Alfonso Fabio Mitilini
Model-Based ECU calibration: leveraging Machine Learning to optimize engine test time.
Rel. Federico Millo. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Elettronica (Electronic Engineering), 2025
Abstract
Engine ECU calibration is costly, time-consuming, and requires expert effort. Traditionally, for each operating point (fixed speed × load) engineers test many input–parameter combinations, measure the output, and iteratively retune an approach that becomes impractical as the number of parameters grows. This thesis investigates the potential of Machine Learning to develop new control-calibration methods, with the aim of drastically reducing calibration effort and improving robustness in real-world operations. Premise. With surrogate models, the primary objective is to learn a predictor with high accuracy across the entire admissible input domain while using as few training points as possible. Achieving this reduces physical engine tests and there- fore development time and cost.
In an open-loop configuration, the only effective lever to cut the number of points is the shape and quality of the initial space-filling DoE—i.e., the workflow is fixed and non-adaptive: a DoE is generated a priori, the points are tested on the engine, outputs are collected, a model surrogate is trained, and calibration is performed on the surrogate alone; this hinges on the surrogate having high predictive capability over the reference domain
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