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The present paper aims at developing an innovative procedure to create a one-dimensional (1D) real-time capable simulation model for a heavy-duty diesel engine. The novelty of this approach is the use of the top-level engine configuration, test cell measurement data, and manufacturer maps as opposite to common practice of utilizing a detailed 1D engine model. The objective is to facilitate effective model adjustments and hence further increase the application of Hardware-in-the-Loop (HiL) simulations in powertrain development. This work describes the development of Fast Running Model (FRM) in GT-SUITE simulation software. The cylinder and gas-path modeling and calibration are described in detail. The results for engine performance and exhaust emissions produced satisfactory agreement with both steady-state and transient experimental data.

The requirements set for the next-generation powertrain systems (e.g. performance and emissions) are becoming increasingly stringent with ever-shortening time-to-markets at reduced costs. To remain competitive automotive companies are progressively relying on model-driven development and virtual testing. Virtual test benches, such as HiL (Hardware-in the-Loop) simulators, are powerful tools to reduce the amount of physical testing and speed up engine software calibration process. The introduction of these technologies places new, often conflicting demands (such as higher predictability, faster simulation speed, and reduced calibration effort) upon simulation models used at HiL test benches. The new models are also expected to offer compliance to industry standards, performance and usability to further increase the usage of virtual tests in powertrain development.