Development of an Software Algorithm Based Semi-automated Data Acquisition System for Gasoline Vehicle Calibration on Chassis Dynamometer

Vehicle level testing is one of the crucial part of the calibration development. In this, chassis dynamometer is used to collect the vehicle level data. Different engine and vehicle level parameters are logged at various speed and load points covering the entire engine operational zone. This data acquisition is a repetitive activity and covers over 30-40% of the total testing duration. This phase includes base calibration verification, transient development, and emissions-related calibrations, all of which follow a standardized and repetitive sequence. However, these tasks are predominantly performed manually, leading to potential human error and inefficiencies. This paper presents a novel and comprehensive algorithm developed using INCA FLOW software; the first of its kind for this application. Here, crucial vehicle data acquisition activities are identified, mapped into detailed steps. The algorithm introduces a semi-automated, stepwise process for data acquisition during chassis dynamometer testing, significantly reducing manual intervention. The different safety monitoring conditions are also introduced to take care of possible failure conditions occurring due to thermal and mechanical limits of the engine, vehicle and human safety while testing. Additionally, a sophisticated data processing algorithm has been designed to significantly reduce manual intervention, improve data accuracy, and streamline the overall calibration development timeline.