INTELLIGENT TECHNOLOGIES

IN VEHICLE DEVELOPMENT

22

Founded in 1978, FEV has become an internationally recognized leader in the design and development of internal combustion engines and a supplier of ad-vanced test and instrumentation systems. FEV has consistently expanded its range of expertise into powertrain, calibration, electronics / electrification, vehicle NVH and chassis mechanics.

Today, more than half of the FEV’s 1,800 employees are working on vehicle system projects. They are primarily placed in FEV’s engineering centers located

in Aachen, Detroit, Dalian and Pune. In addition, FEV also offers its engineering competency in the form of resident engineers who are placed at client locations.

This brochure provides examples of FEV’s develop-ment capabilities in vehicle-related systems, which in Germany are concentrated in Alsdorf, near Aachen. These capabilities are also provided by FEV’s other engineering centers.

FEV has access to a new test track that is located within a 10 minute driving distance of FEV’s Vehicle Application Center. It includes a 3.0 km autobahn loop and skidpad. Additional driving trials as well as hill climbing test areas are also under development.

Engineering Centers

Test track near FEV Vehicle Application Center

FEV Vehicle Application Center near Aachen, Germany

3

Modern vehicle development has to be quick, efficient and reliable. FEV provides superior develop-ment quality for any form of vehicle development program.

FEV’s engineering portfolio contains many aspects of performance and vehicle subsystems. Our portfolio is also complimented in all vehicle body and struc-ture-related topics with the engineering expertise of FEV’s preferred partner, EDAG.

Vehicle Development

3

FEV Vehicle Development Portfolio

FEV Scatter-bands

Opel Meriva development in cooperation between GM, EDAG, FEV

FEV’s unique experience includes:

Benchmarking database of over 100 vehicles

Vehicle powertrain integration Chassis, ride and handling NVH, sound design Homologation Future vehicle concepts Full vehicle development with partner EDAG Derivative vehicle development

Project Management

Chassis

Ride & Handling

Electrics / Electronics

Homolo-gation

Active Safety

Durability Testing

Package DMU

Noise Vibration

Thermal

Intake System

Exhaust System

Powertrain Mounting

Engine Development

Driveline Development

Powertrain Calibration

Energy Management

Heating / Air Conditioning

4

The chassis team consists of qualified engineers, who have gained valuable experience working for FEV, OEMs and Tier1 chassis / vehicle dynamics teams. FEV’s chassis experts have proven their competence to many satisfied customers.

The test facilities available consist of workshops with divided areas (allowing confidentiality for each customer), proving grounds with a vehicle dynamic platform, as well as measurement equipment for all of the relevant vehicle dynamic parameters, such as:

Steering wheel angle Steering wheel torque All 6 Degrees of Freedom (DOF) for the complete vehicle (position, speed and acceleration) Brake pedal force and travel Additional equipment for measuring force, dis-

placement or acceleration regarding any desired component or system of the vehicle

The following CAE tools are used to provide strong simulation performance:

ADAMS/ADAMS Car, Motion View Nastran, Ansys Hypermesh, I-DEAS MATLAB ® / Simulink ®

Design of Experiments (DoE) In-house coding for quick and easy set-up

FEV’s chassis engineering capabilities include:

Chassis development from concept up to SOP Chassis tuning for optimized ride and handling

performance Benchmarking and target setting based on FEV’s

worldwide accepted scatter-bands Troubleshooting to obtain the best short-term

solution Development and calibration of active chassis devices, e.g. active damper and active steering CAE and testing support

Chassis

Concept Layout Design

Kinematics andCompliance

PrototypeWorkshop

Vehicle Dynamics Evaluation

Tuning and Measurement

Validation Chassis Electronics

SOPRelease

Chassis Development Tasks

4

Phone System

Display Cluster

Engine CU

Transmission

ABS/ESP

Entertainment

Air Conditioning

Sunroof CU

Door CUs

Navigation

Body CAN

Powertrain CAN

MOST

Gateway

DiagnosticsTester Communication

Temp.-Sensor 2

Temp.-Sensor 1LIN

5

FEV can manage overall vehicle NVH development programs. These programs are typically conducted in close cooperation between OEM specialists, suppliers and FEV. FEV provides all of the necessary testing and CAE facilities, as well as 40 years of experience in NVH development.

FEV’s project managers are skilled in coordinating activities between the different working groups, ensuring a streamlined development process. FEV has successfully covered programs from small motorcycles up to heavy-duty trucks.

Interior NVH Quality: Sound Insulation Squeak and Rattle HVAC Noise Electro-Servo Motor NoiseAudio and Entertainment Systems ...

Noise Vibration Harshness (NVH)

FEV’s NVH engineering capabilities include:

Interior and exterior noise development Full responsibility for vehicle NVH development System and component level target setting Development for the OEM, according to

specific processes and strategies NVH robustness for production Sound design CAE and testing support using FEV’s unique

in-house tools and methods

Powertrain-induced NVH: Engine and Transmission Driveline Powertrain Mount Intake and Exhaust System ...

Aero Acoustic: Body Shape Sealing Windows Side Mirror(s)Wipers ...

Body NVH: Global Stiffness Stiffness of Front-End Section Impedances at Interface Points Vibro-Acoustic Transfer Functions Heavy Layer Distribution ...

Chassis NVH: Stiffness of Axles and Subframes Bushing Insulation Tire Noise Steering NVH Brake NVH ...

NVH “fingerprint” Campbell diagram

MBS driveline model

6

FEV is experienced in developing software functions, from initial concept to production code, for engine control, hybrid-electric powertrains, transmissions, engine-generator sets and other systems.

FEV offers the design and implementation of standard control concepts, as well as model-based methods for advanced technologies, such as CAI, HCCI, Flex-Fuel, turbocharged CNG, new hybrid and exhaust gas aftertreatment concepts, and even fuel cell systems.

Specially designed human-machine interfaces, such as the display in a hybrid vehicle, facilitate consumer acceptance and promote their identification with new products and technologies. Software quality is ensured by using standardized and managed processes throughout the development process, from requirement specifications to acceptance tests for the vehicle. FEV software development is CMMI Maturity Level 2 certified.

The models can be used as “executable specifica-tions” and can be applied to simulations, control design, verification and validation. This enables an early understanding of the challenges and can provide direct responses for each phase of development, as well as help define appropriate testing.

Functional Development and Integration

Model-based control concept and software development

Rapid control prototyping for demonstrators Production vehicle software code Diesel, gasoline, alternative fuels Automated transmissions Hybrid electric vehicles, fuel cell vehicles Advanced technologies (HCCI, SCR, etc.) Simulink ®/ Stateflow / RTW /TargetLink, ASCET SE, C CMMI process model for software and

hardware development

Automotive Software

Integrated Model-Based Software Development and Calibration Process

for the Development of Control Units by

Detailed Simulations

System Design

Model-in-the-Loop (MiL)

Control Design

MiL Unit Testing

Software Design

Prototype or Production Target

Base CalibrationSoftware-in-the-Loop (SiL)Processor-in-the-Loop (PiL)

ECU Code SiL/PiL Unit Testing

Calibration on the Test Bench Hardware-in-the-Loop (HiL)

Component

Vehicle Calibration

Integration

Feasibility Studies System Simulation

Requirements Acceptance Tests

Coding

7

Validation and Verification Hardware-in-the-Loop (HiL)

Hardware-in-the-Loop Support

Real time model development HiL-test bench setup Test plan generation Test execution and documentation Support of test automation Network testing Offline vehicle calibration

Vehicle Calibration

7

Based on experience from a number of production vehicle projects, FEV is capa-ble of generating relevant test cases for validation and verification using Model-in-the-Loop (MiL), Software-in-the-Loop (SiL) and Hardware-in-the-Loop (HiL) simulations.

FEV can complete functional, commu-nication, network, I/O- and regression tests on HiL test benches or on-site. Our extensive experience in simulation and calculation with MATLAB ® / Simulink ® can provide the detailed modeling of control systems for internal combustion engines, hybrid drives, all electric drives or fuel cell systems.

FEV Model Library

8

FEV’s Passenger Car Calibration

Turn key Global emissions and fuel consumption

requirements Drivability (highest customer expectations) Certification and post-launch support Function development Automated test bench and in-vehicle Tool supported calibration process

CalibrationPassenger Cars

FEV’s diesel and gasoline calibration knowledge is based on many years of calibration experience with a large number of OEMs and other clients. This broad base of project experience affords FEV engineers the opportunity to work with different project require-ments and applications in a variety of target markets. This experience con-tributes to FEV’s capability to serve as a proven development partner for production calibration and turnkey development solutions.

Meeting customer requirements for drivability, engine performance and robustness, emissions and fuel economy, among others, is a key to ensuring customer satisfaction. In addition to the calibration of control strategies using modern standard software architectures, FEV has also developed advanced controller con-cepts in conjunction with its partners.

FEV uses standards and tools (TOPexpert Vehicle Suite) for the calibration tasks, to ensure an effective, robust, fast and cost-efficient calibration process.

Design of Experiments (DoE) methods and dynamic measurement procedures are used to calibrate the complete engine map. Additionally, a global optimization of specific map areas leads to a target focused development on the following:

✓ Limiting emissions ✓ Fuel consumption ✓ Combustion noise ✓ Calibration stability ✓ Interactions between

different calibration parameters

One of the main topics in the course of modern ve-hicle development is achieving a robust calibration of the exhaust gas aftertreatment system control maps.

Independent of whether the system is a catalyst, a particle trap or NOx-reduction device, FEV’s experts offer the expertise to provide optimal cost-effective aftertreatment production calibrations.

In order to fulfill the strong emission durability requirements, FEV provides aftertreatment systems that are aged on FEV’s advanced hot gas aging test benches.

Cold climate test trip

Emission chassis Dynamometer

Climatic test cell

Hot /Altitude trip

9

Truck and Commercial Engines

Integration High efficiency combustion layout ECU calibration for all existing - emission scenarios - control strategies - exhaust gas technologies Functional development Certification

From its inception, FEV has focused on the develop-ment of heavy-duty and industrial diesel engines. To initiate development, we have generated a wide range of technologies and procedures, dedicated to the specific demands of commercial vehicles and industrial engines. In addition to the classical emis-sion and performance tasks, FEV is accustomed to working on engine integration, hybrid drivetrains and NVH optimization.

FEV engineers perform diesel combustion system development projects for high fuel efficiency and low emission engine concepts, as well as special services, such as engine certification and emission deteriora-tion factor evaluation programs. Great emphasis is placed on the development of control strategies and software functional design to implement effective and robust advanced exhaust gas aftertreatment technolo-gies.

Calibrations for altitude correction, hot and cold operation, and the vehicle’s starting and warm-up phases will be optimized and validated under real-life conditions.

As a special task during the truck calibration process, the different engine brakes are also tested and calibrated on the truck.

© Team de Rooy - all rights reserved

Calibration Trucks and Commercial Vehicles

Engine certification

in close cooperation with

0 2 4 6 8 100.0

0.1

0.2

0.3

0.4

0.5

EURO I

PM [g

/kW

h]

NOx [g/kWh]

EURO IIEURO IIIEURO IVEURO VEURO VI

1010

Transmission and Hybrid Powertrain Calibration

FEV’s unique production calibration approach allows calibration of the transmission, engine and diagnostic functions to be combined under the direction of a single team of experts. This close interaction between the different subjects guarantees a very effective application process. FEV has gathered a tremendous amount of experience through AT, CVT, DCT, AMT and hybrid system calibration.

Supporting all common calibration systems

FWD / RWD transmission test bench

FEV enables rapid and effective calibration with the following modern tools and processes:

FEV Shift Analyzer: Effective model-based calibration of shift strategy

FEVos: Objective shift quality evaluation and optimization Automated calibration testing using HiL test

benches Use of transmission test benches Universal TCU and rapid prototyping systems

(MATLAB ® / Simulink ®, dSPACE, ASCET) for a fast application of initial prototypes and demonstration vehicles

Support for all common calibration systems, such as INCA, ATI, CANape and CalDesk

Effective and reliable requirement-based parameter set handling

11

Calibration of New Powertrain Concepts and Demonstrator Vehicles

In today’s market, the continually increasing customer and legislative requirements demand new powertrain concepts. These concepts must employ new control functionalities, due to the growing number of influencing parameters.

FEV has developed a variety of powertrain concepts, which have been shown in demonstrator vehicles. Some of these concepts include:

Downsizing with charging concepts, direct injection and CAI

Alternative fuels (see page 16) Mild and full hybrids Plug-In Electric Drive with range extender Advanced Diesel Combustion and controls

(HECS: High Efficiency Combustion System)

FEV provides these Calibration advantages:

Expertise in all future engine and trans-mission technologies

Benchmarking analysis to compare and assess all state-of-the-art technologies

Rapid prototyping for components and controller hardware and software

Rapid design and optimization of a variety of demonstration vehicles

Close interaction between simulation, combustion development and calibration departments for the best compromise between vehicle performance, fuel consumption and emissions.

Plug-In electric vehicle with Wankel range extender Full hybrid vehicle with electric torque converter

Gasoline two-stage turbocharger

11

Diesel Demonstrator with High Efficiency Combustion System

12

In addition to legislative conformity, On-Board Diag-nostics (OBD) also have a strong impact on customer satisfaction and the OEM’s image, upon which the commercial success of the vehicle depends. Increas-ingly strict emissions limits, advances in combustion technology, aftertreatment systems, alternative fuels and hybrid/electric vehicle developments create more and more challenges in implementing a successful OBD system. These ever tightening OBD regulations demand significant changes in OBD development processes. For example, In-Use-Monitoring-Perfor-mance-Ratio (IUMPR) legislation stipulates that OBD monitoring must be effective over a broad range of engine modes and driving conditions. Thus, the robustness and reliability of the OBD monitors and calibrations is of utmost importance.

FEV offers significant knowledge and experience in OBD calibration for any type of powertrain, engine management system and vehicle market.

The increasing complexity of OBD systems makes the use of numerical solvers and tools essential to the development process. These tools and methods are not only implemented for time and workload reduc-tion, but also to ensure a sound calibration which fulfils all legislative and customer requirements.

One example of a tool that has been designed and developed at FEV is the Diagnostic Failure Simula-tion (DFS) Box. The tool allows On-the-fly simulation of Lambda-sensor failures without influencing the engine management system or hardware changes. Thus, accurate and comprehensive testing of all Lambda-sensor related monitors can be easily ac-complished, safeguarding legislative compliance.

Diagnostic Failure Simulation (DFS) Box

On-Board Diagnostics (OBD)

FEV OBD calibration capabilities:

OBD II and (E)OBD calibrations integrated into turn-key calibration projects or individual solutions Broad knowledge of many types of engine management systems, from a variety of powertrain control system suppliers State of the art and advanced vehicle and emission concepts Software functional development High level calibration tools, off- and online Validation programs and test programs/facilities for worldwide markets/ OBD fleet verification Homologation / certification support and preparing certification documentation at FEV or on-site Excellent contact with global legislative governing bodies

Governor Deviation

Regular Operation

Fault Case

Overlap inhibitsclear monitoring results

- 1.00Nu

mbe

r of M

onito

ring

Even

ts

- 0.5 0.0 0.5 1.0 1.5

50

100

150

200

250

Monitoring Enable ConditionsNarrow Range MonitoringWide Range Monitoring Influence of enable conditions

on monitoring results

1313

Testing under race conditions on the Nürburg- ring Nordschleife

FEV fleet testing capabilities:

Experience and contacts within all global markets

Access and driving experiences on a variety of proving grounds

Professional and skilled drivers Robust program control in close

cooperation with our clients Calibration and durability experience

within one team

Fleet Testing

Test program

Hot Test track at Nardo, Italia

City / Highway and Overland, Germany

Cold-Test in Sweden

FEV has been performing vehicle testing for many years, with a focus on performance, fuel consump-tion, emission, durability, NVH, and ride & handling. Robust vehicle testing programs are still a key to developing successful vehicles for the marketplace.

FEV has served the demand for quality and reliabil-ity with a close collaboration between its durability team and the calibration specialists. FEV employs a specially trained and experienced driver pool that has performed more than 35 million kilometers of durability runs with the highest levels of safety. The examination program, which is conducted by a fleet management group and driven on specifically defined worldwide test routes, offers statistically confirmed results.

These routes can lead our team through the cold temperatures of Scandinavia, the high altitudes of the Sierra Nevada Mountains, the heat of South Af-rica, and the demanding roads and low quality fuels of China, Brazil, Russia and India. Testing can also be conducted on-site at our customer’s facilities, as well as on the challenging Nürburgring Nordschleife, which is near Aachen. FEV offers the service of direct collaboration in vehicle testing on customer-approved test routes and on accessible proving grounds.

Intensive testing programs, covering a variety of driving profiles can be applied with the following options:

Professional drivers and technicians Test operations 24 hours a day / 7 days a week Data recording and processing on client’s demand Automatically controlled vehicle safety limits Established data analysis procedures Transportation and preparation of the

vehicles on site

14

The workshop contains divided areas, allowing confidentiality for each customer.

Test Facilities

Test track near FEV Vehicle Center

Anchoic chassis dyno

Divided workshop areas

Climatic chassis dyno

Emission chassis dyno

Climate chassis dynamometers are available with a tem-perature range capability from -30 °C up to +50 °C.

A new test track is available within a 10 minute driving distance of the FEV vehicle center in Alsdorf / Aachen, Germany:

3.0 km loop and skid pad in use (2010) Additional trials and climbing hills being planned Directly located near the FEV Vehicle Center Shielded from external viewing Initial driving trials and drive-by noise measurements Access to several large test tracks including F1

circuits within a short distance (e.g. Circuit de Spa-Francorchamps, Belgium ➞ 30 min. Nürburgring, Germany ➞ 60 min.)

Emission chassis dynamometers are available, which are capable of measuring low future emission levels.

15

FEV’s long history of calibration knowledge has been incorporated into the TOPexpert Vehicle Suite, which is the central platform for all of the vehicle calibration tools used by FEV.

The TOPexpert Vehicle Suite provides model-based calibration tools for both base and OBD calibrations (e.g. misfire detection, thermal diagnostics, dynamic AFR compensation, engine warm-up adjustment, exhaust temperature models, cold start analysis, particle filter load estimation and oil dilution). The Vehicle Speed Tracer provides real-time images of individually configurable driving profiles. Additional TOPexpert tools enable the flexibility of data to be imported, filtered and exported. It also contains tools that can perform numerous other data processing operations and simulate any function of the control unit for offline calibration.

The TOPexpert Vehicle Suite is commercially available to customers and is delivered with calibration guide-lines, individual training courses, service and main-tenance. It can also be customized to accommodate customer requirements.

Based on their calibration expertise, FEV engineers have designed the PROcal tool for model-based test-bench calibrations. Its intuitive nature enables FEV’s engineers to efficiently deal with the continuously increasing complexity of ECU calibration.

PROcal provides routines for optimal test planning, model-based engine analysis and automated calibra-tion optimization.

FEV also offers a range of workshops, which enable our customers to apply cutting-edge DoE methodol-ogy to their projects. As a customer you will gain valuable insight into exactly what is needed in the field of statistics and optimization. The participants gain hands-on experience, using real-world calibra-tion examples.

Combined multi-criteria map optimization

Sensitivity analysis

Calibration Tools

TOPexpert Vehicle Suite (Commercially available)

Calibration Methods:

Model-based calibration solutions Well-defined and tool-aided calibration process High quality standards TOPexpert Vehicle Suite PROcal for DoE-based modeling and optimization Sensitivity analysis of control and sensor concepts Tailored automotive calibration trainings Customized tool development

16

Alternative fuels are gaining importance worldwide, as a substitute for oil-derived fuels, to increase re-source diversification, and to reduce greenhouse gas and toxic emissions. FEV has developed a variety of alternative fuel concepts for production and gathered vital experience in research programs, such as the new cluster of excellence for tailor made fuels from biomass.

FEV has investigated the following alternative fuels: Alcohol fuels, such as ethanol, butanol, methanol

and various blends Natural gas, biogas and liquefied petroleum gas Hydrogen in combustion engines and fuel cells Diesel substitutes as: GTL, HVO, 2nd and 3rd

Generation Biofuels, Naphtha, Gasoline / Diesel blends

A special focus is given to the interaction of these alternative fuels with powertrain technology. FEV demonstrated the benefits of combining ethanol E85 turbocharging and a variable compression ratio.The prototype vehicle demonstrated additional benefits through a reduction in CO2 emissions.

Alternative Fuels

FEV´s experience with alternative fuels:

Natural gas, GTL, LPG, alcohols, HVO, 2nd and 3rd generation biofuels, naphtha, hydrogen, gasoline / diesel blends

Research, mixture improvement and combustion system development and production develop-ment and including advanced combinations (e. g. natural gas and lean burn, ethanol and CAI, ethanol and VCR)

Software development and ECU calibration, including advanced functional development for multi-fuel control gasoline and diesel; closed loop combustion control, and model-based air loop control

Combination of Flex-fuel and VCR – maximized benefit

Fuel Cell Range Extender Module

Cluster of excellence for tailor made fuels at RWTH Aachen

Shell/Audi/FEV GTL Demonstrator car

17

The battery development process at FEV consists of a variety of different technical tasks as shown in the E-Mobility Development Process figure. FEV’s experi-ence covers each element of that development process. Simulation tools are available, which have proven to be successful for establishing the system layout. FEV’s battery design includes underbody packs, which of-fer the advantage of virtually no interference with the vehicle´s infrastructure. The FEV LiiONMAN system is available, offering a number of key functions, shown in the figure below.

FEV has built up a special test bench for batteries, with a power unit cycler.

E-Mobility

FEV LiionMan Key Functions:

Protection of battery-cells from critical operating points (voltage, current, temperature)

Calculation of important system variables (such as SOC, SOH, power prediction)

Cell- and system-diagnostics (such as detection of worst cell, short circuit detection)

Advanced cell diagnostic functions (such as model-based condition estimation, parameter adaption concepts)

BEHR battery module with FEV LiiONMAN

FEV underfloor battery design

Performancesimulation and requirementspecification

Cell electionModule and pack design

Battery manage-ment system

Battery assemblyand testing

Vehicle integration and calibration

E-Mobility development process at FEV

Battery Test Bench Equipment:

Available as a container system Power unit (Cycler): up to 240 kW Climate chamber: -30°C up to 80°C Simulation of various cooling systems FEV Control and Measurement System Battery management simulation Separate control center Li-Ion Safety System

18

References

Vehicle Physics and Acoustics Development

Gasoline Engines Calibration

Saab 9-3 XWD NVH AWD integration

Mercedes Sprinter Vehicle NVH development support Chassis tuning and testing for ride and handling

VW Transporter T5 Chassis / Road noise analysis

Fiat Coupe 5 cylinder turbo, engine, vehicle and OBD calibration

Mercedes 55 SLK AMG engine calibration

BMW 1.6L 4 cylinder Valvetronic engine and transmission calibration

© V

olks

wag

en A

G

19

Transmission Calibration and Hybrid Development

Diesel Engine Calibration

Integration and calibration of Renault 3.0L V6 diesel engine into Nissan Pathfinder and Navara, Infiniti EX, FX and M. ➞ SOP 2010

CO2 reduction through calibration of actual Volvo 1.6D DRIVe-vehicles

CO2 reduction through calibration of Peugeot 207 Blue Lion towards 99 g/km CO2 (3.8L / 100km)

DPF Calibration development with PSA vehicles, including the first production program in 2000

Engine and hybrid calibration for BMW X6 V8, software development in cooperation with BMW

Development and build of 15 ChangAn Jiexun parallel hybrid demonstrator vehicles, used as taxi cabs during the 2008 Olympics in Bejing, China

Alfa Brera transmission calibration

99g CO2/km