Lean Approach for Virtual Calibration Using Hardware-in-the-Loop and Electronic Control Unit (ECU)-Capable Engine Simulation

Gottorf, Simon; Fryjan, Johannes; Leyens, Lucas; Picerno, Mario; Habermann, Knut; Pischinger, Stefan

doi:10.4271/03-14-04-0032

Cited by 5 publications

(2 citation statements)

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“…For the HiL setup, the entire vehicle is typically simulated, including all drive components and, if required, also the emissions. The ECU or HCU are coupled with the simulation as real components [69,70]. The highest virtualization level is used in the MiL or Software-inthe-Loop (SiL) setup.…”

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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“…Physics-based mean value approaches have been used to predict the engine behavior throughout the operational driving cycle while enhancing its adaptability through the use of multi-scale or mixed modeling accuracy [21,22]. The implementation of computationally inexpensive algorithms, and the search for lean approaches to optimize the model calibration effort, emissions prediction, and processes, are actual topics of research [23][24][25][26][27][28][29]. On the other hand, the integration of chemistry-based simulation processes to improve accuracy and to enhance the extrapolation capability in extreme ambient conditions has made its way also in both research and industrial applications [30][31][32][33].…”

Section: Challenges In Virtual Ecu Calibrationmentioning

confidence: 99%

Real-Time Emission Prediction with Detailed Chemistry under Transient Conditions for Hardware-in-the-Loop Simulations

Picerno

Lee

Pasternak³

et al. 2021

Energies

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The increasing requirements to further reduce pollutant emissions, particularly with regard to the upcoming Euro 7 (EU7) legislation, cause further technical and economic challenges for the development of internal combustion engines. All the emission reduction technologies lead to an increasing complexity not only of the hardware, but also of the control functions to be deployed in engine control units (ECUs). Virtualization has become a necessity in the development process in order to be able to handle the increasing complexity. The virtual development and calibration of ECUs using hardware-in-the-loop (HiL) systems with accurate engine models is an effective method to achieve cost and quality targets. In particular, the selection of the best-practice engine model to fulfil accuracy and time targets is essential to success. In this context, this paper presents a physically- and chemically-based stochastic reactor model (SRM) with tabulated chemistry for the prediction of engine raw emissions for real-time (RT) applications. First, an efficient approach for a time-optimal parametrization of the models in steady-state conditions is developed. The co-simulation of both engine model domains is then established via a functional mock-up interface (FMI) and deployed to a simulation platform. Finally, the proposed RT platform demonstrates its prediction and extrapolation capabilities in transient driving scenarios. A comparative evaluation with engine test dynamometer and vehicle measurement data from worldwide harmonized light vehicles test cycle (WLTC) and real driving emissions (RDE) tests depicts the accuracy of the platform in terms of fuel consumption (within 4% deviation in the WLTC cycle) as well as NOx and soot emissions (both within 20%).

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Development of virtual control terminal for high-horsepower tractor control system based on ISO-11783 protocol

Huang,

Bai,

Qiu

et al. 2024

Preprint

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Precision control is a crucial aspect of fine agriculture. Enhancing the control performance of agricultural and forestry vehicles can reduce driver fatigue, improve productivity, and enhance operational accuracy. This study focuses on the ISO-11783 protocol of the serial communication network of a high-horsepower tractor control system. It combines the information frame of the controller area network (CAN) arbitration field and designs the CAN communication protocol network topology for the high-horsepower tractor control system. Based on the time-hierarchical controller area network protocol, the CAN communication protocol of the high-powered tractor control system is optimized to achieve dynamic scheduling of telegram messages. To evaluate the effectiveness of the virtual control terminal of the high-powered tractor control system designed in this paper, simulation tests and analyses are conducted. The results demonstrate that when the tractor speed drops below 15 km/h, the high-powered tractor engages the four-wheel-drive state, and when the tractor engine enters the idling state at 30.2 seconds, the tractor speed decreases considerably. Meanwhile, the CAN message update period obtained using the time-hierarchical controller area network is 86.5 ms, and the maximum transmission delay time of CAN message is 0.92 ms. The virtual terminal of the control system of the high-powered tractor designed with the ISO-11783 protocol can effectively carry out the state control of the high-powered tractor. It meets the requirements of real-time communication, ensuring the reliability of CAN communication and enabling the high-powered tractor to operate safely according to the driver's intention.

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Lean Approach for Virtual Calibration Using Hardware-in-the-Loop and Electronic Control Unit (ECU)-Capable Engine Simulation

Cited by 5 publications

References 0 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

Real-Time Emission Prediction with Detailed Chemistry under Transient Conditions for Hardware-in-the-Loop Simulations

Development of virtual control terminal for high-horsepower tractor control system based on ISO-11783 protocol

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