RDE ENGINEERING AT THE ENGINE TEST BENCH Jan Gerstenberg, Dr. Sandra Sterzing-Oppel, Dr. Benjamin Hartmann, Dr. Stephan Tafel Bosch Engineering GmbH
Overview RDE challenges Engineering strategies Engine-in-the-loop [EiL] tool-chain RDE Data Analyzer Summary 2
tomorrow today RDE Engineering Today and Tomorrow Organization 3 Torque / (Nm) T Exhaust / ( C) 8 7 6 5 4 3 2 1 NEDC WLTC RDE normal RDE aggressive 1 2 3 1 2 3 1 2 3 1 2 3 Engine Speed / (rpm) 6 4 2 4 8 12 6 12 18 2 4 2 4 Time / (s) Engine Hardware Engine Software Gearbox Control RDE enabling Driveability After treatment RDE could lead to an organisational change during the development phase.
RDE Engineering Strategies Road test (PEMS) Only real road tests Chassis dyno Chassis dyno + engine test-bench Vehicle simulation + engine test-bench [EIL***] Stand-alone Copy values to engine test-bench Vehicle-, driver and tracksimulation Environmentsimulation Driver/ Vehicle- PEMS Simulation Chassis Dyno Chassis Dyno GPS Data Driver-/vehicle simulation RDE RDE test reproducibility RDE tests/24h multiple variants testing RDE development w/o vehicle HEV simulation Real Road +++* + 4 Chassis Dyno ++** + + Engine Testbench Engine Testbench [EIL] +++ +++ ++ ++ + +++ +++ +++ +++ +++ +++ most suitable ++ suitable + useable not efficient *PEMS is legally relevant **no robot driver ***EIL Engine-in-the-loop
RDE Engineering RDE-Analysis using Engine-in-the-loop (EiL) Longitude Latitude roadgrade GPS data of track 1 Engine speed accelerator-pedal Simulation (InMotion/ CarMaker) RDE engine test-bench RDE track 1 Sim. vehicle Sim. driver Engine Aftertreatment Measure Equipment Track: 64 km Latitude Höhe / (m) altitude [kph] Longitude 55 5 45 4 35 3 25 1 2 3 4 5 6 7 Distanz / (m) Distance [m] 12 8 4 speed [kph] Geschwindigkeit / (km/h) Engine torque Emission 5
Etas ES91 RDE Frontloading Setup CANoe-PC Electronic control unit Flexray engine dyno Mess-CAN ETK Hardware Interface Vector ch1/5 ch3/7 Ch A Ch B Ch A Ch B ETAS Interface module CAN1 FLX1 ETK Host Cal-PC Test-bench automation PUMA CAN1 CAN3 Simulation CarMaker: vehicle, track, CAN1 CAN2 traffic, gearbox Residual bus 6
performance performance RDE Frontloading Engineering competences in-house Pedal-lift in driver model Fixed-deltatorque intervention d. shifting Delta-torque by feedbackmodel Basic map Sport, altitude, driver Code-extract from TCU complexity complexity Depending on the project case different performance steps are possible. 7
RDE Frontloading Example RDE project: Acceleration 2 8-4 -16 135 12 15 9 12 18 96 84 1 4 9-4 8-48 7-92 1 2 Nr.Linienfarbe Name Cursor 1Cursor 2Cursor-Diff. Einheiten 1 [1] zw [1] opt_msg\etkc:1 zw opt_msg\et... 17.25 15.75-1.5 Grad KW 2 [1] zw [1] outakt_msg\etk... zw outakt_msg... 19.5* -11.25*-3.75Grad KW 3 [1] redistb1_msg\etkc:1 [1] redistb1_msg\... 4 [1] redistb2_msg\etkc:1 [1] redistb2_msg\... Ignition retard 5 [1] [1] VehV_v\ETKC:1 94.8* 95.6*.8 km/h 6 [1] ActMod_trqClth\ETK... [1] ActMod_trqClt... 156.6 74.6-82 Nm 7 [1] Epm_nEng\ETKC:1 [1] Epm_nEng\ETK... 2989.5*2596.5*-393 rpm 8 [1] Strg_phiWhl\ETKC:1 [1] Strg_phiWhl\ET... deg StWhl Fuel cut-off [1] redistb1_msg\etkc:1-28 -4-52 [1] VehV_v\ETKC:1 75 6 45 [1] Strg_phiWhl\ETKC:1 72 6 [1] zwopt_msg\etkc:1 6-136 5-18 48 4-224 velocity torque -64 3 36 3-268 engine-speed -76 15 24 2-312 steering -88 12 1-356 -1-15 -4 C D E F 3 4 5 Zeit s 6 7 Datum: 2.8.216 Zeit: 15:36 Aufzeichnungsdauer: :1:38 Datenbank: 1535x_porschev8kovomo_rde_inno_v2 Experiment: Torque MDG1_1SG_KoVOMo_V8_IBN_MPST_21781 demand from gear box simulation \31-Prüfstandsmessungen\1-Restbus_Schalten\216-8-2 provided by CarMaker. Arbeitsumgebung: Arbeitsumgebung Geräte: ETKC:1,FLX Monitoring A:1,CAN-Monitoring:1 Programmbeschreibung: 1585_MY18B1_IFX, RBS_Pruefstand_216421 AS: DM4E5_B1CI22_PTA8_RDE_MHEV-PST-DCMs_IBN_216722A_1 Datum: 2/8/216 Zeit: 15:34:39 Benutzer: RIN4ABT Firma: Bosch Engineering GmbH Fahrzeug: IN-J-774 Projekt: KoVOMo V8T Messdatei: [1] \\bosch\dfsrb\dfsde\div\beg\dgp\5_prj_t\ _RB\BEG\47997_RDE_Inno_216\3_Cal\1_272_Otto_RDE _KoVOMo_V8T_Test_5_MD_Red_ok3_m_lenkw inkel.dat 8
RDE Frontloading Example RDE project: 1-2 upshift 18 16 14 12 135 12 15 9 12 18 96 84 1 4 9-4 8-48 7-92 1 2 Nr.Linienfarbe Name Cursor 1Cursor 2Cursor-Diff. Einheiten 1 [1] zw [1] opt_msg\etkc:1 zw opt_msg\et... 16.5* 16.5* Grad KW 2 [1] zw [1] outakt_msg\etkc:1 zw outakt_msg\... -8.25* -11.25*-3 Grad KW 3 [1] redistb1_msg\etkc:1 [1] redistb1_msg\e... 1* * -1 Ignition timing 4 [1] redistb2_msg\etkc:1 [1] redistb2_msg\e... 1* 1* 5 [1] [1] VehV_v\ETKC:1 25.75 27.42 1.67km/h 6 [1] ActMod_trqClth\ETK... [1] ActMod_trqClth\... 36* 44.5* 8.5 Nm 7 [1] Epm_nEng\ETKC:1 [1] Epm_nEng\ETK... 2834.5*2474.5*-36rpm 8 [1] Strg_phiWhl\ETKC:1 [1] Strg_phiWhl\ET... * * deg StWhl torque [1] redistb1_msg\etkc:1 1 8 6 [1] VehV_v\ETKC:1 75 6 45 [1] Strg_phiWhl\ETKC:1 72 6 [1] zwopt_msg\etkc:1 6-136 5-18 48 4-224 engine-speed ignition 4 3 36 3-268 2 15 24 2-312 12 1-356 -2-15 -4 C D E F 27 28 Zeit s 29 3 Datum: 2.8.216 Zeit: 15:36 Aufzeichnungsdauer: :1:38 Datenbank: 1535x_porschev8kovomo_rde_inno_v2 Experiment: MDG1_1SG_KoVOMo_V8_IBN_MPST_21781 Arbeitsumgebung: Arbeitsumgebung Geräte: ETKC:1,FLX Monitoring A:1,CAN-Monitoring:1 Programmbeschreibung: 1585_MY18B1_IFX, RBS_Pruefstand_216421 AS: DM4E5_B1CI22_PTA8_RDE_MHEV-PST-DCMs_IBN_216722A_1 Torque request by TCU can be modified _KoVOMo_V8T_Test_5_MD_Red_ok3_m_lenkw in the simulation inkel.dat (engineering). 9 Datum: 2/8/216 Zeit: 15:34:39 Benutzer: RIN4ABT Firma: Bosch Engineering GmbH Fahrzeug: IN-J-774 Projekt: KoVOMo V8T Messdatei: [1] \\bosch\dfsrb\dfsde\div\beg\dgp\5_prj_t\ _RB\BEG\47997_RDE_Inno_216\3_Cal\1_272_Otto_RDE \31-Prüfstandsmessungen\1-Restbus_Schalten\216-8-2
RDE Frontloading Simulation Real Driving at Engine Test-Bench Vehicle simulation @ testbench Alpha- AccPed Test bench: urban driving GPS tracks simulated vehicles simulated gearboxes real engines 1
RDE Engineering Matrix Test Configuration on Test Bench (EiL) RDE track Stuttgart RDE track Driver characteristics Mild Boundary conditions No traffic Mountain track Austria Aggressive (hot) Heavy traffic London city Nervous Traffic Hannover flat RDE track Normal 12-35 C ambient temp. Multiple test situations (event-matrix) to enable a frontloading for RDE Engineering. 11
RDE Engineering RDE Data Analyzer Automatic data analysis to improve efficiency. 12
RDE Engineering Virtual Vehicle at Engine Test-Bench: Traffic, Drivers NOx CO2 Driver set-up % % easy going 1. 1. normal 19. 11.4 nervous 115.7 12.3 System test for heavy traffic Nervous driver worst case test 13
RDE Engineering Summary The engine test-bench combined with a vehicle simulation enables to work in a reproducible area with a minimum demand for test vehicles. RDE Frontloading to save time and costs Variation of different tracks, traffic conditions and driver behavior. Evaluation of new components in the overall system. Special investigations possible (OBD, GPS-based functions, Aftertreatment performance) Early variants approval for hard- and software optimizations before running PEMS-tests. 14
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