Nico Besser’s research while affiliated with RWTH Aachen University and other places

Development challenges in the automotive industry are constantly increasing due to the high number of vehicle variants, the growing complexity of powertrains, and future legal requirements. In order to reduce development times while maintaining a high level of product quality and financial feasibility, the application of new model-based methods for virtual powertrain calibration is a particularly suitable approach. In this context, TME and FEV combine advanced thermal management models with electronic control unit (ECU) models for model-in-the-loop applications. This paper presents a development process for ECU and on-board diagnostics (OBD) functions of thermal management systems in hybrid electric vehicles. Thanks to the highly accurate 1D/3D-models, optimal control strategies for electrically actuated components can be developed in early development phases. Virtual sensors for local temperatures are developed for the ECU software to enable a cost-effective use of dedicated control functions. Furthermore, an application for OBD cooling system leakage detection is shown. Finally, the transferability of the methodology to a battery cooling system is demonstrated.

The development challenges in the automotive industry are constantly increasing due to the high number of vehicle variants, the growing powertrain complexity and future legal requirements. In order to reduce development times while maintaining high quality levels and financial feasibility, the application of new model-based methods for virtual powertrain calibration is required. As one main pillar to reduce development costs and time, tme and FEV combine advanced thermal management models together with control unit models for X-in-the-Loop applications. Focusing on the function development for thermal management systems in hybrid electric vehicles, an insight into the holistic vehicle design process is presented in this paper. For this purpose, physical thermal models of component structure, radiator package as well as cooling and lubrication systems are coupled with FEV’s modular vehicle model. The goal is to realize the best control for electrically actuated components, e.g., water pumps and valves, which enables lowest CO2 emissions, while maintaining highest thermal safety under real-world conditions. Subsequently, the results are used as a reference for the physical model-based control in Simulink. For the control unit software calibration, both models are coupled in a Model-in-the-Loop approach to exchange thermal parameters such as coolant and oil sensor temperatures. Next to the function development process, the paper includes exemplary transient simulation results for the WLTC, as well as extreme conditions cycles to confirm thermal safety.