V-CAP TM

A FEV VIRTUAL POWERTRAIN CALIBRATION PLATFORM

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VIRTUAL TEST BED, REAL RESULTS: A SOLUTION FOR PASSENGER CAR AND HEAVY DUTY CYCLES

VIRTUAL POWERTRAIN CALIBRATION PLATFORM

V-CAPTM

FEV offers V-CAPTM, a unique simulation-based solution to perform a significant part of up to 30 percent of Engine Control Unit (ECU) calibration on virtual and Hardware in the Loop (HiL) test beds, without the need for an engine test bed. It allows the demanding requirements associated with new transient cycles (WHTC & WLTP) and environmental cycles (Real Driving Emissions (RDE) linked to new temperature and altitude conditions) to be met.

Simulating the powertrain

Up until now, calibration of the ECU by simulating the engine and its environment has encountered major technical problems: - With 0D/1D physical or numerical simulation, it is possible to simulate the impact of the engine design on pollutant emissions and fuel consumption and thus define the most suitable concept to achieve the desired performance. However, the level of accuracy is low and not sufficient for ECU calibration. - On the other hand, design of experiments (DOE) enables reliable statistical models to be created with a limited and reasonable amount of experimental data. As a result, a global DOE enables the modeling and prediction of pollutant emissions and fuel consumption on the whole engine map, taking into consideration specific steady-state operating points, as well as the air path and injection parameters. Accuracy for these operating points (5% to 10% on NOx) is at the requested level for calibration tasks. However, the development of more dynamic cycles with Euro 6/7 and US1065, such as WHTC, WLTP and RDE, reveals the limits of this method: Since the acceleration phases are much more present than on the previous NEDC FTP cycle, air loop control errors are becoming more significant. These air loop differences can result in a loss of accuracy in the prediction of pollutant emissions of up to 25% of NOx emissions per cycle.

TEST CENTERSVIRTUAL POWERTRAIN CALIBRATION PLATFORM

V-CAPTM

A powerful combination of technologiesTo overcome these challenges, FEV offers V-CAPTM, an innovative and simple solution basedon FEV products, in combination with well-known third-party products: MORPHEE, DOE model for combustion and pollutant emissions and Gamma Technologies GT-SUITE or SIEMENS Amesim for physical modeling of the air path. All these items are together coupled and integrated into MORPHEE platform, to optimize CPU performances, easily set-up automated procedures and even connect a real ECU (HiL). This innovative solution achieves good accuracy levels (5 to 10% on NOx) thanks to the excellent behaviour of the complete air path, thus making it an efficient and reliable virtual calibration platform.

With these test beds, engine settings are tested using simulations and results for emissions and fuel consumption can be quickly and easily obtained on RDE, WHTC and WLTC cycles for a wide range of applications.

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ECU MAPPING

ECU SOFTWARE

EXTREME CONDITIONS

AGING CHECKS

OBD ROBUSTNESS

■ Used for ECU control validation and ECU pre-calibration ■ Performed with engine model instead of real engine testing on test bed■ Usual soaking (WLTC, NEDC…) not needed■ Error occurring during repeat testing are avoided

■ Fault simulation ■ For ECU software logic checking (only three days of automation tests expected instead of two weeks of engine test bed and vehicle tests)

■ For RDE, high altitude and winter/ summer testing■ With the Virtual engine, testing (load profile simulations – WLTC, NEDC, WHTC, …) performed easily by changing parameters at any time at virtual engine test lab

■ Aging to be carried out only by parameter changes

■ To be performed partly at the virtual engine test bed instead of the real engine test bed and the real vehicle. Can be tested: production tolerances, actuator failures, …

A SOLUTION COVERING CRITICAL CALIBRATION TASKS

VIRTUAL POWERTRAIN CALIBRATION PLATFORM

V-CAPTM V-CAPTM

VIRTUAL POWERTRAIN CALIBRATION PLATFORMTEST CENTERS

V-CAPTM IS A SOLUTION BASED ON FEV METHODOLOGIES, STANDARD PRODUCTS WITH SPECIFIC ADAPTATIONS FOR EACH CUSTOMER PROJECT

Principle

Advantages

Combining statistical and physical models to get a dynamic engine model: do that in a unique software environement based on MORPHEE framework for integration.

• Model accuracyDue to the unique performance of FEV systems, the accuracy of the models remains the same from the MiL step to the validation at the test bed

• Less physical testsDecrease of the share of physical tests in an engine development: engine test beds, chassis dyno and vehicle, in standard and non-standard conditions (temperature, altitude…)

• Shorter development timeDue to a model based collaborative framework: the simulation, control, calibration and testing teams share the same models, dashboards and variable configuration

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V-CAPTM PLATFORM IS BASED ON THE MORPHEE COLLABORATIVE FRAMEWORK

MIL platform HIL test bed with the real ECU with its harness and actuatorHIL test bed with the real ECU

Physical Models

ECU Models

Statistical Models

MORPHEE Simulation

Module Models

INTRODUCTION

THREE LEVELS OF APPLICATION

V-CAPTM

VIRTUAL POWERTRAIN CALIBRATION PLATFORM VIRTUAL POWERTRAIN CALIBRATION PLATFORM

V-CAPTM

■ A unique system for simulation, testing and validation including calibration taks ■ 2750 licenses installed since 1991, 10,000 users and 12 million test bed running hours per year ■ 5 mega samples per second-->The most open system on the market

Control development: MIL platformThis pure virtual test bed permits to define new control strategies. It can be also used for pre-calibration tests

Calibration: HIL platform The platform is integrated in a HIL test bed with the real ECU. This step is useful for calibration tasks

Calibration and communication validation: HIL platform with Harness and actuatorsThe HIL test bed includes the ECU, the harness and actuators. It is used forcalibration tasks and for a first level of the validation of the communication. In that case, we are very close to the real use of the ECU in the car

Each level can be provided separately considering customer‘s needs.

MORPHEE

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MORPHEEThe collaborative

framework

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Model

Real

01 MODEL TO REAL

MULTI-MODELCO-SIMULATION

02 MODEL TO REAL

VIRTUAL AND REAL EXPERIMENTATION

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REAL DRIVINGCERTIFICATION

MORPHEE capabilitiesWhat makes MORPHEE unique is its versatility and its ability to perform automation tasks, ECU calibration and real-time simulation is one single environment and PC. In a co-simulation configuration, MORPHEE is able to accomodate several third party simulation tasks to create a complex simulated system (Model In the Loop and Software In the Loop applications). Afterwards, this simulation platform can be reused for the subsequent development steps on a Hardware In the Loop test bed and an engine test bed. It enables the real-time connection of hardware and models without compromising the quality and representativeness of the tests, as the precision of the model is retained and can be reproduced directly in the hard real-time and in a deterministic way, on the test bed.

50 g/h

NOx

NOx [g/km] Experimental Simulated

NEDC cumulated value 100% 96%

WLTC cumulated value 100% 107%

Transient cycle Experimental/Simulated

For more information:sales@fev.com | www.fev.com