Abstract
Fuel economy efficiency is one of the most important parameters for vehicle powertrains, which is of particular interest for heavy-duty powertrain calibration. Conventionally, this work relies heavily on road tests, which cost more and may lead to long duration product development cycles. The paper proposes a novel hardware-in-loop modeling and calibration method to work it out. A dSPACE hardware-based test bench was successfully established and validated, which is valuable for a more efficient and easier shift schedule in calibration. Meanwhile, a real-time dynamic powertrain model, including a diesel engine, torque converter, gear box and driver model was built. Typical driving cycles that both velocity and slope information were constructed for different road conditions. A basic economic shift schedule was initially calculated and then optimal calibrated by the test bench. The results show that there is an optimal relationship between an economic shift schedule and speed regulation. By matching the best economic shift schedule regulation to different road conditions; the fuel economy of vehicles can be improved. In a smooth driving cycle; when the powertrain applies a larger speed regulation such as 12% and the corresponding shift schedule; the fuel consumption is smaller and is reduced by 13%. In a complex driving cycle, when the powertrain applies a smaller speed regulation such as 5% along with the corresponding shift schedule; the fuel consumption is smaller and is reduced by 5%. The method thus can provide guidance for economic calibration experiments of off-road heavy-duty vehicles.
Highlights
Vehicles with good fuel economy can reduce the operating cost of vehicles, reduce a country’s dependence on importing oil, save oil resources and reduce engine emissions [1]
The virtual calibration of an economic shift schedule is studied under the varied conditions of different speed regulation regimes
The results of the virtual calibration in the smooth driving cycle are compared with the real experimental data of some heavy-duty vehicles in an experimental field which corresponds with a smooth driving cycle
Summary
Vehicles with good fuel economy can reduce the operating cost of vehicles, reduce a country’s dependence on importing oil, save oil resources and reduce engine emissions [1]. The standard methods of measuring fuel economy are the constant velocity fuel consumption test and driving cycle fuel consumption test [2]. The first method measures a vehicle’s fuel consumption when the vehicle runs 100 km in the highest gear on a good road and under a certain load. The constant velocity driving cycle cannot comprehensively reflect the actual operation of the vehicle. Measurements and statistics of actual vehicles, many countries have established some typical driving cycles to simulate the real vehicle running status [3]. The most popular driving cycles are the American driving cycle, European driving cycle and Japanese driving cycle.
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