VIRTUAL HYBRID ON THE ENGINE TEST BENCH SMART FRONTLOADING

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1 VIRTUAL HYBRID ON THE ENGINE TEST BENCH SMART FRONTLOADING RDE ENGINEERING [EIL] J. GERSTENBERG, DR. S. STERZING-OPPEL, C. FISCHER, B. SEIDEL, D. TRENKLE, M. OFF, DR. M. GLORA

2 Overview RDE tool chain Virtual hybrid Measurement Engineering process Summary 2

3 RDE engineering tool chain & data analysis today Innovation projects Diesel, Gasoline Customer projects Diesel and Gasoline Co-simulation TCU Introduction virtual DCT Virtual Hybrid Dynamic Tool RDE Data Analyzer RDE Track Check RDE Shifting Analyzer RDE Driver Analyzer 3

4 Altitude [m] Virtual hybrid smart front loading Configuration GPS Data RDE Track Vehicle-, driver, -road simulation InMotion powered by CarMaker BUS BUS Engine ECU Combustion engine BUS BUS Add-ons gearbox / hybrid simulation (optional) Engine-in-the-loop Real engine with advanced simulation tools Vehicle simulation Track simulation Driver simulation Höhe / (m) Latitude Longitude Distanz / (m) Distance Input Data Geschwindigkeit / (km/h) Speed [kph] Virtual Vehicle Brakes Track (incl. friction) Steering Vehicle torque Driver behavior Pedal angle CAN CAN Engine dyno Test bench automation AVL-Puma BUS BUS Virtual TCU Converter clutch Actual gear ratio Differential gear Gear box torque Virtual VCU Hybrid strategy Battery simulation Battery charging System Torque (Combustion engine + electric motor) Gearbox simulation Hybrid simulation [m] Setup engine-in-the-loop engine test bench 4

5 Powertrain Control Unit Virtual hybrid smart front loading System architecture Engine test bench ECU Engine Dyno IPG CarMaker HiL Desired Torque Measured Torque Engine Speed Track Driver Des. trq Des. gear ECU MCU TCU Engine wrapper fcn. Vehicle BCU Dynamics Powertrain Virtual hybrid components CarMaker model substituted by real hardware: engine control unit, engine CarMaker powertrain control unit model substituted by virtual hybrid control unit: Simulink RTW model Models Real systems 5

6 Virtual hybrid at the engine test bench on a gps based track around Schwäbisch Hall 6

7 Measure example to EiL video calibration tests Vehicle development 7 Frontloading engineering for complex powertrains before test vehicle available Engine available RDE tests at EiL test bench with virtual vehicle vehicle available

8 ICE & virtual hybrid ICE vs. hybrid strategy Electric motor buffers torque peaks during acceleration phases CO reduction compared to ICE only motor supports hybrid strategy CO peak during ICE only 8

9 Virtual hybrid: PN emission reaction (cold start) The EiL test bench allows to reproduce PN behavior and offers a detailed optimization 9

10 CO 2 vs. particles in different power train concepts Different PHEV hybrid strategies lead to different results on a PN/CO2 trade off dis Bat. chg Bat. RTS-aggressive 10

11 Matrix test configuration on test bench (EiL) RDE track Driver acceleration Traffic Gear shifting Stuttgart Heavy Heavy traffic Early shifting Heilbronn Medium Mild traffic Late shifting Schwäbisch Hall (hilly road) Low Traffic jam Lazy shifting (no back shifting during acceleration) Schwieberdingen Driver Acceleration: aggressive driver with heavy, mild driver with low acceleration Gear shifting characteristics: aggressive driver mild driver engine speed Braking: Deceleration: -3m/s² Curve velocity: mild driver with lower velocity while driving curves re-acceleration to target velocity Traffic: Driving during heavy traffic requires acceleration and deceleration around target velocity, traffic jam with stand still phases Depending on other inputs a driver with low acceleration could lead to high emissions 11

12 Virtual hybrid smart front loading Analysis of driving pattern NEDC driver 12 Average dynamics Mild dynamics High dynamics

13 Emissions Virtual hybrid smart front loading RDE Matrix: Test bench & vehicle tests Extra mild NEDC driver Bad case situation with challenging conditions Test tracks test bench vehicle traffic HN V2 HN V mild Dynamik-Index: v*a pos 95 [m 2 /s 3 ] sporty Matrix of RDE tests on different tracks and circled tests for robustness slightly above the limits 13

14 Process and Tools Example tracks, driver, traffic RDE test-bench Modeling basic Define powertrain topology in CarMaker Extent code by missing features Vehicle measurement Perform vehicle measurements as specified to obtain vehicle parameters (e.g. rolling resistance) Parameterization model, track, driver Set up offline simulation in CarMaker Implement data sheet parameter Determine measurement based parameter Residual bus simulation Set up communication hardware Determine signals to be stimulated Implement logic for dynamically calculated signals Engine launch on testbed Connect CarMaker powered by InMotion to testbed Vehicle model test online Communication test online Testbed automation Test automation system Define RDE matrix to be performed CarMaker special design PEMS RDE Track Check RDE Shifting Analyzer RDE Driver Analyzer 14

15 German OEM V6 TGDI Gasoline, GPF European OEM 3.0 V6 Diesel twin-turbo SCR, LP EGR European OEM cyl. Diesel SCR ATZ September 2015 RDE engineering environment on dynamic engine test bench German OEM European OEM Virtual hybrid 16. Stgt. Symposium 8 cyl. Bi-turbo TDGI Gasoline 12 cyl. Turbo Gasoline 4 cyl. Turbo Gasoline Introducing a method to evaluate RDE demands at the engine test bench Reference projects of several types of vehicle 15

16 Summary The engine test bench combined with a vehicle simulation, enable to work in a reproducible area with a minimum demand for test vehicles. RDE frontloading to save time and costs (minimize risk of iterations) Variation of different tracks, traffic conditions and driver behavior Complex powertrains can be analyzed on real world behavior The future will bring more models which can be used in an early project phase to validate in the overall system. Complex powertrains must be investigated early for real world behavior 16

17 THANK YOU

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