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Minimizing fuel consumption is emerging as the next major challenge for engine control and calibration, even as the requirements of complying with ever lower transient emissions regulations cannot be underestimated. Meeting these difficult and apparently conflicting emissions and efficiency goals is becoming increasingly onerous as engine and aftertreatment control complexity increases. Conventional engine calibration techniques are by nature time-intensive, ad-hoc and repetitive, resulting in low productivity of test facilities and engineering effort. Steady state engine mapping methods, such as design of experiments, do little to ensure transient emissions compliance or fuel consumption optimization. A new model-based Rapid Transient Calibration system has been developed, tested and validated using a 2007 production-specification Detroit Diesel Series 60 heavy-duty diesel engine.

With the adoption of complex technologies such as multiple injections, EGR and variable geometry turbocharging, it has become increasingly onerous to develop optimal engine control calibrations for either light- or heavy-duty diesel engines. The addition of NOx and PM aftertreatment systems increases further the calibration burden, as both diesel particulate filters and NOx absorbers require regeneration initiated by the engine management system. There is significant interest in the industry in reducing development costs by moving as much of the engine calibration process as is feasible from the engine test cell to the virtual desktop environment. This paper describes the development of a model-based calibration optimization system that offers significant advantages in reducing the time and effort required to obtain certification-quality engine calibrations.