Processor-in-Loop

PROtroniC ECU
(Prognoser)
Laptop with
MARC-I
(PROtronic
monitoring
software)
CAN
Engine
Model
Real Time
Simulator
Engine
Control
Strategie
s
Prognosis Algorithm:
1. Estimation of engine states using EKF which contains a non-faulty engine model. The EKF
innovations zero mean under no-fault and develop signatures on fault.
2. Computation of probable signatures for each fault type at current operating point.
3. Detection of signatures in noisy EKF innovations using Matched Filter.
4. Logging of output test statistics for each innovation at every engine cycle.
5. Multiple hypothesis classification of output test statistic.
Prognosis Algorithm
Prognoser in TargetLink PIL: Hardware and Functionalities
Buffer:
1. Stores segments of
engine data
2. Interpolates data
3. Feeds EKFs at
proper sampling
rate
Intake Leak
IV delay
EV not closing
Fault Model Bank






EKF
EKF
EKF
Matched
Filter

Template
Bank

Hypothesis
Bank
Statistical
Hypothesis
Testing
EKF
Engine
Measurements
Engine Inputs
Engine
Inputs
Engine
Measurements (y)
Fault
Info
Innovations (r)
1
y
2
y
3
y
1
r
2
r
3
r
Prognoser: Functional Blocks within the ECU
(The EKF is split to meet the
ECU constraints)
3
EKF Innovations for different faults
0 2 4 6 8 10 12 14
-600
-400
-200
0
200
400
600
800
1000
1200
Crankangle (radians)
I
n
t
a
k
e

m
a
n
i
f
o
l
d

p
r
e
s
s
u
r
e
r
e
s
i
d
u
a
l

(
N
/
s
q
.
m
)
0 2 4 6 8 10 12 14
-0.4
-0.2
0
0.2
0.4
0.6
0.8
1
Crankangle (radians)
I
n
t
a
k
e

m
a
n
i
f
o
l
d

t
e
m
p
e
r
a
t
u
r
e
r
e
s
i
d
u
a
l

(
K
)
0 2 4 6 8 10 12 14
0.98
1
1.02
1.04
1.06
1.08
1.1
1.12
1.14
x 10
5
Crankangle (radians)
I
n
t
a
k
e

m
a
n
i
f
o
l
d

p
r
e
s
s
u
r
e
e
s
t
i
m
a
t
e

(
N
/
s
q
.
m
)
0 2 4 6 8 10 12 14
450
500
550
600
650
700
750
800
850
Crankangle (radians)
E
x
h
u
a
s
t

m
a
n
i
f
o
l
d

t
e
m
p
e
r
a
t
u
r
e
e
s
t
i
m
a
t
e

(
K
)
Legend:

Exhaust manifold leak
Intake valve not closing
Exhaust valve delay in
open and close
Normal/No-fault

Intake manifold pressure
innovation
Mass air flow rate innovation
Intake manifold temperature
innovation
Intake manifold pressure
estimated state
Exhaust manifold temperature
estimated state
4
10 15 20 25 30 35
6
8
10
12
14
x 10
7
T
e
s
t

S
t
a
t
i
s
t
i
c
Engine Cycle No.
3. Matched Filter Output
0 500 1000 1500
-2
0
2
4
6
8
10
12
x 10
7
Sample Index
M
a
t
c
h
e
d

F
i
l
t
e
r

O
u
t
p
u
t


Actual Output
Ideal Output
4. Test Statistic across engine cycles 5. Plausible Hypotheses of a typical test statistic
Intermediate Steps and Results (Offline)
188.5081 201.0826
-4000
-2000
0
2000
4000
Crankangle (radians)
I
n
n
o
v
a
t
i
o
n

(
N
/
s
q
.
m
)
0 200 400 600
-200
0
200
400
600
800
1000
1200
Sample Index
T
e
m
p
l
a
t
e

(
N
/
s
q
.
m
)
1. EKF Innovation 2. Matched Filter Template
-5 0 5 10 15 20
x 10
7
0
0.5
1
1.5
2
2.5
x 10
-8
P
r
o
b
a
b
i
l
i
t
y

d
e
n
s
i
t
y

f
u
n
c
t
i
o
n
s
a
n
d

L
i
k
e
l
i
h
o
o
d
s
Test Statistic
Test Statistic
Engine
Cycle
5
Calibration Pane Measurement Pane
List of Calibratable/
Measureable Variables
ECU details
Monitoring the ECU using MARC software
Experiment: Control logic in ECU and Plant model in OP 5600
6
Interfacing Tata Nano with RT Simulator
32.08 32.1 32.12 32.14 32.16 32.18 32.2 32.22 32.24 32.26 32.28
-10
-8
-6
-4
-2
0
2
4
6
8
10
Time (sec)
T
a
t
a

N
a
n
o

M
e
a
s
u
r
e
m
e
n
t
s

(
V
)


Crankangle
Intake manifold pressure
Intake Manifold and Crankshaft measurements logged in MATLAB
The Data Acquisition model in RT-Lab
Acquired measurements logged in RT-Lab
console in real time and displayed in CRO
Tata Nano to Opal-RT harness