Design and evaluation of an engine-in-the-loop environment for developing plug-in hybrid electric vehicle operating strategies at conventional test benches

Due to a large number of degrees of freedom and connected powertrain functionalities, the development of operating strategies for plug-in hybrid electric vehicles is an especially complex task. Besides optimizations of drivability, noise, vibrations and harshness as well as energy efficiency, the main challenge lies in ensuring emissions conformity. For this purpose, test vehicles are typically applied to achieve a realistic test and validation environment. However, operating strategy calibration using test vehicles has the drawbacks, that (i) it is very time consuming and cost intensive, (ii) it can only be conducted in late development phases and (iii) cannot be applied to reproducing driving loads for a valid comparison. To overcome these issues, this paper presents a consistent engine-in-the-loop approach combining real engine hardware and multiple software elements to represent PHEV behavior at the engine test bench. Thereby, an environment is created, which allows for realistic, flexible, cost efficient and reproducible testing. The effectiveness of the presented framework is evaluated by comparing relevant on-road measurements with their reproduction at the engine test bench. The results show that the vehicle on-road behavior can be replicated using the described testing environment. Particularly engine start/stop behavior and load levels—the core functionalities for operating strategy calibration—are matched. The proven level of realism in powertrain behavior enables further use cases beyond on-road measurement reproduction, i.e. varying individual component properties and observing real-world consequences at the test bench without the need for vehicle tests.