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Vehicle development involves the design and integration of subsystems of different domains to meet performance, efficiency, and emissions targets set during the initial developmental stages. Before a physical prototype of a vehicle or vehicle powertrain is tested, engineers build and test virtual prototypes of the design(s) on multiple stages throughout the development cycle. In addition, controllers and physical prototypes of subsystems are tested under simulated signals before a physical prototype of the vehicle is available. Different departments within an automotive company tend to use different modelling and simulation tools specific to the needs of their specific engineering discipline. While this makes sense considering the development of the said system, subsystem, or component, modern holistic vehicle engineering requires the constituent parts to operate in synergy with one-another in order to ensure vehicle-level optimal performance.

Complexity of electronics and embedded software systems in automobiles has been increasing over the years. This necessitates the need for an effective and exhaustive development and validation process in order to deliver fault free vehicles at reduced time to market. Model-based Product Engineering (MBPE) is a new process for development and validation of embedded control software. The process is generic and defines the engineering activities to plan and assess the progress and quality of the software developed for automotive applications. The MBPE process is comprised of six levels (one design level and five verification and validation levels) ranging from the vehicle requirements phase to the start of production. The process describes the work products to be delivered during the course of product development and also aligns the delivery plan to overall vehicle development milestones.

Whilst the primary function of the active grille shutters is to reduce the aerodynamic drag of the car, there are some secondary benefits like improving the warm up time of engine and also retaining engine heat when parked. In turbocharged IC engines the air is compressed (heated) in the turbo and then cooled by a low temperature cooling system before going into the engine. When the air intake temperature exceeds a threshold value, the engine efficiency falls - this drives the need for the cooling airflow across the radiator in normal operation. Airflow is also required to manage the convective heat transfer across various components in the engine bay for its lifetime thermal durability. Grill shutters can also influence the aerodynamic lift balance thus impacting the vehicle dynamics at high speed. The vehicle HVAC system also relies on the condenser in the front heat exchanger pack disposing the waste heat off in the most efficient way.

Under bonnet thermal encapsulation is a method for retaining the heat generated by a running powertrain after it is turned off. By retaining the heat in the engine bay, the powertrain will be closer to its operating temperatures the next time it is started, reducing the warm up time required. This reduces the period of inefficiency due to high friction losses before the engine reaches it operating temperature, and as a result reduces the vehicles fuel consumption and CO2 emissions. To develop an integrated and efficient encapsulation design, CAE methods can be applied to allow this work stream to start as early in a vehicles development cycle as possible. In this work, the existing test methods are discussed, and a new Thermal CFD method is presented that accurately simulates the fluid temperatures after a customer representative 9 hour park period.