Creating a Virtual Test Bed Using a Dynamic Engine Model with Integrated Controls to Support in-the-Loop Hardware and Software Optimization and Calibration

Mohsen Mirzaeian,Simon Langridge

doi:10.3390/en14030652

Abstract

In the current study, a 0D/1D engine model built in the commercial code GT-Suite was coupled with the Electronic Control Unit (ECU) model created in the Simulink environment, aiming to more accurately predict the interaction of the engine and aftertreatment system (ATS) operating parameters, both during steady-state and transient maneuvers. After a detailed validation based on extensive experimental data from a heavy-duty commercial diesel Internal Combustion Engine (ICE), the engine model was fine-tuned and the 0D predictive diesel combustion model, DIPulse, was calibrated to best predict the combustion process, including engine-out NOx emissions. For correct prediction of the engine’s behavior in transient operations, the complete control strategy of the air path, including boost, exhaust gas recirculation (EGR), main and pilot Start of Injection (SOI), injection pressure, and exhaust flap, was implemented in the Simulink environment. To demonstrate the predictive capability of the model, a hot World Harmonized Transient Cycle (WHTC) was simulated, obtaining good agreement with the experimental data both in terms of emissions and performance parameters, confirming the reliability of the proposed approach. Finally, a case study on possible fuel consumption improvement through thermal insulation of the exhaust manifold, exhaust ports, and turbocharger was carried out.

Highlights

The need to reduce man-made greenhouse gas emissions has led to new and challenging targets for future CO2 emissions [1]
GT-Suite is utilized extensively in the Internal Combustion Engine (ICE) analysis, the current study shows the capability to create a virtual test bed using GT-Suite coupled with
Good agreement was achieved across the entire engine operating map

Summary

Introduction

The need to reduce man-made greenhouse gas emissions has led to new and challenging targets for future CO2 emissions [1]. The main challenge in the automotive industry is to find an optimal balance between fuel consumption and drivability within the boundaries set by emissions legislation, prompting Original Equipment. Manufacturers (OEMs) to utilize different technologies such as exhaust gas recirculation (EGR) [2], Variable Valve Actuation (VVA) [3,4], exhaust line and turbocharger insulation [5], cylinder deactivation [6], and high-injection pressure systems [7] on the engine side together with complex aftertreatment layouts [8] with catalytic heating [9]. Since new complex engine and aftertreatment systems demonstrate considerable interactions and interdependencies [10], stand-alone aftertreatment system considerations might not lead to the optimal solution for the whole system. As total system complexity increases, using robust and reliable engine simulation models will bring aftertreatment system (ATS) boundary conditions into the loop during ATS development.

Objectives

Results

Conclusion