Engine Mass Flow Estimation through Neural Network Modeling in Semi-Transient Conditions: A New Calibration Approach

Nowadays, engine experimental research represents a very expensive field within the automotive industry, but it remains fundamental for engine and vehicle development. The present work aims to investigate a novel approach for engine control system calibration, by adopting machine learning techniques to model physical parameters of the engine starting from experimental data measured at the test bench. The main goal is to create a methodology which accelerates the calibration process without losing accuracy. A model that estimates air mass flow is created by adopting either a tree ensemble model or an artificial neural network trained on a small dataset, which was previously acquired at the test bench using a random calibration of the volumetric efficiency map. The model’s performance is first validated on a larger, random dataset. Then, the volumetric efficiency calculated from the air mass flow model estimation is used to calibrate the transfer function of the Engine Control Unit. Finally, the sensitivity of the model error correlated with the number of data points acquired is used in order to determine the best practice for a Design Of Experiment, which minimizes data acquisition. The methodology proposed can lead to reduced time and costs of the whole calibration process of the engine, without losing accuracy. The analysis was conducted on the entire vehicle, which is crucial for drivability, especially in motorcycles since they are highly sensitive to air-to-fuel ratio adjustments. This work demonstrates that machine learning models can be adopted for the fine-tuning of the calibration process, which is normally performed manually.