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Automotive embedded systems have become very complex, are strongly integrated, and the safety-criticality and real-time constraints of these systems raise new challenges. The OSEK/VDX standard provides an open-ended architecture for distributed real-time capable units in vehicles. This is supported by the OSEK Implementation Language (OIL), a language aiming at specifying the configuration of these real-time operating systems. The challenge, however, is to ensure consistency of the concept constraints and configurations along the entire product development. The contribution of this paper is to bridge the existing gap between model-driven systems engineering and software engineering for automotive real-time operating systems (RTOS). For this purpose a bidirectional tool bridge has been established based on OSEK OIL exchange format files.

Current developments in automotive industry such as hybrid powertrains and the continuously increasing demands on emission control systems, are pushing complexity still further. Validation of such systems lead to a huge amount of test cases and hence extreme testing efforts on the road. At the same time the pressure to reduce costs and minimize development time is creating challenging boundaries on development teams. Therefore, it is of utmost importance to utilize testing and validation prototypes in the most efficient way. It is necessary to apply high levels of instrumentation and collect as much data as possible. And a streamlined data pipeline allows the fleet managers to get new insights from the raw data and control the validation vehicles as well as the development team in the most efficient way. In this paper we will demonstrate a data-driven approach for validation testing.

Vehicle driveability evolves more and more as a key decisive factor for marketability and competitiveness of passenger cars, since the final decision of customers to buy a car is usually taken after a more or less intensive test drive. Car manufacturers currently evaluate vehicle driveability with subjective assessments and by having their experienced test drivers fill out form sheets. These assessments are time and cost intensive, limited in repeatability and not objective. The real customer requirements cannot be recognized in detail with this method. This paper describes a completely new approach for an objective and real time evaluation of relevant driveability criteria, for use in a vehicle and on a high dynamic test bed. The vehicle application enables an objective comparison between vehicles and an application as a development tool in many development and calibration phases, where ever fast and objective driveability results are required.

Gasoline direct injection is one of the main issues of actual worldwide SI engine development activities. It requires a comprehensive system approach from the basic considerations on optimum combustion system configuration up to vehicle performance and driveability. The general characteristics of currently favored combustion system configurations are discussed in this paper regarding both engine operation and design aspects. The engine performance, especially power output and emission potential of AVL's DGI engine concept is presented including the interaction of advanced tools like optical diagnostics and 3D-CFD simulation in the combustion system development process. The application of methods like tomographic combustion analysis for investigations in the multicylinder engine within further stages of development is demonstrated. The system layout and operational strategies for fuel economy in conjunction with exhaust gas aftertreatment requirements are discussed.

At the moment the documentation of failure inhibition matrices and the fault path management for different controller types and different vehicle projects are mainly maintained manually in individual Excel tables. This is not only time consuming but also gives a high potential for fault liability. In addition there is also no guarantee that the calibration of these failure inhibition matrices and its fault path really works. Conflicting aims between costs, time and fault liability require a new approach for the calibration, documentation and testing of failure inhibition matrices and the complete Diagnostic System Management (DSM) calibration. The standardization and harmonization of the Diagnostic System Management calibration for different calibration projects and derivates is the first step to reduce time and costs. Creating a master calibration for the conjoint fault paths and labels provides a significant reduction of efforts.

The present contribution gives an overview of the use of different simulation tools for the optimization of injection parameters of a diesel engine. With a one-dimensional tool, the behavior of the mechanics and fluid dynamics of the entire injection system is calculated. This simulation provides information on the dynamic needle lift, injection rates, pressures, etc. The flow within the injector is simulated using a three-dimensional CFD tool. By use of a two-phase model, it is possible to analyze the cavitating flow inside the injector and to calculate the effective nozzle hole area as well as the exit flow characteristics. Mixture formation, combustion and pollutant formation simulation is performed adopting three-dimensional CFD. In order to provide the initial and boundary conditions for the engine CFD simulation and to optimize the engine cycle performance a one-dimensional tool is adopted.

The objective of this study to introduce the newly developed Discrete Channel Method (DCM) as a fast and efficient method for the prediction of the 3d and transient behavior of honeycomb-type catalytic converters in automotive applications. The approach is based on the assumption that the regions between the channels are treated as a reactor with a homogeneously distributed heat source due to chemical conversion. Therefore, each radial direction can be described by a center, a boundary and only a few intermediate channels between them. The discrete channels are described by transient, 1d conservation equations that characterize the behavior of channels at different radial positions. The heat entering and leaving each discrete channel is evaluated by the gradients of the temperature field in conjunction with the heat conductivity of the substrate. The approach is validated by experimental data and serves as a module in the thermodynamic and engine analysis design tool BOOST.

A calibration and validation workflow will be presented in this paper, which utilizes common static global models for fuel consumption, NOx and soot. Due to the applicability for warm-up tests, e.g. New European Driving Cycle (NEDC), the models need to predict the temperature influence and will be fitted with measuring data from a conditioned engine test bed. The applied model structure consisting of a number of global data-based sub-models is configured especially for the requirements of multi-injection strategies of common rail systems. Additionally common global models for several constant coolant water temperature levels are generated and the workflow tool supports the combination and segmentation of global nominal map with temperature correction maps for seamless and direct ECU setting.

For achieving the forthcoming CO2 emission targets of 95g/km by 2020 and for the years beyond, comprehensive activities for powertrain technology as well as development methodology has to be utilized. It will by far not be enough to add a few single technology features to achieve the desired result. More and more the success will result from comprehensive combining of synergetic utilization of complementary effects. This will be the powertrain perfectly matched to the vehicle, including the energy source, and all together integrated by means of advanced development tools and methodology.

The need to improve the engine performance and fuel consumption subject to ever more stringent emission standard spar the interest in the aspects of understanding and quantifying the thermal behavior of engine components and systems. Considering these points during the design of the vehicle thermal management system based on test would consume far too many resources. Fortunately, the simulation tools have become more prominent in the pre-prototype phase of the vehicle development process and they had reached a mature stage; where they can contribute successfully to a significant extend to meet the vehicle development targets. In this work, a methodology to model the Vehicle Thermal Management System (VTMS) in order to understand and quantify its behavior has been developed. The partial systems under consideration are: the gas circuit, the cooling circuit, the lubrication circuit and the thermal capacitance of the engine structure under the vehicle driving conditions.

HTOE (High Temperature Operation Endurance) and PTCE (Power Thermal Cycle Endurance) tests are typically performed according automotive group standards, such as LV 124 [1], VW80000 [2], FCA CS.00056 [3] or PSA B21 7130 [4]. The LV 124-2 group standard, composed by representatives of automobile manufacturers like Audi AG, BMW AG, Volkswagen AG and Porsche AG describes a wide range of environmental tests and their requirements. In addition, calculation parameters and a method are given in the standard. These group standard tests are often attributed to IEC 60068-2-2 [5] for HTOE and IEC 60068-2-14 [6] for PTCE. As both of these tests are typically of long duration, fundamentally linked to reliability (therefore requiring a statistically significant number of samples) and of considerable importance to power electronic, they are worthy of additional scrutiny for automotive developers as most automotive development moves towards electrification.

Actual automotive themes in the beginning century are globalization and platform concepts. Platforms reduce manpower for basic power train development and enable a higher vehicle quality by sharing development cost to many models. New drive train generations with direct injected diesel and gasoline engines, variable valve train systems and hybrid drives require complex electronic control systems with many control parameters, which must be calibrated for each platform model to fulfill the targets for emissions, diagnostics and driveability. Calibration becomes a critical procedure in vehicle development. A negative effect of the platform is the reduced possibility to give a model or an OEM a brand specific driveability character, traditionally an important sales - promoting factor. The paper describes a tool for the objective real time assessment of vehicle driveability and vehicle character, using a new subjective - objective approach.

Originally developed for the automotive market, a fully automatic real-time measurement tool AVL-DRIVE is commercially available for analyzing and scoring vehicle drive quality, also known as “Driveability”. This system from AVL uses its own transducers, calibrated to the sensitivity and response of the human body to measure the forces felt by the driver, such as acceleration, shock, surging, vibration, noise, etc. Simultaneously, the vehicle operating conditions are measured, (throttle grip angle, engine speed, gear, vehicle speed, temperature, etc.). Because the software is pre-programmed with the scores from a multitude of different vehicles in each vehicle class via neural networks and fuzzy logic formula, a quality score with reference to similar competitor vehicles is instantly given. This tool is already successfully implemented in the market for years to investigate such driveability parameters for passenger cars.

Real world operating scenarios have a major influence on emissions and fuel consumption. To reduce climate-relevant and environmentally harmful gaseous emissions and the exploitation of fossil resources, deep understanding concerning the real drive behavior of mobile sources is needed because emissions and fuel consumption of e.g. passenger cars, operated in real world conditions, considerably differ from the officially published values which are valid for specific test cycles only [1]. Due to legislative regulations by the European Commission a methodology to measure real drive emissions RDE is well approved for heavy duty vehicles and automotive applications but may not be adapted similar to two-wheeler-applications. This is due to several issues when using the state of the art portable emission measurement system PEMS that will be discussed.

This paper gives insights in the theoretical measurement uncertainty of E-Drive rotor position dependent results, like Id and Iq calculations, done by a modern propulsion power analyzer (PA). The calculation of Id and Iqis fundamental to perform control optimization and application tasks for an E-Drive system. To optimize the E-Drive system application towards e.g., best efficiency, best performance, or improved NVH the importance of the testing toolchain is described: a power analyzer delivering the required results, an automation system, and a Design of Experiment tool to set improved target values. Consequently, inverters applications featuring field-oriented control (FOC) with permanent magnet synchronous machines (PMSM) are updated with a chosen control strategy. For achieving a certain behavior of an E-Drive, different degrees of freedom in the Inverter Control Unit are available; Lookup tables Id and Iq represent two fundamental application labels to be considered.