Portfolio

Ford Cmax Powertrain Harmonic Oscillation analysis / Fix

Long standing production problem in Ford Hybrid System (Ford internal name Bang Oscillation) of abnormally high dynamic loads. Hardware analysis led to discovery of harmonic overlap of 2 systems.
Root caused errors in simulation parameters and core methods which lead to inaccurate results.
Implemented a robust hardware test process to obtain component parameters which improved the simulation accuracy by 40% relative to test data.
Test method updates implemented worldwide
Developed AmeSim App (Force App) to automate up to 18 DOF analysis
proptype build with before / after test (100 g-force load reduction)
Organized executive ride and drive at test track for A/B comparison

Led team building ADAMS powertrain model for test playback for correlation
Full vehicle model / SIL used to sweep initial speed for panic ABS stop / launch event over 6 separate 3d roads
Post processing of road data to determine peak loads for load forecasting / data visualization.
Peak load forecasting results cascade to mounts / transmission / structure fatigue teams
Dynamic parameters testing method developed for future programs and PT Dyno testing

8 DOF model, automated AI/ML method of parameter tuning such that model matches test for modal, operational harmonics and gear lash

Worked with numerous vehicle teams in development of plant models with sufficient fidelity to reproduce test event issues
Correlated plant models integrated into a closed loop SIL to enable desktop calibration of test event issues
Developed scenario sweeping and surface visualization methods to help calibrators visualize results in new ways

Invented / developed predictive feed forward driver model to replace PID system
Pedal driver emulates a human driver beautifully and has adjustable aggressiveness
Pedal driver model / robot automatically characterizes itself in SIL and Dyno, leading to significant cost savings by eliminating supplier Dyno robot driver
Greatly simplified user front end
Used in Fuel Economy certification in Ford

Dynamic, simplified plant model include external ratio and inertia input
Separate torque and inertia phasing and a variety of potential transmission hardware options / loss scenarios
System was flexible for potential future programs
Simplified control methods specifically for simplified plant model to enable smooth shifting with little calibration change across different target hardware
Simplified control handled the complex interaction of engine start / shutdown / gear shifting while maintaining near perfect drivability
The simplified transmission system was used for Explorer production hybrid and engine control strategy development
Simplified system was developed in 2007 for systems groups and later extended for Modular Hybrid Transmission Systems Control development until AmeSim hydraulic transmission / SIL was available