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What are the most important validation procedures for engine management systems?

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Engine management systems (EMS) are the brains of modern vehicles, controlling fuel injection, ignition, emissions, and other functions. They rely on sensors, actuators, and software to optimize performance, efficiency, and reliability. But how can you ensure that your EMS is working properly and meets the standards and specifications of your design and customers? In this article, we will discuss some of the most important validation procedures for EMS, covering the following aspects:

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Birkan Atlamaz, MSc

Chief E/E Officer | E/E, SW, HW | vCISO Vehicle Cybersecurity @ ANADOLU ISUZU | Innovative Startup Mentor | Blogger

1 Hardware testing

Before you can validate the software of your EMS, you need to verify that the hardware components are functioning correctly and within the expected range. Hardware testing involves checking the electrical and mechanical properties of the sensors, actuators, wiring, connectors, and the electronic control unit (ECU). You can use various tools and methods, such as multimeters, oscilloscopes, signal generators, and load simulators, to measure voltage, current, resistance, frequency, and other parameters. You also need to test the hardware under different environmental conditions, such as temperature, humidity, vibration, and electromagnetic interference, to ensure its durability and robustness.

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Warlley Ferreira

Engenheiro Eletricista | Controle e Automa??o | Especialista em Eletroeletr?nica Automotiva | Hybrid and Electric | Instrutor de Forma??o Profissional
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Antes de tudo, pela minha experiência, devemos certificar o bom funcionamento do conjunto de órg?os fixos e móveis do motor, aferir a press?o de compress?o e a press?o do sistema de lubrifica??o, s?o pontos iniciais, assim como a análise preditiva do óleo lubrificante. Certificando o bom funcionamento dos órg?o fixos e móveis, podemos ir ent?o, para a verifica??o das alimenta??es de referencia e os sinais emitidos pelos sensores, seja através de multímetros e/ou osciloscópios, mas em conjunto com os softwares de gerenciamento eletr?nico. Podemos também realizar testes em bancadas, desde que seja possível simular as condi??es de opera??o do componente, sejam eles sensores ou atuadores.

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2 Software testing

Software testing is the process of verifying that the software of your EMS meets the requirements and specifications of your design and customers. Software testing involves checking the functionality, performance, reliability, and security of the software. You can use different levels and types of software testing, such as unit testing, integration testing, system testing, and acceptance testing, to validate the software at different stages of development and deployment. You also need to use various tools and techniques, such as debuggers, code analyzers, simulators, and test cases, to detect and correct any errors, bugs, or vulnerabilities in the software.

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Birkan Atlamaz, MSc

Chief E/E Officer | E/E, SW, HW | vCISO Vehicle Cybersecurity @ ANADOLU ISUZU | Innovative Startup Mentor | Blogger
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In a CAN protocol file such as *.dbc, one should simulate what's engine sending and receiving as a HIL and SIL testing. So that you can be sure that your algorithm works fine to save you some time beforehand on an actual vehicle.

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3 Calibration testing

Calibration testing is the process of adjusting the parameters and settings of your EMS to optimize its performance, efficiency, and emissions. Calibration testing involves using data from sensors, actuators, and other sources to tune the software algorithms and maps of your EMS. You can use different tools and methods, such as calibration software, data loggers, dynamometers, and emission analyzers, to perform calibration testing. You also need to test the calibration under different operating conditions, such as engine speed, load, temperature, and fuel quality, to ensure its adaptability and robustness.

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4 Vehicle testing

Vehicle testing is the process of validating your EMS in a real vehicle under real driving conditions. Vehicle testing involves evaluating the functionality, performance, reliability, and emissions of your EMS in relation to the vehicle dynamics, driver behavior, and road environment. You can use different tools and methods, such as test drivers, test tracks, road tests, and on-board diagnostics, to perform vehicle testing. You also need to test the vehicle under different scenarios, such as urban, rural, highway, and off-road driving, to ensure its suitability and compliance.

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Birkan Atlamaz, MSc

Chief E/E Officer | E/E, SW, HW | vCISO Vehicle Cybersecurity @ ANADOLU ISUZU | Innovative Startup Mentor | Blogger
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?n ICE vehicles, engines are the ultimate source of information. Every aspects of any algorithm are based on engine communication such gearbox, cruise control etc. So vehicle testing must consist of any CAN messages TX and RX from the engine with different driving profiles.

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Highlander Halfeld

Engenharia Automotiva | Gest?o de Projetos | Analista de Produto | Scrum Master | PMO
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It is very important to test the vehicle in the most varied conditions possible, as flaws in the software and operation can be hidden in situations we cannot even imagine. It is necessary to think about all the situations that the user will expose the vehicle to so that these faults can be anticipated and fixed during the design phase, ensuring that no errors are found by the end customer

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5 Simulation testing

Simulation testing is the process of validating your EMS using computer models and simulations of the engine, vehicle, driver, and road. Simulation testing involves replicating the behavior and responses of your EMS in a virtual environment without the need for physical hardware or vehicles. You can use different tools and methods, such as simulation software, models, and scenarios, to perform simulation testing. You also need to test the simulation under different conditions, such as engine speed, load, temperature, and fuel quality, to ensure its accuracy and validity.

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6 Verification and validation testing

Verification and validation testing is the process of confirming that your EMS meets the standards and specifications of your design and customers. Verification and validation testing involves comparing the results and outputs of your EMS with the expected and desired outcomes and criteria. You can use different tools and methods, such as verification and validation software, protocols, and reports, to perform verification and validation testing. You also need to test the verification and validation under different regulations, such as emission standards, safety standards, and quality standards, to ensure its conformity and compliance.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are the most important validation procedures for engine management systems?

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1 Hardware testing

2 Software testing

3 Calibration testing

4 Vehicle testing

5 Simulation testing

6 Verification and validation testing

7 Here’s what else to consider

Automotive Manufacturing

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