Creating a Virtual Test Bed Using a Dynamic Engine Model with Integrated Controls to Support in-the-Loop Hardware and Software Optimization and Calibration

In the current study, a 0D/1D engine model built in commercial code GT-Suite was coupled with Electronic Control Unit (ECU) created Simulink environment, aiming to more accurately predict interaction of and aftertreatment system (ATS) operating parameters, both during steady-state transient maneuvers. After detailed validation based on extensive experimental data from heavy-duty diesel Internal Combustion Engine (ICE), fine-tuned 0D predictive combustion model, DIPulse, calibrated best process, including engine-out NOx emissions. For correct prediction engine’s behavior operations, complete control strategy air path, boost, exhaust gas recirculation (EGR), main pilot Start Injection (SOI), injection pressure, flap, implemented environment. To demonstrate capability hot World Harmonized Transient Cycle (WHTC) simulated, obtaining good agreement terms emissions performance confirming reliability proposed approach. Finally, case study possible fuel consumption improvement through thermal insulation manifold, ports, turbocharger carried out.