Emissions & RDE: Developing sustainable solutions

In 2017, the new emission legislation enacted by the European Union with the goal of reducing pollutant emissions will come into force. At the same time, discrepancies between the measurements of vehicle emissions in real test runs (RDE) and conventional emission tests are to be a thing of the past. The pollutants emitted by vehicles that are actually driven on the road are therefore increasingly in the spotlight. As a result, development requirements will become more stringent, testing expenditure will increase and there will be a need to make new methods available.

Internal engine modifications, exhaust gas after-treatment, the electrification of powertrains or the use of predictive functions: Are you looking for the ideal solution for reducing emissions for various vehicle concepts and would like to test the effects of the different measures under real-world conditions? With virtual test driving, we support you in overcoming these challenges.

The CarMaker product family enables you to model real-world test driving realistically and reproducibly – from a diverse range of RDE routes with random traffic scenarios to vehicles and driver behavior up to variable environmental conditions. All relevant values can be analyzed at an early phase of development through simulation alone as well as in a virtual test run on the test bench at a later stage of development. As a result, you will be ideally equipped to develop and test future-proof vehicles.

Simulation-based calculation of emissions

Office simulation for calculating real driving emissions

Are you in an early phase of development and want to make initial statements about your engine concepts and the respective emissions? Typically hardware is not yet available at this point. With our simulation solutions, we can nevertheless help you to calculate the real driving emissions (RDE) of your vehicle using detailed engine models from other development environments.

We can support you in making simulation-based calculations of RDE in the following ways:

  • The office simulation can be carried out without a test bench or engine, making it a cost-efficient option in the very early development phases
  • Real driving simulation with CarMaker or TruckMaker can be incorporated into existing emission calculation models
  • Integrate detailed external models of the engine and exhaust gas after-treatment system using our interfaces – the Functional Mock-up Interface or the direct model interfaces to GT-SUITE and AVL CRUISE
Test bench tests: engine-in-the-loop

Model-based real test runs on the engine test bench

In the area of emissions, increasing attention is being paid to the issue of devising a suitable method for developing powertrains that reduce RDE as well as suitable measurement methods. There is as yet a wide discrepancy between real driving emissions and the certified values determined on the test bench.

Our simulation solutions and test systems enable us to carry out real test runs on the engine test bench for reproducible RDE measurements. In this process the internal combustion engine is integrated directly into our CarMaker simulation environment on the test bench. The test bench control system enables the engine to be run dynamically under all the loads that the vehicle would be subject to during a real test run. By using the online calculation and overlaying all driving resistances, we bring real test runs to the test bench with virtual test driving. The connection is made via our test bench interface, which we have specially developed to meet the particular requirements of test bench operation. Our solution is available for new test benches as well as for an upgrade of your existing test benches.

By applying the “engine-in-the-loop” approach in combination with virtual test driving, real driving emissions can be measured on the test bench both flexibly and at the same time reproducibly, enabling selective assessments of discrete internal engine modifications, modifications to the exhaust gas after-treatment or modifications to variants of electrification systems for different vehicle variants.

Benefit from the combined advantages of simulation and test bench tests with our model-based testing approach:

  • Real driving simulation can be used with a complete model environment on the test bench
  • The parameterizable driver model enables different types of drivers to be reproducibly modeled in real-world driving situations
  • Vehicle models can be quickly constructed using a data set generator and easily exchanged
  • CarMaker, TruckMaker and MotorcycleMaker allow for exact repeatability of all driving situations and provide an online visualization of the driving scenario
  • The CarMaker product family allows the vehicle to be electrified virtually by altering the powertrain model
  • Real route data from GPS measurements or map data from ADAS RP can be used
  • The INCA interface makes online calibration or application with real and virtual control units possible
Test bench tests: powertrain-in-the-loop

Model-based real test runs on the powertrain test bench and the whole vehicle test bench

Our simulation solutions and test systems help you carry out real test runs, enabling you to take reproducible, real-world consumption measurements on the powertrain test bench and the whole vehicle test bench. In this process, the entire real powertrain of the vehicle is integrated directly into our CarMaker simulation environment on the test bench and is therefore subjected to the loads that arise during a real test run. To this end we connect individual load machines to the vehicle’s wheel hubs on the powertrain test benches, whereas on roller test benches or flat belt test benches, loads are fed in through the tires of the vehicle, just as they are on the road.

 The test bench is connected using our test bench interface, which we have developed for the particular requirements of operating on powertrain test benches and whole vehicle test benches.

Our model-based testing approach combines the benefits of simulation and test bench tests:

  • Real-world driving situations can be flexibly modeled using CarMaker maneuver control, allowing you to test the entire powertrain system including the vehicle’s thermal behavior and operating strategy 
  • A large number of interfaces make it easy to exchange parameterizable vehicle models
  • Both real route data from GPS measurements and map data from ADAS RP are available for your virtual test runs
  • Our parameterizable driver model enables different types of drivers to be reproducibly modeled in real-world driving situations
  • CarMaker, TruckMaker and MotorcycleMaker allow for exact repeatability of all driving situations
  • Use standard and special measurement methods on the test bench in reproducible real-world driving situations
  • Flexibly carry out automated engine and gearbox or powertrain system applications under transient, real-world operating conditions in all kinds of scenarios

Find more information here.

Brochure Dyno Interface
1.86 MB / PDF / 2017 / IPG Automotive/ English
Real-world driving simulation on the test bench: CarMaker at APL (Apply & Innovate 2016)
5.49 MB / PDF / 2016 / APL Automobil-Prüftechnik Landau GmbH, Christian Lensch-Franzen/ English
RDE engineering on the engine test bench: CarMaker at BEG (Apply & Innovate 2016)
1.54 MB / PDF / 2016 / Bosch Engineering GmbH, Jan Gerstenberg/ English
Altitude simulation and RDE: CarMaker at Horiba (Apply & Innovate 2016)
1.54 MB / PDF / 2016 / HORIBA Europe GmbH, Dr. Stefan Bender/ English
RDE and consumption analysis: CarMaker at Kanazawa Institute of Technology (Apply & Innovate 2016)
3.12 MB / PDF / 2016 / Kanazawa Institute of Technology, Prof. Dr. Kaname Naganuma/ English
Real-world driving simulation on the test bench: CarMaker at KS Engineers (Apply & Innovate 2016)
2.9 MB / PDF / 2016 / KS Engineers, Dr. Thomas Haidinger/ English
Study at University of Southampton: CO2 reduction for fleets (Apply & Innovate 2014)
0.77 MB / PDF / 2014 / University of Southampton, Anthony Velazquez/ English
Front-loading for a gain in efficiency and safety at AVL (Apply & Innovate 2014)
3.16 MB / PDF / 2014 / AVL List GmbH, Dr. Stephen Jones/ English
Engine-in-the-loop: CarMaker at IFKM at KIT (Apply & Innovate 2012)
4.07 MB / PDF / 2012 / IFKM/KIT, Christian Disch/ English

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