Hardware-in-the-Loop-Based Virtual Calibration Approach to Meet Real Driving Emissions Requirements

Lee, Sung-Yong; Scheel, Thomas; Neumann, Daniel; Ehrly, Markus; Aktas, Sahin; Andert, Jakob; Koetter, Matthias; Miccio, Michele; Schaub, Joschka; Quérel, Carole

doi:10.4271/2018-01-0869

Cited by 39 publications

(16 citation statements)

References 36 publications

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“…Especially in conceptual design and technology selection as well as for On-Board Diagnostics (OBD) verifications, simulation-based test scenarios are used [59,60]. Increasing virtualization is also taking place in the area of drivability [10,61,62] and emissions calibration [63][64][65] to increase the efficiency of the development processes.…”

Section: Virtual Test Benchesmentioning

confidence: 99%

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

et al. 2021

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The combination of different propulsion and energy storage systems for hybrid vehicles is changing the focus in the field of powertrain calibration. Shorter time-to-market as well as stricter legal requirements regarding the validation of Real Driving Emissions (RDE) require the adaptation of current procedures and the implementation of new technologies in the powertrain development process. In order to achieve highest efficiencies and lowest pollutant emissions at the same time, the layout and calibration of the control strategies for the powertrain and the exhaust gas aftertreatment system must be precisely matched. An optimal operating strategy must take into account possible trade-offs in fuel consumption and emission levels, both under highly dynamic engine operation and under extended environmental operating conditions. To achieve this with a high degree of statistical certainty, the combination of advanced methods and the use of virtual test benches offers significant potential. An approach for such a combination is presented in this paper. Together with a Hardware-in-the-Loop (HiL) test bench, the novel methodology enables a targeted calibration process, specifically designed to address calibration challenges of hybridized powertrains. Virtual tests executed on a HiL test bench are used to efficiently generate data characterizing the behavior of the system under various conditions with a statistically based evaluation identifying white spots in measurement data, used for calibration and emission validation. In addition, critical sequences are identified in terms of emission intensity, fuel consumption or component conditions. Dedicated test scenarios are generated and applied on the HiL test bench, which take into account the state of the system and are adjusted depending on it. The example of one emission calibration use case is used to illustrate the benefits of using a HiL platform, which achieves approximately 20% reduction in calibration time by only showing differences of less than 2% for fuel consumption and emission levels compared to real vehicle tests.

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Section: Virtual Test Benchesmentioning

confidence: 99%

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

et al. 2021

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“…By this measure to revise the RDE calibration and validation procedures, a lesson learned for the current approaches can be taken into account to overcome the high testing efforts and provide benefits for the future calibration process. The lack of reproducibility 21–23 as a result of unpredictable environmental influences during road tests and the significant increase in possible test cases due to the expansion of the test boundary conditions 8,9,24–27 compared to previous legislation and the increasing complexity of powertrains and engine control units (ECUs) 28 requires the integration of X-in-the-Loop approaches 23,30–34 and supporting tests for monitoring RDE validation on the test bench. 12 Manufacturers mainly investigate validation test matrices consisting of fleet-generic cycles and on-road tests with portable emission measurement systems (PEMSs) to assess whether the type approval tests can be passed.…”

Section: Current and Future Challenges To Comply With The Rde Requirementioning

confidence: 99%

Statistically supported real driving emission calibration: Using cycle generation to provide vehicle-specific and statistically representative test scenarios for Euro 7

Claßen

Pischinger

Krysmon

et al. 2020

International Journal of Engine Research

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The progression of emission legislation has intensified the efforts of the automotive industry to develop improved exhaust gas after-treatment systems. The requirement to fulfill Euro 6d-TEMP in real-world driving scenarios, the already significant calibration effort for Euro 6d and the Euro 7 emission standards in discussion have significantly increased the work load for calibration engineers and the requirements for testing resources. Many original equipment manufacturers are implementing taskforces in order not to have to discard the planned start of production for their products, and some are even already forced to reduce their product portfolio. This is due to the diverse testing matrix required to cover all possible real driving emissions test scenarios. One big challenge is the extension and possible variation of boundary conditions regarding ambient temperatures, traffic conditions, road gradients and other varying driving resistances. Moreover, the test duration can cause considerable differences in the measured emissions, even if the same route is driven repeatedly. Addressing these challenges makes the application of a dedicated, event-targeted emission calibration mandatory. Since only a few sequences of the time-consuming road tests are relevant for improving the emission calibration, the methodology presented in this article focuses on the exact reproduction of these emission events on an emission chassis dynamometer with the aim of implementing calibratable solutions for these events. This is done using a real driving emission-cycle-generator which creates real driving emission compliant severe test scenarios and which focuses on the statistical relevance related to the typical product specific operation. The underlying generation process accesses a large database with real driving emission measurement results focusing on vehicle- or vehicle-group-specific challenges, using statistical approaches. It will be demonstrated how this procedure reduces test time and how it helps to tackle the substantial real driving emission work-load, while providing a dependable base to achieve real driving emission legislation compliance.

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“…The latter two approaches, however, need an extended exchange of fundamental information (for example c-code or map file) between an Original Equipment Manufacturer (OEM) and participating suppliers (function and software (SW) developers). The HiL system provides a strong solution for an ECU calibration platform [21] and, compared to other X in the loop applications, it grants an excellent trade-off between the effort for testing set-up and the reproducibility of testing conditions [22].…”

Section: Introductionmentioning

confidence: 99%

“…To enhance the system-level understanding of ECU software and complex powertrain at different development steps, the HiL-based virtual calibration approaches are a solution for parametrization of ECU functions and integration of calibration and functional updates. The HiL environment helps to manage hardware changes, requirement changes, software releases as well as complex interactions of many control functions and to validate powertrains derivatives as reported in [22]. The authors have transferred these advanced, future-oriented virtual calibration methods into the standard calibration process and this article will provide, through different case studies, an overview of the key success factors and experiences made along the way.…”

Section: Introductionmentioning

confidence: 99%

Towards a Powerful Hardware-in-the-Loop System for Virtual Calibration of an Off-Road Diesel Engine

Riccio

Monzani²,

Landi³

2022

Energies

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A common challenge among internal combustion engine (ICE) manufacturers is shortening the development time while facing requirements and specifications that are becoming more complex and border in scope. Virtual simulation and calibration are effective instruments in the face of these demands. This article presents the development of zero-dimensional (0D)—real-time engine and exhaust after-treatment system (EAS) models and their deployment on a Virtual test bench (VTB). The models are created using a series of measurements acquired in a real test bench, carefully performed in view of ensuring the highest reliability of the models themselves. A zero-dimensional approach was chosen to guarantee that models could be run in real-time and interfaced to the real engine Electronic Control Unit (ECU). Being physically based models, they react to changes in the ECU calibration parameters. Once the models are validated, they are then integrated into a Simulink® based architecture with all the Inputs/Outputs connections to the ECU. This Simulink® model is then deployed on a Hardware in the Loop (HiL) machine for ECU testing and calibration. The results for engine and EAS performance and emissions align with both steady-state and transient measurements. Finally, two different applications of the HiL system are presented to explain the opportunities and advantages of this tool integrated within the standard engine development. Examples cited refer to altitude calibration activities and soot loading investigation on vehicle duty cycles. The cases described in this work are part of the actual development of one of the latest engines developed by Kohler Engines: the KDI 1903 TCR Stage V. The application of this methodology reveals a great potential for engine development and may become an essential tool for calibration engineers.

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Hardware-in-the-Loop-Based Virtual Calibration Approach to Meet Real Driving Emissions Requirements

Cited by 39 publications

References 36 publications

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

Real Driving Emissions—Conception of a Data-Driven Calibration Methodology for Hybrid Powertrains Combining Statistical Analysis and Virtual Calibration Platforms

Statistically supported real driving emission calibration: Using cycle generation to provide vehicle-specific and statistically representative test scenarios for Euro 7

Towards a Powerful Hardware-in-the-Loop System for Virtual Calibration of an Off-Road Diesel Engine

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