Engine calibration is the tuning of embedded parameters in the engine control unit (ECU) software to improve vehicle characteristics and meet legal requirements. Due to the stricter emission limits and rising customer expectations, current ECU software may include variables up to 30,000, which require very much time for engine calibration development. For this reason, automotive manufacturers continuously develop mathematical-based optimization methods to find optimum operating conditions for the engines. This study aimed to develop an online optimization algorithm to conduct automated dynamometer tests in the calibration development process. A modified covariance matrix adaptation (CMA) algorithm, which is an evolutionary strategy (ES) method belonging to meta-heuristic optimization, was integrated with an automation system for online calibration optimization. Some CMA method parameters such as step size and damping factor were initially revised to achieve the method to function efficiently in online engine calibration. Optimization was conducted at three different operating points of a 2-liter common rail direct injection (CRDI) diesel engine, where NOx emission mainly impacts the New European Driving Cycle (NEDC) results. The main injection timing, rail pressure, pilot injection quantity and timing, manifold pressure, and mass air flow were controlled in the optimization process. Optimization targets were determined according to the NOx-PM Pareto curve for each operating point. Covariance matrix adaptation was used to generate Pareto curves. Sixty-five measurements were taken for each operating point in the optimization process. Once optimization targets were determined, optimization occurred at each operating point. A total NOx emission reduction of 3.8% was obtained in the NEDC test, while fuel consumption and PM remained almost the same at steady-state operating points. The modified CMA-ES algorithm is expected to be an efficient method for online calibration optimization.
