The use of Hardware-in-the-Loop (HiL) test systems is an established engineering tool for software development, initial operation and safeguarding of electrical control units in a modern powertrain development process. Model-based controller calibration is a newly introduced application for HiL systems. The coordination between the engine and the vehicle power system serves to illustrate this extension of applications. The associated control functions should solve the conflict between engine idling speed and an adequate supply of electricity for consuming vehicle components. The main challenges which affect the development of simulation models for this applications are the increasing requests for accuracy and versatility of the used models: Simulation must not only account for the complex interaction between thermodynamics and electro-mechanics within each domain, but they must also include details of actuator interfaces. Synchronous to this module-oriented modelling of target values (engine speed and torque as well as fuel consumption) calculations must be performed for transient cases in addition to cases of steady state engine operation. To reach the goal of high accuracy and concurrent validity for special engine operation modes such as cold start, a physically/thermodynamically based engine model based on engine cycle computation was developed. The model of the 14V electrical systems provides a correct computation of the transient alternator torque as a result of the increasing energy demand after switching on specific electrical loads of the vehicle. The engine speed behaviour of the used system of real-time models in combination with the real control unit shows results that are in the range of measurements done on the real engine and electrical system. The developed models can be easily incorporated into the existing BMW model database. A parameterization process regarding available measurement data allows the productive use of a model-based calibration in all powertrain development projects.
Hardware-in-the-Loop simulation for the virtual calibration of control functions for the coordination between engine and electrical system
2008
17 Seiten, 12 Bilder, 8 Quellen
Conference paper
Storage medium
English
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