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

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 HiL (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 HiL 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. This paper presents the methodology for creating and calibrating a computational model of a heavy-duty diesel engine suitable for HiL simulations. The novelty of the study is two-fold: it relies solely on engine dynamometer test data (does not use manufacturers’ inputs) and it employs a generic builder in GT-SUITE simulation software to create a baseline real-time model for calibration (does not rely on a detailed simulation model). The obtained results for engine performance and exhaust emissions provide favorable results for both steady-state and transient operating conditions. The developed model is successfully employed at the VIRTEC (VIRtual Test Cell) system at Volvo Penta for the purpose of validation and optimization of engine control strategies.