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IN VEHICLE DEVELOPMENT
Engineering Centers
Founded in 1978, FEV has become an internationally in Aachen, Detroit, Dalian and Pune. In addition, FEV
recognized leader in the design and development of also offers its engineering competency in the form of
internal combustion engines and a supplier of ad- resident engineers who are placed at client locations.
vanced test and instrumentation systems. FEV has
consistently expanded its range of expertise into This brochure provides examples of FEV’s develop-
powertrain, calibration, electronics / electrification, ment capabilities in vehicle-related systems, which in
vehicle NVH and chassis mechanics. Germany are concentrated in Alsdorf, near Aachen.
These capabilities are also provided by FEV’s other
Today, more than half of the FEV’s 1,800 employees engineering centers.
are working on vehicle system projects. They are
primarily placed in FEV’s engineering centers located
Active Chassis
Safety
Project
Durability Management
Testing
Package Ride &
DMU Handling
FEV Scatter-bands Noise
Vibration
Electrics /
Thermal
Electronics
Intake Homolo-
System gation
Heating /
Air Conditioning
Exhaust
Energy
System
Management
Powertrain
Powertrain Calibration
Mounting
Driveline
Development
Engine
Development
In-house coding for quick and easy set-up Vehicle Dynamics Tuning and
Evaluation Measurement
SOP Temp.-Sensor 2
Phone System
Navigation
Entertainment
MOST
Gateway
Diagnostics
Tester Communication
Release
Temp.-Sensor 1 Air Conditioning
LIN Body CAN
Sunroof CU Display Cluster
Transmission
ABS / ESP
4
Noise Vibration Harshness (NVH)
FEV can manage overall vehicle NVH development FEV’s project managers are skilled in coordinating
programs. These programs are typically conducted in activities between the different working groups,
close cooperation between OEM specialists, suppliers ensuring a streamlined development process.
and FEV. FEV provides all of the necessary testing FEV has successfully covered programs from small
and CAE facilities, as well as 40 years of experience in motorcycles up to heavy-duty trucks.
NVH development.
Aero Acoustic:
Body Shape
Sealing
Windows
Side Mirror(s)
Chassis NVH: Wipers
Stiffness of Axles ...
and Subframes
Bushing Insulation
Tire Noise Powertrain-induced NVH:
Steering NVH Engine and Transmission
Brake NVH Driveline
... Body NVH: Powertrain Mount
Global Stiffness Intake and Exhaust System
Stiffness of Front-End Section ...
Impedances at Interface Points
Vibro-Acoustic Transfer Functions
Heavy Layer Distribution
...
Sound design
5
Automotive Software
Integrated Model-Based
Requirements Software Development and Calibration Process Acceptance Tests
for the Development of Control Units by
Feasibility Studies
System Simulation
Coding
FEV is experienced in developing software functions, The models can be used as “executable specifica-
from initial concept to production code, for engine tions” and can be applied to simulations, control
control, hybrid-electric powertrains, transmissions, design, verification and validation. This enables an
engine-generator sets and other systems. early understanding of the challenges and can provide
direct responses for each phase of development,
FEV offers the design and implementation of standard as well as help define appropriate testing.
control concepts, as well as model-based methods
for advanced technologies, such as CAI, HCCI, Flex-
Fuel, turbocharged CNG, new hybrid and exhaust gas Functional Development and Integration
aftertreatment concepts, and even fuel cell systems.
Model-based control concept and
Specially designed human-machine interfaces, such software development
as the display in a hybrid vehicle, facilitate consumer Rapid control prototyping for demonstrators
acceptance and promote their identification with Production vehicle software code
new products and technologies. Software quality Diesel, gasoline, alternative fuels
processes throughout the development process, Hybrid electric vehicles, fuel cell vehicles
from requirement specifications to acceptance tests Advanced technologies (HCCI, SCR, etc.)
for the vehicle. FEV software development is CMMI ®
Simulink / Stateflow / RTW /TargetLink, ASCET SE, C
Maturity Level 2 certified. CMMI process model for software and
hardware development
6
Validation and Verification
Hardware-in-the-Loop (HiL)
Hardware-in-the-Loop Support
7
Calibration
Passenger Cars
FEV’s diesel and gasoline calibration knowledge is FEV uses standards and tools (TOPexpert Vehicle
based on many years of calibration experience with Suite) for the calibration tasks, to ensure an effective,
a large number of OEMs and other clients. This broad robust, fast and cost-efficient calibration process.
base of project experience affords
FEV engineers the opportunity to Design of Experiments (DoE)
work with different project require- methods and dynamic measurement
ments and applications in a variety of procedures are used to calibrate the
target markets. This experience con- complete engine map.
tributes to FEV’s capability to serve
as a proven development partner for Additionally, a global optimization of
production calibration and turnkey specific map areas leads to a target
development solutions. Emission chassis Dynamometer focused development on the following:
Automated test bench and in-vehicle In order to fulfill the strong emission durability
Tool supported calibration process
requirements, FEV provides aftertreatment systems
8
that are aged on FEV’s advanced hot gas aging test
benches.
Calibration
Trucks and Commercial Vehicles
0.3
emission engine concepts, as well as special services,
such as engine certification and emission deteriora-
EURO I
tion factor evaluation programs. Great emphasis is 0.2 EURO II
placed on the development of control strategies and EURO III
software functional design to implement effective and 0.1
EURO IV
robust advanced exhaust gas aftertreatment technolo- EURO V
EURO VI
gies.
0.0
0 2 4 6 8 10
Calibrations for altitude correction, hot and cold NOx [g/kWh]
operation, and the vehicle’s starting and warm-up
phases will be optimized and validated under real-life
conditions. Engine certification
in close cooperation with
As a special task during the truck calibration process,
the different engine brakes are also tested and
calibrated on the truck.
Integration
High efficiency combustion layout
ECU calibration for all existing
- emission scenarios
- control strategies
- exhaust gas technologies
Functional development
Certification
9
Transmission
and Hybrid Powertrain Calibration
benches
Use of transmission test benches
10
Calibration of New Powertrain Concepts
and Demonstrator Vehicles
Gasoline two-stage turbocharger Diesel Demonstrator with High Efficiency Combustion System
11
Plug-In electric vehicle with Wankel range extender Full hybrid vehicle with electric torque converter
On-Board Diagnostics (OBD)
In addition to legislative conformity, On-Board Diag- FEV offers significant knowledge and experience in
nostics (OBD) also have a strong impact on customer OBD calibration for any type of powertrain, engine
satisfaction and the OEM’s image, upon which the management system and vehicle market.
commercial success of the vehicle depends. Increas-
ingly strict emissions limits, advances in combustion The increasing complexity of OBD systems makes
technology, aftertreatment systems, alternative fuels the use of numerical solvers and tools essential to the
and hybrid/electric vehicle developments create more development process. These tools and methods are
and more challenges in implementing a successful not only implemented for time and workload reduc-
OBD system. These ever tightening OBD regulations tion, but also to ensure a sound calibration which
demand significant changes in OBD development fulfils all legislative and customer requirements.
processes. For example, In-Use-Monitoring-Perfor-
mance-Ratio (IUMPR) legislation stipulates that OBD One example of a tool that has been designed and
monitoring must be effective over a broad range developed at FEV is the Diagnostic Failure Simula-
of engine modes and driving conditions. Thus, the tion (DFS) Box. The tool allows On-the-fly simulation
robustness and reliability of the OBD monitors and of Lambda-sensor failures without influencing the
calibrations is of utmost importance. engine management system or hardware changes.
Thus, accurate and comprehensive testing of all
Lambda-sensor related monitors can be easily ac-
complished, safeguarding legislative compliance.
250
Monitoring Enable Conditions
Number of Monitoring Events
0
- 1.0 - 0.5 0.0 0.5 1.0 1.5
Governor Deviation
FEV has been performing vehicle testing for many Intensive testing programs, covering a variety of
years, with a focus on performance, fuel consump- driving profiles can be applied with the following
tion, emission, durability, NVH, and ride & handling. options:
Robust vehicle testing programs are still a key to
developing successful vehicles for the marketplace. Professional drivers and technicians
Test operations 24 hours a day / 7 days a week
FEV has served the demand for quality and reliabil- Data recording and processing on client’s demand
ity with a close collaboration between its durability Automatically controlled vehicle safety limits
team and the calibration specialists. FEV employs Established data analysis procedures
a specially trained and experienced driver pool that Transportation and preparation of the
13
Test Facilities
Climate chassis dynamometers are available with a tem- Emission chassis dynamometers are available, which
perature range capability from -30 °C up to +50 °C. are capable of measuring low future emission levels.
FEV’s long history of calibration knowledge has been The TOPexpert Vehicle Suite is commercially available
incorporated into the TOPexpert Vehicle Suite, which to customers and is delivered with calibration guide-
is the central platform for all of the vehicle calibration lines, individual training courses, service and main-
tools used by FEV. tenance. It can also be customized to accommodate
customer requirements.
The TOPexpert Vehicle Suite provides model-based Based on their calibration expertise, FEV engineers
calibration tools for both base and OBD calibrations have designed the PROcal tool for model-based test-
(e.g. misfire detection, thermal diagnostics, dynamic bench calibrations. Its intuitive nature enables FEV’s
AFR compensation, engine warm-up adjustment, engineers to efficiently deal with the continuously
exhaust temperature models, cold start analysis, increasing complexity of ECU calibration.
particle filter load estimation and oil dilution). The
Vehicle Speed Tracer provides real-time images of PROcal provides routines for optimal test planning,
individually configurable driving profiles. Additional model-based engine analysis and automated calibra-
TOPexpert tools enable the flexibility of data to be tion optimization.
imported, filtered and exported. It also contains tools
that can perform numerous other data processing
operations and simulate any function of the control
unit for offline calibration.
Sensitivity analysis
Calibration Methods:
15
Alternative Fuels
Alternative fuels are gaining importance worldwide, A special focus is given to the interaction of these
as a substitute for oil-derived fuels, to increase re- alternative fuels with powertrain technology. FEV
source diversification, and to reduce greenhouse gas demonstrated the benefits of combining ethanol E85
and toxic emissions. FEV has developed a variety of turbocharging and a variable compression ratio.The
alternative fuel concepts for production and gathered prototype vehicle demonstrated additional benefits
vital experience in research programs, such as the through a reduction in CO2 emissions.
new cluster of excellence for tailor made fuels from
biomass.
The battery development process at FEV consists of FEV has built up a special test bench for batteries, with
a variety of different technical tasks as shown in the a power unit cycler.
E-Mobility Development Process figure. FEV’s experi-
ence covers each element of that development process.
Simulation tools are available, which have proven to be
FEV LiionMan Key Functions:
successful for establishing the system layout. FEV’s
battery design includes underbody packs, which of- Protection of battery-cells from critical operating
fer the advantage of virtually no interference with the
points (voltage, current, temperature)
vehicle´s infrastructure. The FEV LiiONMAN system is
Calculation of important system variables
available, offering a number of key functions, shown in
(such as SOC, SOH, power prediction)
the figure below.
Cell- and system-diagnostics (such as detection
Performance Vehicle
simulation and Module and Battery manage- Battery assembly integration
requirement Cell election and
pack design ment system and testing
specification calibration
17
References
Mercedes Sprinter
Vehicle NVH development support
Chassis tuning and testing for ride and handling
© Volkswagen AG
VW Transporter T5
Chassis / Road noise analysis
18
Transmission Calibration and Hybrid Development