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Rapid Controller Prototyping (RCP) is an efficient method for design & development of ECU (Electronic Controller Unit) at early stage. Usually, RCP requires firstly performing Software-in-the-loop simulation and then connecting universal controller (e.g. MicroAutoBox) to real controlled system for testing of controller functionality. During this process, it is likely that some problems related to signal configuration and real time characteristics occur and consequently give rise to unexpected results, e.g., sensor signals or controlling signals produce large deviation and possibly damage components of real system under severe condition. On the other hand, it cannot make sure that the real time characteristics of designed controller are suitable just after applying Software-in-the-loop simulation.

Torque profile control is one of required technologies for propulsion engines. A smaller parametric model is more preferable for control algorithm design and evaluation. Mean value engine torque can be obtained from throttle opening change using a transfer function. A transfer function for a turbocharged engine was investigated with thermo-dynamic equations for a turbine and a compressor and test data. A small turbocharged engine was tested to model the air transfer process. Turbine speed was measured with temperatures, pressures and air mass flow. Turbine speed response is like a first order system to air mass flow into a combustion chamber. The pressure ratio at the compressor is approximated by a curve proportional to the turbine speed square. Based on those findings, a reduced order model for describing dynamic air transfer process with a turbocharger was constructed. The proposed model is compact and suitable for engine torque control design and controller implementation.

OBD (On Board Diagnosis) has been applied to detect malfunctions in powertrains. OBD requirements have been extended to detect various failures for ensuring the vehicle emission control system being normal. That causes further costs for additional sensors and software works. Two layers diagnosis system is proposed for a passenger car gearbox system to detect changes from normal behavior. Conventional physical constraints based diagnosis is placed on the base layer. Model based diagnosis and specific symptom finding diagnosis are built on the second layer. Conventional physical constraints based diagnosis is direct and effective way to detect the failure of system if the detected signals exceed their normal ranges. However under the case of system failure with related signals still remain in normal ranges, the conventional detection measures can not work normally. Under this case, Model based diagnosis is proposed to enhance the functionality of diagnosis system.