Engine ECU Function Development Using Software-in-the-Loop Methodology 2005-01-0049

The computer-aided and model-based development of engine control device software is currently regarded to enhance the design and development process significantly. Hardware-in-the-Loop (HiL) tests of the ECUs are the most common part of such an approach. The development of ECU controller functions earlier in the development process using rapid controller prototyping or Software-in-the-Loop (SiL) techniques is, however, not as common.

This paper aims at showing the modern approach of function development where an engine model replaces the real engine as the controlled system. This method shifts the emphasis away from expensive on-vehicle work towards the development at the engineer's desk. The first section deals with the possibilities and benefits of the SiL approach - it also points out its limitations. The second section lists the demands on a simulation environment for SiL applications. The main part following shows some examples for controller development with controllers for battery management and OBD diagnosis functions. The main development steps starting from proof-of-concept up to pre-calibration are discussed on these examples. Some typical use cases like driving test cycles using fast simulation on the PC are shown as well. The final section is dedicated to the further steps in ECU development like rapid controller prototyping, HiL-tests and final in-vehicle tests.

We will also point out the key features of the model used and results obtained with the described methodology. The results will be illustrated by several plots.