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Developing a Real-Time Heavy-Duty Engine Model Build Using GT-SUITE’s Fast Running Model (FRM) Builder and Running on Virtual Test Bed A CASE STUDY PUBLISHED BY AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA (ARAI) AND GAMMA TECHNOLOGIES
BS VI norms, which are stringent on
emissions, require improved performance.
As a result, the number of labels to be
calibrated increases and with increased
complexity due to aftertreatment and
diagnostics.
In addition to this, RDE requirements call for
extended range calibration. All these
requirements lead to calibration efforts on
engine / chassis dyno as well as on vehicle.
Upcoming Stage IV and CPCB 4+ norms in
off-road and genet categories respectively
also bring similar calibration challenges.
Therefore, calibration using a virtual test bed
becomes essential to frontload the activities
as shown in Figure 1.
Figure 1 BSVI calibration efforts
Key Aspects of Calibration with Virtual Test Bed (VTB):
• Calibration not dependent on
weather, location and prototype
availability
• Improved calibration quality with high
reproducibility and good
extrapolation capability
• Concept definition, calibration
robustness investigation
• Minimized usage of expensive test
facilities
• Reduced number of prototypes
resulting in faster time to market
Virtual Calibration Lab at ARAI:
The virtual calibration lab setup at ARAI as
shown in Figure 2 is equipped with PUMA,
an open test bed controller with a CAMEO
DOE tool integrated to dSPACE’s
SCALEXIO system. The calibration
environment is exactly the same as a real
calibration test bed. The heart of the virtual
calibration is the plant model and therefore it
is very important to get the required fidelity in
the shortest time depending on the purpose
of activities as shown in Table 1. Here the
Level 1 modeling approach using GT’s Fast
Running Model (FRM) builder tool is
explored for six-cylinder heavy duty
application. The objective is:
• Assess FRM builder approach for
engine calibration
• Achieve reasonable accuracy with
minimum efforts using FRM builder,
when limited test data is available
• Convert to Real Time model and run
on VTB
• Run steady state and transient cycle
Figure 2 ARAI Virtual Test Bed system
Table 1 Plant model fidelity level
Plant model development using GT-SUITE FRM builder tool:
The FRM builder tool provides the ability to
select engine configuration. After filling the
required details, the Mean Value engine
model is automatically generated with all
default settings. Changes are made in inputs
such as TC maps, speed range, fueling, and
EGR to match the existing six-cylinder
engine configuration as shown in figure 3.
Combustion and emission parameters are
tuned quickly with limited steady state data
and different parameters such as torque,
BSFC, in-cylinder pressures, MFB 50, turbo
speed, manifold pressures, and
temperatures. Emissions limited to NO were
compared to check the accuracy of the
model and were found to be satisfactory. The
results are shown in figure 4 for the Level 1
model. The required real time factor is
achieved on the fast running model after
some simplifications in the model.
Figure 3 Engine plant model built using FRM builder
Figure 4 Comparison of simulation vs test results for Level 1 Model
VTB integration of RT FRM model:
The next step is to run the RT plant model on
the VTB system. The load drawer metering
unit, which consists of actuators such as
injectors, is prepared and integrated with a
RT plant model. Inputs required for engine
plant models such as fueling are taken from
the ECU in the real-time domain. The ECU
exchanges signals with the virtual engine
through soft sensors and with actual
hardware such as injectors through electrical
signals. The VTB setup of the load drawer
along with ECU and RT plant model is shown
in figure 5.
Figure 5 VTB setup for Level 1 RT FRM Model
The steady state and transient operating
points are run on VTB at standard ambient
conditions and compared with test data. The
results shown in figures 6,7, and 8 show very
good accuracy at steady as well as at
transient conditions. Considering the limited
test data, time, and efforts put into calibrating
the model the results are very encouraging
and prove the usefulness of an FRM
approach for level 1 activities.
The VTB is now ready for carrying out
calibration at steady state and transient
points at standard ambient conditions.
“The GT-SUITE FRM
builder approach took very
little effort and time to
reach good accuracy at
steady as well as at
transient conditions”
-Hitesh Chaudhari
Figure 6 Steady state results at standard conditions
Figure 7 Transient results at standard conditions
Summary:
The engine plant model built using GT’s FRM
builder approach showed very good fidelity
and real time capability. These results show
the usefulness of an FRM approach for
concept investigation, function development
etc. The summary of the work is as follows:
• The FRM builder approach took very
little effort and time to reach required
accuracy level
• The plant model built with limited test
data has shown very good correlation
with experimental data at steady
state & transient level
• The FRM model showed real time
compliance and therefore is useful for
calibration using a VTB approach
This approach has shown huge potential in
reduction of calibration efforts, ease of
calibration, screening of various hardware
options, and fast calibration of engine
derivatives for various applications.
Depending upon the plant model fidelity the
usage of VTB can be listed as follows:
Authors
Mr Hitesh B Chaudhari, Manager, PTE, ARAI chaudhari.edl@araiindia.com
Dr N. H Walke, Deputy Director, PTE, ARAI walke.edl@araiindia.com
About ARAI
Automotive Research Association of India (ARAI), established in 1966, is the leading automotive R&D organization of the country set up by the Automotive Industry with the Government of India. ARAI is an autonomous body affiliated to the Ministry of Heavy Industries and Public Enterprises, Government of India. The Department of Scientific and Industrial Research, Ministry of Science and Technology, Government of India, has recognized ARAI as a Scientific and Industrial Research Organization (SIRO). Further, ARAI is a prime Testing and Certification Agency notified by Government of India under Rule 126 of Central Motor Vehicle Rules, 1989. Powertrain Engineering Department (PTE) at ARAI is a state of art R&D centre for engine and transmission development. PTE is engaged in research, design, development and evaluation of all types of IC engines, such as diesel, gasoline, LPG, CNG, HCNG, Hydrogen, Ethanol, Bio-Diesel, Dual-Fuel & Hybrid systems. PTE is engaged in design engines from concept to prototype to production support for various applications like HGV, LCV, utility vehicles, tractor, genset, 2 and 3 wheelers. PTE is equipped with capabilities to develop BS VI/ Stage IV/ Stage V solutions and hybrid vehicle systems More Information at https://araiindia.com/home
About Gamma Technologies
Gamma Technologies is the developer of GT-SUITE, the leading 0D/1D/3D multi-physics CAE system simulation software. GT-SUITE supplies a comprehensive set of component libraries which simulate the physics of fluid flow, thermal, mechanical, electrical, magnetic, chemistry, and controls. From those libraries, one can build accurate models of almost any engineering system, including vehicles, engines, drivelines, transmissions, general powertrains and mechanical systems, hydraulics, lubrication and friction, thermal management, cooling, chemistry, aftertreatment and much more. More Information at: https://www.gtisoft.com/ Gamma Technologies
Contact Information by Territory: https://www.gtisoft.com/about-gt/contact-by-territory/
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