The aim of this work is to elaborate a new simulation-based development methodology, virtual calibration, for the development of modern mobile propulsion and vehicle systems. Hardware-in-the-loop(HiL) simulation is a well-established testing environment. The main objective of the work is to extend the application fields of HiL to the calibration and validation of emission-related functions of engine control units (ECU) using real hardware ECUs and real-time capable plant models. The previous utilization of the model-based ECU calibration has provided only limited benefits for emission calibration, which requires the interaction of multiple involved powertrain components at the system level. However, the simulation of a complete vehicle and its environment is often neglected due to its complexity. Therefore, in this work, the HiL-based approach is introduced to build a simulation platform that can reproduce the complex interactions between vehicle, driver and environment. However, there are numerous requirements on the model quality for the emissions under the transient and extended boundary conditions. The focus of the work is to develop an efficient HiL setup and a comprehensive HiL model landscape that is suitable for real-time simulation of diesel engine combustion and emission formation for emission calibration, despite the various uncertainties in model validation, e.g. measurement tolerances. In this regard, the problem statement and the objective are presented in the introduction chapter. This is followed by an overview of the current state of development in terms of vehicle calibration and simulation methodology, an overview of the developed HiL test bench and plant models, the validation and evaluation results as well as a discussion of the overall results. The application of physical plant models to predict transient engine behavior predestines the usage of the HiL test bench especially for ECU calibration. They allow extrapolation of system behavior under a wide range of Real Driving Emissions (RDE) conditions with limited development effort for model parameterization. In this work, highly flexible and accurate (semi-)physical mean value modeling (MVM)for internal combustion engines and its broad applicability for virtual vehicle calibration are discussed. Combined modeling approaches for heterogeneous domains of the internal Diesel combustion engine can be used to further increase simulation accuracy while meeting the requirements for flexibility, real-time capability, and accuracy. Regulatory requirements for RDE have significantly increased the demand for accurate as well as efficient engine modeling, especially for pollutant emissions. However, this has simultaneously led to an increase in simulation and modeling effort. Therefore, the present work demonstrates the practical application of various ECU calibration tasks to establish adequate modeling approaches. These allow the optimal trade-off between real-time capability, model complexity, and the effort required for modeling. However, the selection of the most appropriate models often depends on various project requirements, such as the accessibility of measured data from the base engine for characterizing the thermodynamic processes to be reproduced. Furthermore, the required quality of the reproduction of the required physical phenomena to be virtualized depends on the calibration tasks to be performed on the HiL test bench.
Virtuelle Kalibrierung von Motorsteuergeräten mittels Hardware-in-the-Loop Simulationen
Virtual calibration of engine control units using hardware-in-the-loop simulation
2023-01-01
1 Online-Ressource : Illustrationen pages
Dissertation, Rheinisch-Westfälische Technische Hochschule Aachen, 2023; Aachen : RWTH Aachen University 1 Online-Ressource : Illustrationen (2023). = Dissertation, Rheinisch-Westfälische Technische Hochschule Aachen, 2023
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German
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