provide immediate correction, and if this correction is needed to maintain the required value on an on-going basis, then the long term fuel trim will learn this and provide a permanent offset to the basic fuelling map. Note though, this process is monitored and maintained within calibrated limits that correlate with tailpipe emissions. If the long term trim value becomes greater than a certain, pre-set limit. Then this is used as a trigger in the diagnostic (OBD) system to inform the driver of an emissions related problem, via the MIL (Malfunction Indicator Lamp) and storage of an appropriate DTC (Diagnostic Trouble Code).




Fig 1 - Fuel trim is effected by modifying the basic injector demand, for the engine operating condition

Fuel trim diagnostics
A useful aspect of fuel trim values is the potential of being able to use them as part diagnostic procedures. Many fault coder readers, including low cost, generic devices, can provide fuel trim values. If you know and understand what these values are, and how they are generated, then you can use them to help you understand the nature and root cause of many fuel systems related faults that you may come across.

Assuming you can access fuel trim information, how does it help you? During normal engine operation, the ECU records long (LTFT) and short (STFT) term fuel trim values as ECU labels (accessible via a scan tool). STFT normally cycles at the same frequency as the oxygen sensor switches, in effect it reflects the operation of the closed loop lambda control. LTFT is normally quite stable, and any adjustment of the value is made over a long period of time, so is less noticeable. Remember that LTFT is held in non-volatile memory (also known as KAM – keep alive memory), but STFT is dynamic, thus constantly changes during run-time, but starting at zero, both values re-set when DTC’s are cleared.


Gasoline engines are inherently unstable! The cycle-to cycle, and cylinder to cylinder variations cause loss of efficiency and roughness. So the ECU is continually adjusting spark timing and fuelling to compensate for this fact. As injectors wear, the delivered quantity and spray pattern are compromised, and this can cause cylinder specific fuelling faults that can be identified very efficiently using fuel trim values! The long and short term fuel trim value will reflect any variations in injector delivery or combustion efficiency for a specific cylinder, and can help diagnose faults like leaking blocked or dirty injectors.



Fig 2 - Typical fuel trim values at idle, as shown on a standard scan tool, connected to the vehicle OBD connector. Note that STFT is negative and follows closed loop lambda operation. LTFT is much more stable over time, and is a positive value. Both are within acceptable limits


Trim values should generally not exceed 10% either way. Positive means the ECU is trying to compensate for a weak mixture, it does this by extending the basic injector pulse width. This could indicate faults caused by air leaks in the flow system, manifold or vacuum pipework. In addition, MAF (mass airflow meter) or oxygen sensor issues. Lean mixture problems are the most common failure mode. Negative trims mean that the engine is running rich, and the base pulse width is reduced to compensate. This could indicate problems with EGR, MAF, fuel pressure regulator, leaking injectors or oxygen sensor problems. Individual cylinder contributions can also be evaluated. Disconnecting the injectors one-by-one and monitoring fuel trim values allows the technician, to compare each cylinder with the others. Thus individual misfire or injector problems can be identified clearly.



Fig 3 - Fuel trim - high idle speed. STFT is now positive, LTFT has switched negative, this shows how both work together to achieve the required target of Lambda 1.


Summary
It is worth to remember though that different ECU’s will respond differently to a given fault or diagnostic stimulus, in particular with respect to how LTFT and STFT work together to address a deviation or system problem. This is part of the ECU calibration strategy, so there are no hard a fast rules, but if you understand what LT and ST fuel trims are, and what they do. Then you can observe what you see and make an informed judgement. There is no doubt that being familiar with the concept will help your diagnostics of fuelling related problems. If you have time, it’s always worth making some observational measurements of a known ‘good’ vehicle, and record/note the data. Ready for the next faulty vehicle of that type or make to appear!



12:26:00 AM

Markets Roundup April 2013 (Updated)

Leaf's speeding up sales
Editor's note - I've added new figures to this post, for easier identification of this new data, it will be written in blue.


Nissan Leaf Superstar - World Edition

With the risk of repeating this title a lot in the coming months, the truth is that the japanese hatchback is improving its performance everywhere, in April the Leaf conquered the monthly leadership in two more countries, Germany and Austria, adding them to an extensive list of countries at number one (Nine, to be more precise).

Besides the two countries mentioned above, it's important to say that since the beginning of the year, Nissan added three countries (Denmark, Australia, Estonia) to their #1's list, without losing any of those it had (Norway, UK, Hong Kong, Ireland) in December 2012...Not bad, eh?

Another measure of Nissan's electric car is that the lowest position on the several EV sales rankings is one #4 in Holland, but even this position isn't all that shabby, because it is the best among pure electrics...

Although with a handful of units, nevertheless it's important to register the landing of the Leaf in two more countries: The first four units were sold in Iceland and the first three in the Czech Republic. Will they the 10th and 11th countries in Leaf's list of #1's?

In a different level, the Nissan Leaf improves even further in Norway, in April it was #2 in the global ranking with 3,3% share, that's even before the british built, improved and cheaper 2013 model arrives. Will we then see Nissan's electric car #1 in Norway?

All these good performances country-wise contribute to the global leadership of the Nissan Leaf, holding that position since January and allowing a comfortable 10% margin (24% share vs 14%) over the number 2 in the ranking, the Model S. 



Trends in the Great 7 

Of the 7 largest markets for EV's, five (USA, Japan, France, Norway and China) have improved their share, while two (Germany and the Netherlands) saw their EV share decrease.

In the US, Tesla's Model S is leader for the second month in a row, an important feat since it has a price tag several thousands above its main competitors, it will be interesting to see for how long can Tesla keep this title.

In France, the Renault Zoe earns a third consecutive #1 and represents now 48% of the EV market, something that should only improve in the months to come.



Fragmented Markets

While it's normal for this early stage of EV markets to be dominated by one or two models, there are a some countries where things are more fragmented and because of that, more interesting.

Here are three markets where the #1 has less than 30% share:

In the USA, the Model S is leader with 28%, followed by the Volt and the Leaf with 22% and it's this last one, presently #3, that analysts predict to be #1 in the end of this year, so a lot should happen here until then.

With four different leaders in four months, the German EV is in "no mans land" territory, with the #1 (Smart Fortwo ED) managing 29% share and 390 sales, followed by three models at 19% with just 21 units separating them. In December things should be a lot different, by that time VW and BMW should be fighting for #1, leaving present contenders way back.

In Austria and despite the small figures, things are also leveled, with just 8% share separating the number one (Renault Twizy - 27%) from the third place (Opel Ampera - 19%). And between them, the #2, the Nissan Leaf is hoping to increase sales and win over the #1 position in the next months.

A white-ish Fluence ZE in Israel, the only country that actually likes it
Other Markets

Giving some love to less visible markets, it's possible to confirm the fall of EV share in another euro market, the Czech Republic  is down to 0,02% from 0,06% in 2012, but things are looking better elsewhere, in Israel there were 422 EV's sold this year, with EV share improving to 0,58%, up from 0,37% in 2012, making this middle eastern country the 11th largest EV market in the world, ahead of countries like Italy, Spain or Switzerland.

A curious thing about this market is the fact that the only electric car selling significantly is the Renault Fluence ZE, which coincidentally is also the only market where the electric sedan sells in decent numbers, thanks to the Better Place deal.

For all you EV Sales blog readers from Russia, this month i have figures from their home market, in 2012 there were sold a hundred of electric cars there, 49 of which were Mitsubishi's I-Miev.

Will the I-Miev hold on to the russian title in the end of the year?

Austria April 2013

A couple of white Renault Twizies (?)

Nissan Leaf Superstar - Austrian Edition

April saw the Austrian EV market showing some pulse, with 45 sales, the best month of the year but still far from the near hundred sales/month it used to register last year. As consequence of this, the EV share is down to 0,09% when last year it ended at 0,30%.

Looking at the models chart, three models stand out: like in 2012, the Renault Twizy is #1 YTD but in the April chart the Nissan Leaf won the top spot  for the first time and with it climbed four positions, regarding last year, to a brilliant #2 YTD.  The Opel Ampera secures a brilliant third place, up 8(!) positions comparing with last year chart and already selling more units than in the whole year of 2012 (10 units), this is a rare bright spot for the Opel Plug-In, which is watching their sales go down everywhere.

Stumbling Dropping in the chart are the Kangoo ZE and Fluence ZE, both tied in number 9, when last year they were much higher (#3 and #4 respectively), but despite these weak points, Renault is still the #1 brand here, with 36% share.

PlAustriaAprilYTD%'12Pl
1Renault Twizy1125271
2Nissan Leaf1319206
3Opel Ampera11181911
4Citröen C-Zero1662
5Peugeot iOn
557
5Renault Zoe455N/A
7Mitsubishi I-Miev3445
7Smart Fortwo ED1449
9Renault Fluence ZE1224
9Renault Kangoo ZE
223

TOTAL4593



#QNXLive Twitter Sessions Return!

Ask us your questions about self-driving cars and the secrets of the QNX Garage

Paul Leroux
We’re back for more of your questions. Back in December, we held our first #QNXLive Twitter sessions leading up to CES 2013; next week, we’re revving up for Telematics Detroit (June 5-6) with not one, but two #QNXLive sessions with experts from the QNX auto team.

Autonomous cars continue to captivate the popular imagination and are quickly becoming a reality. On Tuesday, May 28 at 4pm ET, Justin Moon, global technical evangelist,will give a preview of his Telematics Detroit panel, “The Autonomous Car: The Road to Driverless Driving” in his first #QNXLive session. Justin will share his thoughts on the latest developments in autonomous and assisted driving, how the industry defines “autonomous”, how your car is already autonomous in certain respects, and how self-driving cars will change your driving experience.

On Thursday, May 30 at 1pm ET, Alex James, concept development team software engineer, will take you Behind the scenes at the QNX Garage in his #QNXLive session. Have you ever wondered what a day looks like in the QNX garage for the concept design team? What does the team enjoy most about working in the garage? Alex will give you a behind-the-scenes look at the birthplace of the QNX technology concept car based on a Bentley Continental GT and the reference vehicle based on a Jeep Wrangler Sahara — both will be at Telematics Detroit.

You can submit your questions now or on the day of the Twitter sessions by tweeting @QNX_Auto with the hashtag #QNXLive. As usual, we’ll be sure to call you out if you asked a question that we selected.

Be sure to follow @QNX_Auto for next week’s live Twitter sessions – and the latest from Telematics Detroit. I’m looking forward to being your host for #QNXLive.

In the meantime, check out our recent posts on autonomous cars and the following videos:

Meet Justin Moon, product manager turned concept designer (Justin is nothing if not versatile: he's since taken on the role of global technical evangelist.)


    Meet the QNX concept team: Alex James, software engineer


      QNX technology concept car - Bentley Continental



        Cisco study: people want a safer, more personalized driving experience

        And they're willing to give up some of their privacy to get it.

        Paul Leroux
        Call me old-fashioned, but my hackles go up every time a web site or business asks me for personal information. My reaction is at once emotional and rational. Emotional because I'm a private person by nature; sharing details about myself simply goes against the grain. Rational because I know that people want this information more for their own benefit than for mine.

        Does that mean I never share personal information? Of course not. Even if someone wants it primarily for their benefit, I may still enjoy some benefit in return. That said, I weigh the pro's and con's carefully. And I ask questions. For instance, who will have access to the information? And what will they do with it?

        In effect, personal information becomes a form of tender — something I barter in exchange for a perceived benefit. And it seems I'm not alone.

        Recently, Cisco published the results of a study on what car drivers would be willing to give up in exchange for a variety of benefits. For instance, 60% would provide DNA samples or other biometric information in return for personalized security or car security. And a whopping 74% would let their driving habits be monitored in return for lower insurance or service maintenance costs. Cisco sums it up in this infographic:


        In autonomous we trust
        The study also found that people are willing to embrace autonomous cars — but the enthusiasm varies significantly by geography. For instance, Canada trails the U.S. by 8 percentage points, but both countries are miles behind India or Brazil.


        The study surveyed more than 1,500 consumers across 10 countries. That's only about 150 people per country, so I wouldn't put too much credence into this geographic breakdown. That said, the differences are dramatic enough to suggest that self-driving cars will see faster adoption in some countries than others.

        For more on these and other findings, visit the Cisco website.

        Spain April 2013

        White and green Mitsubishi I-Miev advertising car
        Back to Life Edition

        Thanks to the Endesa-Mitsubishi deal and the new PIVE incentives, the spanish EV market reached 124 units in April, it was a much needed shot in the arm, making this the best sales month since last September. Thanks to the deal with the spanish electric company Endesa, the Mitsubishi I-Miev holds firmly the #1 spot, with 101 cars sold YTD, followed by the Renault Twizy with 54 sales and in third, benefiting from April's generous discounts, comes the Nissan Leaf with 43 sales.

        In April Renault sold its first 21 Zoe's, an important recruitment for the french manufacturer to recover the #1 spot in the model and brand charts.


        PlSpainAprilYTD%'12Pl
        1Mitsubishi I-Miev441014110
        2Renault Twizy1554221
        3Nissan Leaf3643183
        4Renault Zoe21219N/A
        5Smart Fortwo ED612516
        6Toyota Prius Plug-In
        527
        7Opel Ampera1429
        8Renault Fluence ZE1214

        TOTAL124244100


        Source: Manufacturers, autoblog.es

        Germany April 2013

        Smart electric cars and bikes in front on Brandenburg Gates
        Nissan Leaf Superstar - German Edition

        This year the german EV market is eventful, with already four different leaders (Smart Fortwo ED in January, Citröen C-Zero in February, Renault Twizy in March and Nissan Leaf in April) and a new YTD leader, the Smart Fortwo ED, looking to recover the #1 place it had in 2010.

        This month the Nissan Leaf scored for the first time the best selling trophy, with a personal best 191 units, followed by the Twizy with 106 units and looking to recover some positions it had lost during the Winter (It is now in third place YTD, behind the #1 position it had last year). Dropping 3 places to #5, the Opel Ampera is losing steam, just like its Volt cousin, which still has his scorecard in blank.

        The Renault Zoe scored a respectable #4 in April and now is #5 YTD, something tells me that the french supermini is heading for the top three spots in the coming months.

        By brands, Renault has a 22% share, down from 56% in '12, losing the #1 place to Smart (29%).


        PlGermanyAprilYTD%'12Pl
        1Smart Fortwo ED (e)30390297
        2Citröen C-Zero2262194
        3Renault Twizy106256191
        4Nissan Leaf191241185
        5Opel Ampera1910072
        6Renault Zoe28433N/A
        7Mitsubishi I-Miev243939

        TOTAL4131.381


        (e) - Estimate


        Source: kba.de

        Technology focus - Automotive ECU Development – a technology insight


        We are all familiar with the fact that the complexity of modern vehicles is growing rapidly! With each new generation of vehicle, the sophistication of the power train, chassis and body control systems increases significantly. This is only possible due to the increasing number of electronic controllers around the vehicle (ECU's) and with each vehicle generation, they become more powerful (in terms of memory and processing power), and they are increasingly more 'connected' - sharing data and information during vehicle operation.

        Having a complicated controller is now essential to achieve the required performance levels, as well as driver expectation – but have you ever considered the task of getting these control units to function and behave in the correct way. To set them up - fine tuning them for the application. This task is undertaken during vehicle and powertrain system development, and is known as 'calibration'!

        Fig 1 - Typical ECU parameters needing to be adjusted in order to achieve the required targets for a modern diesel engine – this is ECU calibration!

        What is ECU Calibration?
        An ECU is a micro-processor based control unit that performs complex functions by running sophisticated control algorithms. The tuning of these to suit the application (e.g. engine, vehicle type etc.) is a task commonly known as CALIBRATION. The Calibration Engineer will adjust the parameters of the control function algorithms that are stored in permanent memory inside the ECU (maps, tables etc.) during development. This will allow optimisation the controller based on targets (good fuel consumption, good drivability) whilst keeping within boundary limits (noise, temperatures).


        Fig 2 - The increasing complexity of the ECU calibration task

        Within the ECU software, each physical data value is known as a 'label' - this could be a calibration value (i.e. a value that needs adjusting or 'calibrating') or a measurement value (i.e. an internal value used within the software, for example 'engine temperature' or ' desired ignition angle for spark advance'). The number of 'labels' has grown massively with increasing complexity - 10 years ago there were 3000 to 5000 labels to deal with, now, it is 40,000 to 50,000 labels. This shows what a massive task the overall calibration of an ECU is!

        In order to 'calibrate' effectively, access to these labels is needed during ECU operation! Actually, that is not strictly true - in years gone by, the 'calibrations', which were much simpler, were held on memory chips. These chips could be replaced or re-written off line and re-installed into the ECU, thus providing a new calibration. There were (and are) many providers in the aftermarket doing this, providing updated calibrations that added horsepower (at the expense of other things, like fuel consumption and driveability) to boy racer types! The technical term for this approach is 'off line' calibration!

        But this offline technology does not support an efficient calibration process in development - typically, there is a lot of 'round trip Engineering' when calibrating an ECU. For example, changing values, checking responses, comparing with measurement data on-line, and off-line. To support this task efficiently, 'on line' calibration technology is needed. That is, seeing and changing what is going on inside the ECU, during operation! Anyone who has used a scan tool to view and record data during a test drive will experience seeing on-line measurement labels. However, the calibrator needs to see all the labels for his task, including being able to change some of them, and test and measure the response immediately. For this, a suitable software and hardware tool chain is needed. Typically, this consists of application software running on a PC, in combination with an interface to the ECU.


        Fig 3 - The calibration tool runs on a PC and connects to the ECU via an interface that allows changing of parameters during runtime (Source: ATI)



        Fig 4 - ECU access methods and their relative performance


        5:28:00 AM

        Technology focus - Engine Control Unit (ECU) - Torque based architecture explained

        In older generation engine management systems, different internal control subsystems had conflicting demands on the overall control system, with no real co-ordination. This meant that there was an interdependence between these systems, which was difficult to handle during calibration and did not provide the optimum with respect to an overall engine control concept. The answer was a 'torque' based architecture in the ECU - that is, to focus on the driver demand for torque, rather than respond to the throttle pedal postion.

        Fig 1 - Conflicting torque demands in an Engine control unit

        The block diagram above shows the conflicting requirements - the answer was a torque based control architecture – an overall torque demand manager (TDM) co-ordinates all the overall torque and efficiency input values. Internal inputs are typically defined by the engine operating mode and protection limits, external inputs are driver demand, cruise control and vehicle dynamic control values (ABS, Stability control etc.). The TDM process the inputs, taking into account drivability optimisation factors (thus allowing ‘tuning’ of the vehicle behaviour with respect to vehicle type and driver expectation). The final output from the TDM is a required torque value, this is realised by the controller output stages and connected actuators which are available to influence the engine torque output – typically throttle angle, ignition timing (SI engine), injection parameters (SI and CI engine) and turbocharger control.

        Fig 2 - Overview of the TDM function (Torque Demand Manager)

        But how is engine torque measured? well it isn’t! it is derived from an internal model that takes into account cylinder air charge, lambda and ignition timing (SI engine). Combustion generates a cylinder based ‘internal’ torque, from this gas exchange and friction losses are estimated and subtracted, and this gives a final engine output torque. Clutch torque can then be derived by subtracting engine ancillary torque absorbers, for example, Electrical and HVAC loads.

        Fig 3 - Virtual torque sensor function which forms the basis of a torque based ECU structure









        4:40:00 AM

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