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Due to more and more complex powertrain architectures and the necessity to optimize them on the whole driving conditions, simulation tools are becoming indisputable for car manufacturers and suppliers. Indeed, simulation is at the basis of any algorithm aimed at finding the best compromise between fuel consumption, emissions, drivability, and performance during the conception phase. For hybrid vehicles, the energy management strategy is a key driver to ensure the best fuel consumption and thus has to be optimized carefully as well. In this regard, the coupling of an offline hybrid strategy optimizer (called HOT) based on Pontryagin’s minimum principle (PMP) and an online equivalent-consumption-minimization strategy (ECMS) generator is presented. Additionally, methods to estimate the efficiency maps and other overall characteristics of the main powertrain components (thermal engine, electric motor(s), and battery) from a few design parameters are shown.

Regulations in terms of pollutant emissions are becoming more and more constraining. The car manufacturers need to adopt a global optimisation approach of engine and exhaust after-treatment systems. An engine architecture definition coupled to an adapted control strategy seem to be an ideal way to address this issue. The problem is particularly complex, considering the trade off between the drivability which must be maintained, the reduction of the in-cylinder pollutant emissions, the reduction of the fuel consumption and the optimisation of the operating conditions to reach high conversion efficiencies via exhaust gas after-treatment systems. Sophisticated control strategies and models can only be developed with a complete understanding of the physical phenomena occurring in the combustion chamber, thanks to experimental measurements and engine system simulations.

This paper presents the development of torque-based engine control strategies for a downsized SI engine, from simulation design to final validation on a demonstration car. One main issue to reach performance, fuel consumption and pollutant emission demands is in-cylinder mass observation and control. A simulation-based approach is first presented to design accurate observers from a reference simulator. In this study, a multivariable and non-linear control has been developed and focused on in-cylinder mass trajectories. It has been tested on a real time Software-In-the-Loop platform before a complete validation and calibration on the test bed. Finally, the complete torque-based engine control has been successfully integrated on the vehicle.