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Drivability and powertrain refinement continue to gain importance in the assessment of overall vehicle quality. This notion has transcended its light duty origins and is beginning to gain considerable traction in the medium and heavy duty markets. However, with drivability assessment and refinement also comes the high costs associated with vehicle testing, including items such as test facilities, prototype component evaluation, fuel and human resources. Taking all of this into account, any and all measures must be used to reduce the cost of drivability evaluation and powertrain refinement. This paper describes an analysis based co-simulation methodology, where sophisticated powertrain simulation and objective drivability evaluation tools can be used to predict vehicle drivability. A fast running GT power engine model combined with simplified controls representation in Matlab/Simulink was used to predict engine transients and responses.

Cummins has recently launched next-generation aftertreatment technology, the Single ModuleTM aftertreatment system, for medium-duty and heavy-duty engines used in on-highway and off-highway applications. Besides meeting EPA 2010+ and Euro VI regulations, the Single ModuleTM aftertreatment system offers 60% volume and 40% weight reductions compared to current aftertreatment systems. In this work, we present model-based approaches that were systematically adopted in the design and development of the Cummins Single ModuleTM aftertreatment system. Particularly, a variety of analytical and experimental component-level and system-level validation tools have been used to optimize DOC, DPF, SCR/ASC, as well as the DEF decomposition device.