Test Technologies Contributing to Electrification - 4. Virtual–Real, Simulator–Test Technology for Optimizing Electric Powertrain Performance Without Using an Actual VehicleFig. 9 HC comparison between actual vehicle and VRSFig. 10 Effect of workhour reduction achieved by VRS test for emission complianceFig. 11 Result of tests using FDV for validating the reproduced Fig. 12 Development front-loading achieved by applying new actual vehicle statesmethod4. Summary3.3 Overview of NVH evaluation test using FDVA model of the e-POWER system in the PT-VRS test system was used to verify whether the FDV could reproduce the vibrations observed in an actual vehicle. Fig. 11 shows the vertical vibration measured at the engine mount on the rear side of the engine near the center of gravity of the PT system. The figure shows a comparison between the measurement results obtained by the driving vehicle test and the results reproduced by the FDV using the VRS test system. The solid lines represent the results log-fitted to the measurement data, as shown by the dashed line; the difference between the solid lines is less than 3 dB. In the same type of test, the same level of accuracy was obtained at other measurement points and in other vibration directions. These tests demonstrate that the vehicle vibration measured in the test with C/D can be reproduced by the PT-VRS bench-top test. The PT vibration of new vehicles can now be analyzed and evaluated before the prototype vehicle is constructed.A VRS test system was developed for powertrain development. The temperature environment was set close to that of the actual vehicle to simulate the driving conditions of an actual vehicle with good real-time performance and model accuracy. With this system, the exhaust emissions and driving performance were evaluated using test bench. This development has made it possible to satisfy the increasingly stricter fuel consumption and exhaust emissions regulations. In addition, the development period was not lengthened, and rework caused by defects occurring in later processes was reduced, even as the electrification of vehicles made the systems more complex. Fig 12 shows the effects of the proposed method. The conventional development method requires a large number of workhours during the later stages of development. In contrast, the application of the new method realizes not only the front-loading of development but also the prevention of rework. We will continue to develop this method and promote its use as a standard to further streamline the development process.54
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