rde engineering at the engine test bench · rde engineering at the engine test bench jan...

RDE ENGINEERINGAT THE ENGINE TEST BENCH

Jan Gerstenberg, Dr. Sandra Sterzing-Oppel, Dr. Benjamin Hartmann, Dr. Stephan Tafel Bosch Engineering GmbH

Bosch Engineering | BEG-PT/EAE1 Gerstenberg | 20/09/2016

© Bosch Engineering GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property

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RDE challenges

Engineering strategies

Engine-in-the-loop [EiL] tool-chain

RDE Data Analyzer

Summary

Overview



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RDE EngineeringToday and Tomorrow Organization

tod

ay

tom

orr

ow

Engine Speed / (rpm)

Time / (s)

To

rqu

e /

(N

m)

0

100

200

300

400

500

600

700

800

0 1000 2000 3000 0 1000 2000 3000 0 1000 2000 30000 1000 2000 3000

NEDC WLTC RDE normal RDE aggressive

TE

xh

aust /

(°C

)

0

200

400

600

0 400 800 1200 0 600 1200 1800 0 2000 4000 0 2000 4000

RDE

enabling

Gearbox

Control

After

treatment

DriveabilityEngine

Software

Engine

Hardware

RDE could lead to an organisational change during the development phase.



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RDE EngineeringStrategies

Environment-

simulation

Driver/

Vehicle-

Simulation

Vehicle-, driver and track-

simulation

RDE RDE test reproducibility RDE tests/24h

multiple

variants

testing

RDE

development

w/o vehicle

HEV

simulation

Real Road +++* 0 0 + 0 0

Chassis Dyno 0 ++** + + 0 0

Engine Test-

bench0 +++ +++ ++ ++ +

Engine Test-

bench [EIL]0 +++ +++ +++ +++ +++

Road test

(PEMS)Chassis dyno Chassis dyno + engine test-bench Vehicle simulation + engine test-bench [EIL***]

Chassis Dyno

Copy values to engine

test-benchStand-alone

*PEMS is legally relevant **no robot driver ***EIL – Engine-in-the-loop

Only real

road tests

PEMS Chassis Dyno GPS Data Driver-/vehicle

simulation

+++ most suitable ++ suitable + useable 0 not efficient



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Engine torque

Track: 64 km

Sim. driverSim. vehicle

Simulation (InMotion/ CarMaker)

• Engine speed

• accelerator-pedal

• Longitude

• Latitude

• roadgrade

Emission

EngineMeasure

Equipment

After-

treatment

RDE engine test-bench

RDE EngineeringRDE-Analysis using Engine-in-the-loop (EiL)

GPS data of track 1

La

titu

de

Longitude

RDE track 1

Distanz / (m)

0 10000 20000 30000 40000 50000 60000 70000

Hö

he

/ (

m)

250

300

350

400

450

500

550 Ge

sch

win

dig

ke

it /

(km

/h)

0

40

80

120

speed [k

ph

]

altitude [

kph]

Distance [m]

RDE Frontloading



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Setup

engine

ch3/7

Ch A

Ch BE

tas

ES

910

ch1/5

Ch A

Ch B

FLX1

HostCAN1

Residual bus

Mess-CAN

ETK

ETK

Cal-PC

CAN1

CAN2

CAN1

CAN3

Flexray

dynoCANoe-PC

Simulation

CarMaker:

vehicle, track,

traffic, gearbox

Test-bench

automation

PUMA

Hardware

Interface

Vector

Electronic

control unit

ETAS

Interface

module



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RDE FrontloadingEngineering competences in-house

Depending on the project case different performance steps are possible.

Pedal-lift in

driver

model

Fixed-delta-

torque

intervention

d. shifting

Delta-torque

by

“feedback-

model”

Basic map

Sport,

altitude,

driver

Code-extract

from TCU

complexity complexity

perf

orm

ance

perf

orm

ance



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RDE FrontloadingExample RDE project: Acceleration

Torque demand from gear box simulation provided by CarMaker.

7060504030

1 000

900

800

700

600

500

400

300

200

100

0

F

[1] z

wopt_

msg\E

TK

C:1

40

-4

-48

-92

-136

-180

-224

-268

-312

-356

-400

E

[1] S

trg_phiW

hl\E

TK

C:1

1200

1080

960

840

720

600

480

360

240

120

0

D

[1] V

ehV

_v\E

TK

C:1

135

120

105

90

75

60

45

30

15

0

-15

C

[1] r

edis

tb1_m

sg\E

TK

C:1

20

8

-4

-16

-28

-40

-52

-64

-76

-88

-100

Nr.LinienfarbeName Cursor 1Cursor 2Cursor-Diff.Einheiten

1 [1] zw opt_msg\ETKC:1 [1] zw opt_msg\ET... 17.25 15.75 -1.5 Grad KW

2 [1] zw outakt_msg\ETK... [1] zw outakt_msg... 19.5* -11.25*-30.75Grad KW

3 [1] redistb1_msg\ETKC:1 [1] redistb1_msg\... 0 0 0

4 [1] redistb2_msg\ETKC:1 [1] redistb2_msg\... 0 0 0

5 [1] VehV_v\ETKC:1 [1] VehV_v\ETKC:1 94.8* 95.6* 0.8 km/h

6 [1] ActMod_trqClth\ETK... [1] ActMod_trqClt... 156.6 74.6 -82 Nm

7 [1] Epm_nEng\ETKC:1 [1] Epm_nEng\ETK... 2989.5*2596.5*-393 rpm

8 [1] Strg_phiWhl\ETKC:1 [1] Strg_phiWhl\ET... 0 0 0 deg StWhl

Zeit s7060504030

1 2

Datum: 02.08.2016

Zeit: 15:36

Aufzeichnungsdauer: 00:01:38

Datenbank: 1535x00_porschev8kovomo_rde_inno_v2

Experiment: MDG1_1SG_KoVOMo_V8_IBN_MPST_20170801

Arbeitsumgebung: Arbeitsumgebung

Geräte: ETKC:1,FLX Monitoring A:1,CAN-Monitoring:1

Programmbeschreibung: 1585_MY18B01_IFX, RBS_Pruefstand_20160421

AS: DM4E50_B01CI22_PTA008_RDE_MHEV-PST-DCMs_IBN_20160722A_1

Fahrzeug: IN-J-7740

Projekt: KoVOMo V8T

Messdatei: [1] \\bosch\dfsrb\DfsDE\DIV\BEG\DGP\50_Prj_t\000

_RB\BEG\047997_RDE_Inno_2016\3_Cal\10_020702_Otto_RDE

\31-Prüfstandsmessungen\10-Restbus_Schalten\2016-08-02

_KoVOMo_V8T_Test_05_MD_Red_ok03_m_lenkw inkel.dat

Datum: 2/8/2016

Zeit: 15:34:39

Benutzer: RIN4ABT

Firma: Bosch Engineering GmbH

velocity

torque

engine-speed

steering

Fuel cut-off

Ignition retard



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RDE FrontloadingExample RDE project: 1-2 upshift

Torque request by TCU can be modified in the simulation (engineering).

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1 000

900

800

700

600

500

400

300

200

100

0

F

[1] z

wopt_

msg\E

TK

C:1

40

-4

-48

-92

-136

-180

-224

-268

-312

-356

-400

E

[1] S

trg_phiW

hl\E

TK

C:1

1200

1080

960

840

720

600

480

360

240

120

0

D

[1] V

ehV

_v\E

TK

C:1

135

120

105

90

75

60

45

30

15

0

-15

C

[1] r

edis

tb1_m

sg\E

TK

C:1

18

16

14

12

10

8

6

4

2

0

-2

Nr.LinienfarbeName Cursor 1Cursor 2Cursor-Diff.Einheiten

1 [1] zw opt_msg\ETKC:1 [1] zw opt_msg\ET... 16.5* 16.5* 0 Grad KW

2 [1] zw outakt_msg\ETKC:1 [1] zw outakt_msg\... -8.25* -11.25*-3 Grad KW

3 [1] redistb1_msg\ETKC:1 [1] redistb1_msg\E... 1* 0* -1

4 [1] redistb2_msg\ETKC:1 [1] redistb2_msg\E... 1* 1* 0

5 [1] VehV_v\ETKC:1 [1] VehV_v\ETKC:1 25.75 27.42 1.67km/h

6 [1] ActMod_trqClth\ETK... [1] ActMod_trqClth\... 36* 44.5* 8.5 Nm

7 [1] Epm_nEng\ETKC:1 [1] Epm_nEng\ETK... 2834.5*2474.5*-360rpm

8 [1] Strg_phiWhl\ETKC:1 [1] Strg_phiWhl\ET... 0* 0* 0 deg StWhl

Zeit s30292827

1 2

Datum: 02.08.2016

Zeit: 15:36

Aufzeichnungsdauer: 00:01:38

Datenbank: 1535x00_porschev8kovomo_rde_inno_v2

Experiment: MDG1_1SG_KoVOMo_V8_IBN_MPST_20170801

Arbeitsumgebung: Arbeitsumgebung

Geräte: ETKC:1,FLX Monitoring A:1,CAN-Monitoring:1

Programmbeschreibung: 1585_MY18B01_IFX, RBS_Pruefstand_20160421

AS: DM4E50_B01CI22_PTA008_RDE_MHEV-PST-DCMs_IBN_20160722A_1

Fahrzeug: IN-J-7740

Projekt: KoVOMo V8T

Messdatei: [1] \\bosch\dfsrb\DfsDE\DIV\BEG\DGP\50_Prj_t\000

_RB\BEG\047997_RDE_Inno_2016\3_Cal\10_020702_Otto_RDE

\31-Prüfstandsmessungen\10-Restbus_Schalten\2016-08-02

_KoVOMo_V8T_Test_05_MD_Red_ok03_m_lenkw inkel.dat

Datum: 2/8/2016

Zeit: 15:34:39

Benutzer: RIN4ABT

Firma: Bosch Engineering GmbH

torque

engine-speed

ignition

Ignition timing



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Test bench: urban driving

GPS tracks – simulated vehicles – simulated gearboxes – real engines

Vehicle simulation @ testbench

Alpha-AccPed

RDE FrontloadingSimulation Real Driving at Engine Test-Bench



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Multiple test situations (event-matrix) to enable a frontloading for RDE

Engineering.

RDE track

Stuttgart RDE track

Mountain track Austria

London city

Hannover flat RDE track

Driver characteristics

Mild

Aggressive (hot)

Nervous

Normal

Boundary conditions

No traffic

Heavy traffic

Traffic

12- 35°C ambient temp.

RDE EngineeringMatrix Test Configuration on Test Bench (EiL)



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RDE EngineeringRDE Data Analyzer

Automatic data analysis to improve efficiency.



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System test for heavy traffic Nervous driver worst case test

RDE EngineeringVirtual Vehicle at Engine Test-Bench: Traffic, Drivers

NOx CO2

% %

easy going 100.0 100.0

normal 109.0 101.4

nervous 115.7 102.3

Driver set-up



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The engine test-bench combined with a vehicle simulation enables to

work in a reproducible area with a minimum demand for test vehicles.

RDE Frontloading to save time and costs

Variation of different tracks, traffic conditions and driver behavior….

Evaluation of new components in the overall system.

Special investigations possible (OBD, GPS-based functions, Aftertreatment performance)

RDE EngineeringSummary

Early variants approval for hard- and software optimizations before running

PEMS-tests.

THANK YOU.

QUESTIONS?

rde engineering at the engine test bench · rde engineering at the engine test bench jan...

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