IC Engine Calibration using GT-POWER and GT-SUITE

IC Engine Calibration using GT-POWER

  • 0% EMI Option Available
  • Pre-requisites : For Mechanical, Automotive & Aerospace Engineers with Basic Knowledge of Fluid Mechanics, Thermodynamics, and IC Engine Concepts
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A Quick Overview

Diesel and gasoline engines still have significant potential for combustion refinement. The emphasis, today,  is on achieving the highest possible fuel economy along with good performance and driveability, while also focusing on the lowest possible engine-out emission. This task is heavily dependent on calibration studies.

GT-POWER and GT-SUITE comes under the system-simulation domain as it employs sophisticated algorithms to solve fluid flow equations in complex electromechanical systems. Students who aspire to work for Automotive OEMs as a calibration engineer targeting internal R&D projects can choose to opt for this course. This course is especially relevant for those aspiring to or already in the following roles: Product development/systems development engineer; IC engine calibration engineer; 1D-3D thermodynamic system simulation engineer. 

At the end of this course, you will be able to understand the basic concepts and methodology that goes behind the calibration of IC engines. 



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IC ENGINE CALIBRATION USING GT-POWER AND GT-SUITE

Download Syllabus

COURSE SYLLABUS

1Week 1: Introduction to GT-POWER and GT-SUITE

GT-POWER is the industry's first choice when reliable results are needed for engine thermodynamics and combustion/emissions development. The intelligent integration of modules within it [GEM 3D; Cool 3D; GT - VTD; GT - TAItherm ] coupled with Simulink, Star CD, Converge, Fluent and other codes facilitates easy solutions for complex tasks early in the development phase and provides unparalleled accuracy during the detailed design phase.


  • Need of a 1D thermodynamic simulation tool
  • Overview of GT-POWER, GT valve train, GT cool, GT drive, etc.
  • Introduction to GUI
  • Templates and libraries
  • Representation of engine parts
  • Implicit vs Explicit approach
  • Navier Stoke equation relevance

2Week 2: SI Engine Modelling Techniques

Over the past decade, an increase in air pollution all around the globe as well as the recognition that fossil fuels will not be available forever, has inspired OEMs to develop electrified powertrains. But, this has also opened the door to investigate new technologies that could significantly improve the ‘old fashioned’ combustion engine in both efficiency and emissions. In this section you will get an in-depth look at the functioning of SI Engine operations.


  • Challenges in SI engine modelling
  • Combustion modelling approach
  • Port injection and Gasoline direct injection approach
  • Tumble modelling
  • Gas exchange modelling and analysis

3Week 3: Case Study on SI Engine

Virtual prototyping is an efficient and effective way to test new ideas. In this module, you will look into some aspects of SI Engine including the basics of fuel spray in the combustion chamber, spray and wall film models accounting for premixed and sooting diffusion combustion detecting knock precise heat transfer modeling.

  • Engine specifications for modeling
  • Performance and emission prediction

4Week 4: CI Engine Modelling Techniques

Understanding the mechanics for modelling combustion in a CI Engine. These solutions play an integral role in engine simulations to accurately predict performance, fuel consumption, and engine-out emissions. Various models are available to predict combustion and pollutant formation based on in-cylinder conditions, knock, cycle-to-cycle variation (CCV), and other related processes.  


  • Challenges in CI engine modelling
  • DI pulse Combustion modelling approach
  • Swirl modelling
  • Turbocharger modelling


5Week 5: Case Study on CI Engine

Further our understanding by modelling an ‘On road’ application by calibrating critical CI Engine concepts such as ignition delay time for mixtures of air, fuel, and residual gases using detailed kinetics. This challenge enables the user to understand the correlations for ignition delay (CI) or knock (SI) that consider the effect of pressure, temperature, equivalence ratio, residual gas fraction, fuel composition, etc.


  • Engine specifications for modelling

  • Performance and emission prediction

6Week 6: Turbocharger and Supercharger Modelling

Turbocharging allows automakers to reduce engine size and emissions while continuing to deliver the power and performance consumers demand. Students will be taken across the turbine and compressor mechanics to understand the fluid flow and to improve overall engine performance, reduce pollutant formation, optimize NVH and ensure component durability. 

  • Fixed geometry TC modelling
  • Wastegate TC modelling
  • Variable geometry turbine modelling
  • Two stage turbocharger modelling
  • Supercharger modelling
  • eTurbo modelling

7Week 7: Case Study on FRM Builder

GT-POWER engine models and the validated solution methodologies, can be used by the controls system engineer for ECU development, calibration, and testing to generate a fast running, real-time capable engine plant models. With seamless integration with Simulink and the most popular real-time software tools, controls engineers are empowered with the ability to run fully physical, crank angle resolved models, capable of predicting pressure wave dynamics and in-cylinder combustion in a real-time environment. Advanced control strategies, such as combustion control, can now be tested with a detailed physical engine model at significantly faster computation speeds with minimum effort and maximum accuracy, predictiveness, and fidelity.

  • Introduction to FRM builder
  • Modeling of various engines using FRM builder approach
  • Crank-angle resolved, physically conservative formulation for accurate results
  • Built-in DOE and Neural Network trainer for MV model development

8Week 8 : Aftertreatment Modelling Techniques

The starting point for development and optimization of exhaust gas aftertreatment systems is 1D simulation. GT’s Quasi steady state AFT solver offers unmatched modelling depth, simple model setup and extremely short simulation times – faster than real-time if desired. It solves the very demanding fluid flow, heat transfer and chemical reactions taking place in aftertreatment systems of modern IC engines by employing the most advanced set of physics and chemistry models. 

  • Introduction to chemical kinetics
  • modelling precious metal catalysts
  • Pre-defined test cases and scenarios

9Week 9: Case Study on 3-way Cat DOC DPF and SCR System

For the detailed 1D & 2D design of exhaust gas after-treatment components, GT-SUITE offers outstanding capabilities modelling all relevant physics and chemistry. This makes it a crucial element in the design, development and optimization of both diesel and gasoline after-treatment devices. Together with GEM 3D it forms a unique and dependable 1D/3D solution that can be applied consistently throughout the layout, concept and detailed design stages in both component and system development to provide a seamless development approach with the reuse of models and results among tools assuring maximum consistency and efficiency. The after-treatment system performance data integrated in-vehicle models are used to predict drive cycle emissions.

  • Modelling 3-way cat con
  • Modelling DOC
  • Modelling DPF
  • Modelling SCR

10Week 10: Optimization Techniques

Every GT license includes full access to a built-in optimizer that allows optimization of any combination of model inputs (factors) to maximize, minimize, or target any single or multiple model outputs (responses). Key features include: Multiple local and global search algorithms to exploring design trade-offs among multiple competing responses and constraints with the multi-objective Pareto optimization tool and the NSGA-III [Genetic search algorithm].

  • Design of experiments
  • Single-factor optimization
  • Multi-objective optimization
  • Case study on gas exchange optimization

11Week 11: Discretization Techniques

GEM3D is a 3D graphical pre-processor that combines building and importing tools used to create 1D GT-SUITE models from 3D geometries. From primitive components like pipes, flowsplits, etc. it can also be used to import 3D CAD models from other applications, like GT-SPACECLAIM.

  • Introduction to SPACECLAIM
  • Overview of GEM 3D
  • Discretizing intake manifold
  • Discretizing exhaust manifold

12Week 12: Hybrid Engine Modelling

Build any hybrid configuration with any level of electrification, including but not limited to: 48-volt mild hybrids with an electric boost, strong power-split hybrid (HEV), parallel through-the road (TTR) plug-in hybrids (PHEV), or battery electric vehicles (BEV) using a comprehensive controls library, including finite state machines in GT-SUITE, or co-simulate with Simulink to develop and optimize control algorithms.

  • Overview of hybrid system configuration
  • Modeling of P0 and P1 configuration
  • Built-in optimization and DOE tools to evaluate architectures, components, and control strategies


Projects Overview

Tractor Engine

Highlights

    • Perform calibration and simulation on a commercial application on road tractor engine to meet the performance and the emission requirements.
    • Case studies including baseline simulations that compares different variants [Naturally aspirated vs Turbocharged] for performance and [Cooled EGR configuration] for meeting NOx targets.


    AFT System

    Highlights

      • Detailed AFT circuit system integrated with the engine model to accurately model the chemistry that captures the engine out emissions using a 3 way catalytic converter
      • Modelling DOC , DPF and SCR with Urea Injection strategy to meet the stringent Euro emission norms for commercial CI engines.



      Eicher Pro

      Highlights

        Complete Engine + Aftertreatment modelling for a BS IV variant HDT [Heavy duty truck] by employing suitable in cylinder strategies and AFT techniques to convert the same into a BS VI compliant variant.



        WHO IS THIS COURSE FOR ?


        • The course is designed for beginners. All engineering students, and freshers who want to pursue a career in the automotive industry can take this course on 1D thermodynamic simulation tool.
        • Third and final year engineering students, Master’s students or even Phd students who are willing to use analysis tools in their projects can opt for this course.
        • This course will give students an insight on how to apply their engineering skills learned in books to real-world problems. Considering upcoming stringent emission norms there are ample opportunities.for students from mechanical, automotive, electronics (Electronic Control Unit) and chemical (aftertreatment) engineering backgrounds.

        SOFTWARE COVERED

        GT-ISE

        The GT-Power 1D thermodynamic tool is used dominantly all over the world in almost all automotive industries, major aviation industries, power sector, battery manufacturers, etc. There is great demand for engineers who have hands-on experience with 1D thermodynamic tools especially GT-Power.



        Flexible Course Fees

        Choose the plan that’s right for you

        Basic

        2 Months Access

        7000

        Per month for 3 months

        • Access Duration : 2 months
        • Mode of Delivery : Online
        • Project Portfolio : Available
        • Certification : Available
        • Email Support : Available
        • Forum Support : Available
        Premium

        Lifetime Access

        15000

        Per month for 3 months

        • Access Duration : Lifetime
        • Mode of Delivery : Online
        • Project Portfolio : Available
        • Certification : Available
        • Individual Video Support : 12/month
        • Group Video Support : 12/month
        • Email Support : Available
        • Forum Support : Available
        • Telephone Support : Available
        • Dedicated Support Engineer : Available

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        • Top 5% of the class will get a merit certificate
        • Course completion certificates will be provided to all students
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        Frequently Asked Questions

        1Who are the instructors and what is the learning process?

        Our instructors are industry experts working in Fortune 500 companies. We partner with them to deliver the lectures online. You will be given access to recorded content and assignments each week.

        2Are there any prerequisites for this course?

        You should be pursuing or have graduated with a B.E/B.Tech in Mechanical or Automotive Engineering.

        3What kind of support I can expect? What if I have doubts?

        Our support system is amazing!. You can read our reviews on Google to see this. We focus on one-on-one support which no one else does. We will communicate with you through videoconferencing, WhatsApp messages/calls, individual online sessions and also in person. Doubts and queries are addressed by a dedicated support engineer who is assigned to you to walk you through your problem areas and clarify any queries that you may have.


        4How is this different from what I learnt in college?

        Our courses are crafted after consultation with industry experts. This gives you the opportunity to apply what you have learned only as theory and work on projects that will give you a leg up in your career aspirations - be it an MS admit, a new job or growth within your organization. This course will help you bridge the gap between academia and industry and get you market-ready.

        5What advantages will I gain by taking this course?

        You will learn how to use GT-Power tool for system design, optimization post processing, engine modelling techniques, calibration of engines post processing techniques, etc. 

        You will have an edge over your peers by working extensively on industry-relevant projects, practice on tools and software that will set you apart and help you in getting ahead of the competition. Our course will strengthen your portfolio to get better grants and scholarship opportunities for MS Admits, explore options in Research & Development, and land that much-coveted job in top core companies. 



        6What topics does this course cover?

        Engine design is very complex and requires knowledge of thermodynamics, chemical kinetics, heat transfer, fluid mechanics, etc. The course covers the current challenges the industry is facing and how system design tools like GT-Power are used to handle these challenges effectively.


        7What makes 1D simulation different from 2D or 3D simulation and why is it relevant?

        The main difference here is that 2D/3D simulations show the interaction of individual components with their surroundings whereas 1D simulations show the entire design of a system and the interactions of the different components of this system. This makes a 1D simulation excellent for optimising the design of an entire system, while 3D simulation is great for determining the optimum design characteristics of individual components.



        8What software skills are you teaching and how well are these tools used in the industry?

        This course will help you to gain confidence to use the tool effectively for pre and post processing. You will gain skills to understand gas exchange process and therefore need of variable valve train system, forced induction selection methodology and therefore need of advanced turbocharging and supercharging systems, FRM builder methodology discretization techniques, etc. The GT-Power 1D thermodynamic tool is used dominantly all over the world in almost all automotive industries, major aviation industries, power sector, battery manufacturers, etc.  There is lot of demand to engineers who have hands on experience with 1D tool especially GT power.

        9What are the real-world applications for the tools and techniques that we will learn in this course?

        The existing stringent emission norms all over the world are pushing the automotive industries towards zero emissions. It is becoming very challenging to achieve legislative demands and customer expectations simultaneously. The emission norms have moved from laboratory to real-world called Real Driving Emission (RDE) norms. The simulation tools play an important role in facing these challenges in a cost-effective manner and coming out with optimised design in a short time. 

        10Which companies use these techniques and how?

        Here are some examples:

        Cummins India and USA - engine modelling, vehicle modelling, turbocharger matching, aftertreatment modelling and calibration, HiL and controller design, etc. for on-road application

        Jogn Deere India and USA - engine modelling, vehicle modelling, turbocharger matching, aftertreatment modelling and calibration, HiL and controller design etc. for off-road application

        Maruti Suzuki - engine modelling, vehicle modelling, turbocharger matching, aftertreatment modelling and calibration, HiL and controller design etc. for on-road application


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