Accelerating hybrid engine start calibration with ETAS Software-in-the-Loop expertise
Developing hybrid powertrains introduces a new level of system complexity, particularly during complex operating phases such as engine startup. To master the virtual calibration of a hybrid gasoline engine's start behavior, a leading German OEM implemented a customized software-in-the-loop (SiL) environment supported by ETAS tools, including INCA. By combining a virtual engine control unit (vECU) with simulation models, the customer significantly reduced its dependency on physical vehicle testing, accelerating calibration workflows and achieving a deeper understanding of the entire system.
At a glance
Challenge
The increased complexity of the start process for a hybridized gasoline engine required extensive and time-consuming vehicle testing. This made the classic calibration approach very time consuming.
Solution
With support from ETAS tools like INCA, the customer developed a tailored software-in-the-loop (SiL) environment combining a virtual ECU and simulation models to enable automated virtual calibration workflows.
Customer achievement
Running hundreds of virtual cold-start tests in hours instead of weeks significantly reduced development time, minimizing the need for hardware testing and enabling a deeper understanding of the entire system.
The challenge
The starting sequence of a hybrid gasoline engine posed a significant challenge to the OEMs engineers due to the increased system complexity. The intricate interactions between the combustion engine and the hybrid control systems created new calibration challenges that could not be effectively overcome using traditional development methods alone. Initially, the absence of historical data on this new hybrid process made it difficult to establish a structured calibration strategy. Consequently, engineers relied on a large number of physical vehicle tests, which increased development effort and extended project timelines.
The solution
To overcome these challenges, the customer implemented a customized software-in-the-loop environment with the support of ETAS tools, including the ETAS INCA software at its heart. This setup paired a virtual ECU with dedicated simulation models to create a virtual environment for the hybrid engine’s start process. It allowed engineers to perform automated parameter studies and evaluate numerous calibration variants without using physical prototypes. The engineering teams and ETAS collaborated to create an efficient, flexible virtual workflow that integrates seamlessly into existing development processes.
Customer achievement
The implemented SiL environment produced clear, measurable improvements in development efficiency. The simulation results showed a strong correlation with real-world vehicle measurements, validating the accuracy of the virtual methodology. The OEM’s engineers conducted hundreds of virtual cold-start simulations in just a few hours – a task that previously required several weeks of physical vehicle testing. This significant reduction in hardware dependency shortened development cycles, enabling faster iteration and parameter evaluation. Most importantly, the virtual environment provided engineers with deeper insights into the powertrain system's complex interactions, enabling them to make better decisions.
The partnership between the OEM and ETAS demonstrates how virtual development methodologies can accelerate the calibration of complex hybrid powertrains while reducing the need for physical testing. The company has established a more efficient, scalable process for future hybrid projects by integrating simulation-based workflows with ETAS’s powerful toolchain. This lays the foundation for continued innovation in virtual calibration.
Learn how ETAS virtual validation and calibration solutions can speed up your powertrain development projects.
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