Calibration Procedure for Measurement-Based Fast Running Model for Hardware-in-the-Loop Powertrain Systems

Journal article, 2020

The requirements set for the next-generation powertrain systems (e.g. performance and emissions) are becoming increasingly stringent with ever-shortening time-to-markets at reduced costs. To remain competitive automotive companies are progressively relying on model-driven development and virtual testing. Virtual test benches, such as Hardware-in the-Loop simulators, are powerful tools to reduce the amount of physical testing and speed up engine software calibration process. The introduction of these technologies places new, often conflicting demands (such as higher predictability, faster simulation speed, and reduced calibration effort ) upon simulation models used at Hardware-in-the-Loop test benches. The new models are also expected to offer compliance to industry standards, performance and usability to further increase the usage of virtual tests in powertrain development. The present work describes a novel verification process for creating a fast running model for a heavy-duty diesel engine using FRM-d Builder in GT-SUITE simulation software. The approach uniquely applies the combination physical modelling and parameter estimation techniques, while relying solely on test cell measurements without data maps from the manufactures (e.g. for turbine and compressor). The procedure provides detailed description for subsystem calibration for turbocharger and intake path. The developed model is successfully employed at the VIRTEC system in Volvo Penta. The simulation results for engine performance and exhaust emissions provide favourable results for both steady-state and transient operating conditions.