400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org SAE TECHNICAL PAPER SERIES 2003-01-0673 Modeling, Simulation, and Hardware-in-the-Loop Transmission Test System Software Development Joe Steiber and Bapiraju Surampudi Southwest Research Institute Mike Rosati and Marlin Turbett General Motors Corporation Ron Hansen and Tim Tower Anderson Electric Controls, Inc. Reprinted From: Virtual Engineer ing, Simulation, & Optimization (SP-1779) 2003 SAE World Congress Detroit, Michigan March 3-6, 2003Downloaded from SAE International by Birmingham City Univ, Tuesday, August 21, 2018All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,without the prior written permission of SAE. For permission and licensing requests contact: SAE Permissions 400 Commonwealth DriveWarrendale, PA 15096-0001-USAEmail: permissions@sae.orgFax: 724-772-4028Tel: 724-772-4891 For multiple print copies contact: SAE Customer ServiceTel: 877-606-7323 (inside USA and Canada)Tel: 724-776-4970 (outside USA)Fax: 724-776-1615Email: Customer Service@sae.org ISSN 0148-7191Copyright © 2003 SAE International Positions and opinions advanced in this paper are those of the author(s) and not necessarily those of SAE. The author is solely responsible for the content of the paper. A process is available by which discussions will be printed with the pap er if it is publishe d in SAE Transactions. Persons wishing to submit papers to be considered for presentation or publication by SAE should send themanuscript or a 300 word abstract of a proposed manuscript to: Secretary, Engineering Meetings Board, SAE. Printed in USADownloaded from SAE International by Birmingham City Univ, Tuesday, August 21, 2018ABSTRACT This paper describes the development of a generic test cell software designed to overcome many vehicle-component testing difficulties by introducing modern,real-time control and simulation capabilities directly tolaboratory test environments. Successfullydemonstrated in a transmission test cell system, thissoftware eliminated the need for internal combustionengines (ICE) and test-track v ehicles. It incorporated the control of an advanced AC induction motor thatelectrically simulated the ICE and a DC dynamometerthat electrically replicated vehicle loads. Enginebehaviors controlled by the software included not onlythe average crankshaft torque production but alsoengine inertia and firing pulses, particularly during shifts.Vehicle loads included rolling resistance, aerodynamicdrag, grade, and more importantly, vehicle inertiacorresponding to sport utility, light truck, or passengercars. Driver aggressiveness algorithms thatcompensated for sensitivity to high grade,forward/reverse driving, and extremely high speeds werealso incorporated to properly track a variety of severedriving profiles. Test resu lts validating the operation of the system against actual v ehicle data is also included. The paper summarizes the elements required toaccomplish these tasks. INTRODUCTION Detailed simulation and dynamometer testing have beenperformed traditionally as two separate steps in avehicle development process. While the modelingphase typically included some transient behaviors,dynamometer testing has been predominantly understeady-state or idealistic trans ient conditions. Realistic transient behavior assessment and calibration could onlybe performed during actual vehicle testing. The problem was exacerbated by the introduction of hybrid electric vehicle (HEV) systems where the numberof components requiring testing increased whencompared to conventional vehicles. In order to continueprogress at a competitive pac e, laboratory test systems are forced to exploit the power of the latestmicrocontrollers and sophisticated real-time simulationtechnologies such as RAPTOR-RT.