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The increased complexity of the electronic control systems requires exhaustive debugging algorithms. In this paper a validation methodology for the engine management strategies specifications is described. It is based on mathematical simulation and testing using finite state machine (FSM) integrated in an engine model. Considering the strategies management built with states and transitions diagrams, a simulation environment has been developed where a two-ECU (Electronic Control Unit) system is clocked with parallelism. Advantage consists of debug time reduction in the validation and software testing. This paper presents an efficient and exhaustive method to create specifications in terms of FSM and tasks scheduling.

The development of low noise engines and vehicles, accompanied by the reduction of costs and development time, can be obtained only if the design engineer is supported by complex calculation tools in a concurrent engineering process. In this respect, the reduction of vibrations (passenger comfort) and of vehicle noise (accelerated pass by noise) are important targets to meet legislative limits. AVL has been developing simulation programs for the dynamic-acoustic optimization of engines and gear trains for many years. To simulate the structure-born and air-born noise behavior of engines under operating conditions, substantial efforts on the mathematical simulation model are necessary. The simulation tool EXCITE, described in this paper, allows the calculation of the dynamic-acoustic behavior of power units.

Automotive components designed and manufactured with lightweight materials are becoming a means whereby the CO2 emission reduction targets in the use phase can be met. On the other hand, such alternative materials might generate higher environmental impacts and a greater energy consumption in the production phase. As a consequence, the use phase is becoming less critical than the manufacturing phase; moreover, the choice of lighter materials might be or not a winning solution depending on several other factors, which can be managed and compared only through the use of dedicated softwares, like the one developed in Fiat Auto.

An optimisation analysis on an aluminium matrix composites brake drum was carried out in order to obtain a greatly lighter component with equal or better performances than the traditional one. For this reason, a FEM numerical model, fitted on the basis of experimental data, was developed to optimise the design of a brake component in order to meet the required targets; moreover, dynamometer testing allowed to point out the guidelines for the design optimisation. The redesigned MMC drum showed good results, allowing a component weight saving up to 50%.