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Both the automotive and truck industry are facing further regulated emissions legislation in the near future. Understanding the emissions and fuel consumption attributes of an engine/vehicle application during a drive cycle early in an engine development program is a critical step to steer the engine development program to a successful final product. The generally accepted approach is to calibrate an engine on a dynamometer and to adjust the operation of the engine to meet performance targets. With the current build and test approach, these adjustments may not be made until well into the development program, and this calibration is a costly and time consuming step in the engine development process.

Race engine development is a complex multidimensional problem with a large number of interacting parameters. The competitiveness of the engine requires that this set of parameters be fully optimized, and the inevitable limitations of program budget require that this complex optimization task be done quickly and cost-effectively. What is described here is a methodology that has been developed as an addition to traditional techniques; to speed the development process by the use of power development knowledge and computer aided tools. A sound physical model of the engine is manipulated by the use of design of experiment (DOE) tools, and the repetitious iteration of all the calibration parameters is automated This allows for an optimized solution to be converged upon without analyzing every possible combination of parameters.