Session: 04-01: Modelling, Control and Design of Hybrid Powertrains

Paper Number: 172170

172170 - Avl’s Sil Push: Cost-Effective Development Through Integrated Virtual Test Environments and Real-Time Simulation 

Abstract: 

Virtual testing environments such as Hardware-in-the-Loop (HiL) and Software-in-the-Loop (SiL) with virtual control units utilizing object code based on real target software have become indispensable in driving the digital transformation of automotive development, calibration, and testing. By leveraging these advanced simulation platforms, manufacturers can significantly reduce the number of physical test vehicles required and frontload a wide range of validation tasks, resulting in substantial cost savings and accelerated time-to-market.

The increasing complexity of modern vehicle powertrains - driven by evolving end-user requirements and stringent regulatory standards - demands high-fidelity simulation models for each module within a comprehensive powertrain system. These models are not limited to the early concept phase; rather, they are integrated throughout the entire development process, from initial architecture exploration and concept validation to calibration, integration, and even post-production support. This continuous use ensures robust, data-driven decisions and supports both passenger car and heavy-duty vehicle programs through to the end of their product life.

A particularly valuable application of SiL is in the domain of On-Board Diagnostics (OBD). SiL enables engineers to systematically simulate fault conditions, validate diagnostic trouble code (DTC) detection, and verify compliance with regulatory standards in a controlled, virtual environment. For instance, OBD routines can be thoroughly tested for correct responses to sensor failures or implausible signals, ensuring that software meets both legislated and OEM-specific diagnostic requirements before hardware is available. This early and repeatable validation of control algorithms and diagnostic functions greatly reduces the risk of costly recalls, customer dissatisfaction, and regulatory penalties due to software quality issues discovered late in development or after Start of Production (SOP).

However, achieving high-fidelity simulation for complex powertrain and diagnostic systems presents significant modeling challenges. Accurate virtual models must replicate real-world behavior across diverse vehicle architectures and operating conditions, necessitating ongoing refinement, careful parameter management, and validation against hardware benchmarks.

To address the scale and complexity of modern automotive software, the automation of SiL pipelines is increasingly critical. Automated test case triggering and execution allows large regression suites to be run with minimal manual intervention, accelerating feedback loops and supporting continuous integration and delivery. By automating OBD test scenarios—such as systematically injecting faults and verifying DTC responses—teams achieve comprehensive coverage and repeatability, transforming validation from weeks of manual effort to hours of automated execution.

Attendees will gain valuable insights into how virtualization in development has become a cornerstone for addressing today’s engineering challenges at AVL. Beyond ensuring high quality, the primary drivers for adopting virtualization are significant cost reduction and accelerated time-to-market—critical factors in modern powertrain development.

AVL’s expertise in developing and deploying real-time simulation models, coupled with advanced automation of SiL pipelines, is used productively in a magnitude of projects to ensure software quality from early development through SOP minimizes field risks, supports regulatory compliance, and enables manufacturers to deliver reliable, high-quality vehicles on schedule.

This presentation will provide a structured overview of how these simulation environments and topics are set up and utilized across different stages of the development process.

A key focus will be on AVL’s real-time system simulation solutions, with a deep dive into combustion and aftertreatment technologies. This includes not only conventional Diesel and Gasoline applications but also alternative fuels such as Compressed Natural Gas (CNG) and Hydrogen.

Presenting Author: Thomas Glatz AVL Mobility Technologies Inc

Presenting Author Biography: For well over a decade, Mr. Glatz has been working on simulation topics in various roles at AVL, a private global technology company.
AVL specializes in mobility technology development, including simulation, testing, and solutions for the automotive industry and other sectors like rail, marine, aviation, and industrial green energy.
In his current role, he is responsible for the business development of AVL's Advanced Simulation Technologies business for the North American market.
He also serves as the primary technical expert for system simulation of batteries, fuel cells, and powertrain systems.
Mr. Glatz is a member of AVL's strategic initiative for AI and part of the international Creators Expedition team, AVL's startup-partnership initiative.
He supports strategic planning and future product development through market feedback, and represents AVL Simulation at various industry events, as a session chair, panelist, and speaker.

Prior to transferring to North America, Mr. Glatz was a Senior Software Development Engineer for AVL in his home country Austria,
focusing on multi-physical system simulation software.
With 5+ years in software development, he worked on various Battery, Fuel Cell, and Exhaust-aftertreatment solutions, and served as the expert liaison between the development team and internal and external partners.
His detailed industry insight regarding simulation processes and workflows from a user and application perspective can be attributed to his years spent with AVL's Engineering business unit that started his career.

Mr. Glatz holds a MS and BS in Chemical Engineering from Graz University of Technology, where he was awarded a Graduation with honors.

Authors:

Kurt Klumaier AVL List GmbH
Thomas Glatz AVL Mobility Technologies Inc