R2L methodologies to save time and cut costs


Accurately repeating real-world validation on the testbed

As the demands on the powertrain have become greater, so too has the need to precisely replicate real-world driving conditions on the testbed. Emission legislation, the complexity of the electrified powertrain and market demands all require exhaustive testing and validation.

To carry out this level of testing on the road would be time-consuming and nearly impossible. So, the testbed is a vital tool for this type of activity, in what is known as the Road-to-Lab (R2L) approach. At AVL we have developed an advanced robot system to optimize RDE activities of this kind in the lab.

The Real World, Replicated

OEMs are striving to reduce emissions, increase fuel economy and develop new on-board diagnostic (OBD) and auxiliary emission control devices. As a result, validation and testing has become more challenging than ever. Proving the effectiveness of new technologies under all conditions and in all maneuvers would take years, were it not for R2L methodologies.

At AVL our R2L approach enables the recreation and optimization of real-world PEMS measurements on the testbed. They can then be subjected to a wide range of variables. This offers insights that are not possible in road testing alone, and allows us to isolate and repeat emission-increasing events.

Furthermore, we can conduct and repeat maneuvers 24/7, precisely and under a range of environmental conditions that cannot be duplicated in the real world. This approach eliminates human error, and allows values such as road grade and curvature, traffic, head and tailwinds upon vehicle load to be replicated.

An Algorithmic Approach

Our advanced robot system includes a superior driver algorithm for the replication of real-life vehicle road testing on the powertrain and chassis dyno testbed. With high R2L reproducibility, we can measure emissions, CO2 and mass flow fuel consumption with a high level of accuracy. Even human driver behavior can be simulated.

This toolchain enables OEMs to optimize their system concepts to meet performance targets. It also offers benefits for Tier1 suppliers, service providers and regulators.

A Wide Range of Benefits

The benefits of this approach are many, and extend far beyond the obvious and dramatic time and cost savings. More tests can be conducted thanks to a reduced cool-down time of between 30 and 60 minutes instead of the usual 8 hours. Further benefits include:

  • Higher test throughput leading to increased product validation
  • High R2L reproducibility depending on the prototype (ie. delta NOx <3, CO2 <2 %, fuel consumption <1 %)
  • Tried and tested toolchain for OEMs, Tier1 suppliers, service providers and regulators