Virtual Powertrain Development and Calibration methodology: The Role of Model-in-the-Loop in Calibration and Testing of EV power Train integrated with real road simulation tools.

The automotive industry has witnessed significant advancements in powertrain development over recent years, with further evolution expected in the near future. Modern vehicle propulsion systems now encompass a broad spectrum, including fully electric vehicles, plug-in hybrid models, mild 48V hybrid powertrains, and traditional internal combustion engine vehicles. This growing variety demands extensive engineering efforts for development and testing across different powertrain configurations. To facilitate the simultaneous advancement of multiple powertrain technologies while keeping costs manageable, optimizing calibration and testing processes is crucial. A combination of cutting-edge simulation techniques and state-of-the-art testing equipment offers an effective solution, introducing innovative testing methodologies that streamline the development of sophisticated propulsion architectures. This paper explores the implementation of Model-in-the-Loop (MIL) testing as a key methodology in powertrain development, calibration and Validation. Conventional MIL testing provides a simulated environment for validating control algorithms, enabling engineers to detect design flaws and logical errors early in the development cycle. In the proposed methodology, Trained output drive cycle data from AVL Cruise software is integrated with MATLAB plant model to test various real time scenario optimizing the control strategy and virtual calibration are performed. Virtualization serves as a fundamental component in this process, allowing early-stage system-level testing without requiring physical prototype vehicles or Hardware in loop setup. This approach not only enhances calibration accuracy but also by refining control strategies before moving to more resource-intensive validation stages, MIL testing improves efficiency, accelerates development timelines, and enhances the overall performance of advanced vehicle technologies.