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This paper describes a new approach for the calibration of engine management systems based on a newly developed calibration tool. This approach is based on the idea to design the calibration process of a certain calibration task by means of a computer based stateflow/workflow diagram. By means of library methods for certain calibration routines, the calibration engineer can design his calibration process in a Stateflow diagram and then transfer this function in an executable file, guiding and supporting the engineer for performing his task. Due to this approach a documentation of the calibration process, the performed calibration task and a guided and automated calibration process can be performed.

A physically based simulation program developed by IAV makes a notable reduction of test bed measurements for the calibration of the cylinder charge calculation possible. Based upon geometric engine parameters and camshaft profiles, the cylinder charge is calculated from thermodynamic relationships taking into account the contribution of residual gas. After successful engine-specific calibration of the simulation model on the basis of a reduced set of test bed measurements, it is possible to calculate the cylinder air mass over the entire range of valve timing settings and operating points (engine load and speed). The simulation-generated “virtual” measurements can then be used for calibration of the control unit software over the entire operating range.

Due to the integration of many interacting subsystems like hybrid vehicle management, energy management, distance management, etc. into the VCU platform the design steps for function development and calibration become more and more complex. This makes an aid necessary to relieve the development. Therefore, the aim of the proposed simulation-based development and calibration design is to improve the time-and-cost consuming development stages of modern VCU platforms. A simulation-based development framework is shown on a complex function development and calibration case study using an advanced powertrain concept with a plug-in hybrid electric vehicle (PHEV) concept with two electrical axles. Presenter Thomas Boehme, IAV GmbH

Due to the integration of many interacting subsystems like hybrid vehicle management, energy management, distance management, etc. into the VCU platform the design steps for function development and calibration become more and more complex. This makes an aid necessary to relieve the development. Therefore, the aim of the proposed simulation-based development and calibration design is to improve the time-and-cost consuming development stages of modern VCU platforms. A simulation-based development framework is shown on a complex function development and calibration case study using an advanced powertrain concept with a plug-in hybrid electric vehicle (PHEV) concept with two electrical axles.