Calibration and Diagnostics

The management system for a modern heavy-duty diesel engine is based on several tens of thousands of parameters, characteristic lines and maps that are resident in the control units and need calibrating before SOP

The chief aim in calibration is to optimize fuel consumption, noise and emissions while providing the level of performance that is demanded. We do this by taking the calibration defined in steady-state and dynamic operation on the test bench and then validate and optimize it in the vehicle – also in terms of in-use compliance (IUC). We define our own exacting quality criteria for calibrating parameters specified neither by the client nor the legislator.

In addition to calibrating emissions and fuel consumption, we must also meet a wide range of different demands on diagnosing the overall system to ensure proper operation. We then calibrate these diagnostic functions (OBD) to suit a particular engine and transmission and also enhance them in line with client specifications. Diagnostic functionality is validated by HiL simulation in the real-world control unit.

Partially automated calibration

Advanced test benches allow us to perform calibration activities on a partially automated basis using DoE methods or model-based processes. We work with common calibration tools, such as INCA, INCA-FLOW, CANape or Optishift. The IAV CalGuide database program developed by IAV provides the basis for dataset management, change management and calibration documentation. On request, however, we also use the systems preferred by our clients.