Fuel economy improvement of a heavy-duty powertrain by using hardware-in-loop simulation and calibration

Fuel economy efficiency is one of the most important parameters for vehicle powertrains, which is of particular interest for heavy-duty powertrain calibration. Conventionally, this work relies heavily on road tests, which cost more and may lead to long duration product development cycles. The paper proposes a novel hardware-in-loop modeling and calibration method to work it out. A dSPACE hardware-based test bench was successfully established and validated, which is valuable for a more efficient and easier shift schedule in calibration. Meanwhile, a real-time dynamic powertrain model, including a diesel engine, torque converter, gear box and driver model was built. Typical driving cycles that both velocity and slope information were constructed for different road conditions. A basic economic shift schedule was initially calculated and then optimal calibrated by the test bench. The results show that there is an optimal relationship between an economic shift schedule and speed regulation. By matching the best economic shift schedule regulation to different road conditions; the fuel economy of vehicles can be improved. In a smooth driving cycle; when the powertrain applies a larger speed regulation such as 12% and the corresponding shift schedule; the fuel consumption is smaller and is reduced by 13%. In a complex driving cycle, when the powertrain applies a smaller speed regulation such as 5% along with the corresponding shift schedule; the fuel consumption is smaller and is reduced by 5%. The method thus can provide guidance for economic calibration experiments of off-road heavy-duty vehicles.