Description:FIELD OF INVENTION
The invention relates to the automotive testing system. Particularly testing of any fuel-powered or electrified vehicles and powertrains, electric motor levels, battery levels. More particularly to develop an automation system to integrate, monitor and control online electronic control unit data with on-road data to the accurate correlation of various attributes or characteristics in road-to-rig methodologies of vehicles and powertrains testing electric motor levels, battery levels and their systems, subsystems at component level testing with replication trials.

BACKGROUND OF THE INVENTION
The road transport sector is the largest consumer of commercial fuel energy within the transportation system in the world and accounts for nearly one-third part of
the total liquid commercial fuel consumption by all sectors. Therefore, the usage of petroleum products and their derivatives which are derived from hydrocarbons increased and consumption for road transportation has quadrupled in the last few decades due to about nine times increase in the number of vehicles and a four-fold
increase in freight and passenger travel demands. To avail these high demands, electric vehicles which are using rechargeable energy storage device is the most appropriate solution for the transportation system. Electric vehicles have the potential to reshape the transportation sector in the world and electric vehicles can drastically cut carbon emissions and clear the way for significant climate progress. In many countries, transportation is the highest-emitting sector for producing noticeable carbon-di-oxide (CO2) emissions. Electric vehicle could transform this high-emissions sector.
The consequences of climate change are being experienced across the globe at an unprecedented level. It is driving the strong push towards electrification & hybridization of powertrains to make exhaust emission cleaner & because of this, vehicle manufacturers face tougher development challenges as tailpipe emissions from Internal Combustion Engines (ICE) are subject to higher levels of scrutiny and stricter legislation. These emissions contribute to poor air quality metrics, especially in urban areas, where the pollutants NOx and PM pose the most serious harm to human health.
Also, considering global warming due to green gaseous emissions and increasing levels of pollution, technical experts with close association with government authority bodies in many countries are moving towards electrification of mobility. There are different challenges in the case of electrified vehicles with respect to complex system architecture, thermal management challenges and range anxieties which are major focus areas to develop robust electrified vehicles. Major challenges for automotive manufacturers are to reduce the development and validation time and efforts without compromising on the quality and robustness of the end product before launching into the market.
There is one study released by some scientists a few days ago which shows that electric vehicles can generate half or less than half of the emissions of comparable gasoline-powered cars from manufacturing to disposal. In recent years, a number of governments, set dates for ending the sales of fossil fuel-powered vehicles. Therefore, it is projected that research as well as investment in technologies that support mass vehicle electrification will drive down prices and increase the adoption of electric vehicles. As a result, demand for electric vehicles is expected to rise strongly, as many countries call for an end to their reliance on internal combustion engines by the end of this decade.
The major components of electric vehicle are an electric motor, ECM (Electronic control module), a traction battery, a battery management system, a vehicle body, a frame, a special type of fluid for cooling purposes and other fluids required for braking and some more viscous fluids for lubricants. However, the most crucial and important component in an electric vehicle is the battery of that electric vehicle. Moreover, the battery management of that electric battery must be designed and developed in a precise way so that the range of a vehicle and the life of a battery can be extended and it should also perform in an efficient way so that not only it can pocket friendly for a charge per kilometres but also economical for service cost and maintenance cost. In these batteries, different chemicals and heavy metals and their alloys are used which is hazardous to the environment.
In most batteries, a cell is the smallest unit of an energy storage device. This cell comprises four key components including cathode, anode, electrolyte and separator. There are various forms of a cell such as prismatic, cylindrical and polymer. An electrical energy storage or battery system or array may include a plurality of battery cells in relatively close proximity to one another. A plurality of battery cells may be assembled into a battery stack or module, and a plurality of battery modules may be assembled into a battery pack. Batteries may be broadly classified into primary and secondary batteries. Primary batteries, also referred to as disposable batteries, are intended to be used until depleted, after which they are simply replaced with new batteries. Secondary batteries, more commonly referred to as rechargeable batteries, employ specific high-energy chemistries permitting such batteries to be repeatedly recharged and reused, therefore offering economic, environmental and ease-of-use benefits compared to disposable batteries.
Rechargeable batteries may be used to power such diverse items as toys, consumer electronics, and rotary electric machines, such as electric motors generators and also used for powering motor vehicles. Depending on the particular configuration of the rotary subject electric machine, the battery cells may be recharged via an off-board charging station and/or via onboard regeneration. Battery cells may be depleted of charge during the operation of the powered item or through self-discharge during storage. Self-discharge is a phenomenon in batteries in which internal chemical reactions reduce the stored charge of the battery without a connection between the electrodes or with an external circuit. Self-discharge decreases the shelf life of batteries and causes them to initially have less than a full charge when actually put to use.
The consequences of climate change are being experienced across the globe at an unprecedented level. It is driving the strong push towards electrification & hybridization of powertrains to make exhaust emission cleaner & because of this, vehicle manufacturers face tougher development challenges as tailpipe emissions from Internal Combustion Engines (ICE) are subject to higher levels of scrutiny and stricter legislation. These emissions contribute to poor air quality metrics, especially in urban areas, where the pollutants NOx and PM pose the most serious harm to human health.
Also, considering global warming due to green gaseous emissions and increasing levels of pollution, technical experts with close association with government authority bodies in many countries are moving towards electrification of mobility. There are different challenges in the case of electrified vehicles with respect to complex system architecture, thermal management challenges and range anxieties which are major focus areas to develop robust electrified vehicles. Major challenges for automotive manufacturers are to reduce development and validation time and efforts without compromising on the quality and robustness of the end product before launching into the market.
Considering the future emission legislation requirements for internal combustion engines and Electrified vehicles, OEM’s need to spend huge development efforts to validate performance and emissions on their vehicles on roads for emission pollutants control and addressing the range/safety concerns for internal combustion engines and Electrified vehicles as well as powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level respectively. There is road-to-rig methodologies are already available in the market from many engineering consultancy providers as a front-loading approach to reduce overall vehicle program time and efforts. There were several approaches available in the market to simulate on-road cycles in the laboratories to enhance the rapid development of powertrains with lower development costs and efforts. However, every approach and methodology has its own advantages and disadvantages with respect to the accuracy of correlation which is an important factor for manufacturers to develop vehicles within the laboratory.
The prior art reveals that there have been attempts to develop a system to enhance the accurate correlation of various attributes or characteristics in road-to-rig methodologies according to the needs of the user. Following patent literature describes the existing state of the art.
US2014102187A1 discloses electric hybrid powertrains and methods of operating and testing which comprises test and certification methods in which a controller operates a diesel engine. In this invention, there is an integrated motor/generator alone, or both the diesel engine and the motor/generator is provided for brake torque at a common output shaft according to predetermined duty cycle criteria. From which emissions are measured based upon criteria accounting for the effects of regenerative braking, engine shut off, and other operational modes unique to hybrid powertrains. Further exemplary embodiments comprise hybrid powertrain systems and methods of operating the same meeting performance and emissions requirements including respective limits on NOx, hydrocarbon, particulate matter, CO, and CO2 without reliance on conventional emissions reduction devices or techniques. The disclosed method describes emission reduction techniques and meeting performance requirements for hybrid powertrains and not a replication of road testing emission, battery range etc. into lab with better accuracy.

US2021276571A1 discloses apparatus and method for testing automated vehicles wherein a processor, responsive to a set of location or motion data describing one or more objects relative to a first, local frame of reference, generates a transformed set of location or motion data describing the one or more objects relative to a second, local frame of reference different than the first local frame of reference, such that the set of location or motion data and the transformed set of location or motion data relative to a global frame of reference are same. In this invention, the processor gives outputs of the transformed set of location or motion data to a vehicle such that the vehicle performs control operations responsive thereto. This invention is related to the calibration of autonomous vehicle control systems and the measurement of their impact on energy efficiency and Emission components. This invention does not correlate road test data with lab test data so that it can match the emission components, and be processed for the further development of the product.
CN105675824A provides a simple system for testing the emission of a motor vehicle through a transient working condition method. The functions of equipment are simplified on the basis of reserving the large emission detection equipment, and the reliability and traceability of a data source are guaranteed. The system comprises a site. A test region and a control region are arranged on the site, and the test region can be observed from the control region. A test frame, a chassis dynamometer, a draught fan and a monitoring camera are arranged in the test region, the chassis dynamometer is arranged on the front of the test frame, the draught fan is located on the front of the chassis dynamometer, an air blowing opening of the draught fan is formed towards the front end of the vehicle to be tested, and the monitoring camera is used for recording real-time images of the vehicle to be tested. An emission analyzer and a master control computer for a detection mechanism are arranged in the control region, a constant volume sampling unit and connecting pipes are arranged between the test region and the control region, and the tail gas of the vehicle to be tested passes an inlet of the constant volume sampling unit through the input connecting pipe.
CN111122171A requests to protect the multi-source heterogeneous data association analysis method for multiple emission detection methods of a diesel vehicle and a diesel engine based on a VSP (vehicle specific power) working condition. The method includes: acquiring multi-source detection data and a working condition point group, acquiring equivalent working condition points according to VSP Bin classification statistics, retaining the equivalent working condition points with a working condition weight of larger than 0 as final equivalent working condition points, replacing an original working condition point group with the obtained equivalent working condition points, and performing association analysis on the correlation among the multi-source detection data. Directed at multiple emission detection methods provided in multiple emission laws and regulations, the correlation between different detection methods is determined by applying correlation analysis, and technical support is provided for simplifying the detection methods, improving the emission detection efficiency and realizing real-time monitoring. The correlation analysis shows that great correlation exists among an OBD actual road detection method, a drum detection method, a rack detection method and the like, and mutual prediction among results of different detection methods can be realized through reasonable means.
US7049595 provides a method and a measuring system for determining exhaust gas emissions from a moving vehicle by a remote optical measuring technique. The model and/or type of the vehicle under examination is identified, and the driving situation of the vehicle in question is determined at the moment of measurement. A calculatory vehicle model is used to determine a case-specific estimate for the carbon dioxide concentration of the exhaust gas plume depending on the vehicle in question and its driving situation. The accuracy of determining the concentrations of the actual emission gases is improved by eliminating the inaccuracy of the carbon dioxide concentration values.
For the reasons stated above, which will become apparent to those skilled in the art upon reading and understanding the challenges in, there is a need in the art for a system for testing vehicles. The present invention has been made in consideration of the above-described problems of the prior art, and it is an object of the present invention to provide a system for accurate correlation of various attributes or characteristics in road to rig methodologies for testing of vehicles. Henceforth, for solving the abovementioned problems, the system is developed for performing tests of the complex drive system and control system of such fuel-powered vehicles or electrified vehicles and for powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level.
The present inventions deliver more value-added benefits to many automobile manufacturers for the development of electrified vehicles (Hybrid, BEV and FCEV), overcoming obstacles in replicating all real-world driving cycles in the laboratories on all kinds of dynamometers and testing stands. This enables many OEMs to reduce their product life cycle with minimum effort and time.

OBJECT OF THE INVENTION
The object of the present invention is to provide a system and method for testing and support developing of fuel-powered and hybrid or electrified vehicle wherein a variety of tests are performed on the road test and after that on a drive system with a control system of the vehicle and for powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level while it is in a simulated running condition.
Yet another object of the invention is to provide a system and method for testing and support developing of a fuel-powered and hybrid or electrified vehicle and for powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level which enables many OEMs to reduce their product development life cycle with minimum effort and time.
Yet another object of the present invention is to provide a system and method for testing and support developing a fuel-powered and hybrid or electrified vehicle and for powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level to optimize maintenance and reliability of various components and eventually reduce the cost by providing testing with exact replication, emulation and simulation of road testing or customizable testing according to the need of the user in test laboratories
Yet another object of the present invention is to provide a system and method for testing and support developing a fuel-powered and hybrid or electrified vehicle to increase the overall efficiency of the testing and to reduce the errors by providing testing with exact replication and simulation of road testing.
Yet another object of the present invention is to provide a system and method for testing and support developing a fuel-powered and hybrid or electrified vehicle to maximize various testing facilities under a single vehicle testing and for powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level
SUMMARY OF THE INVENTION
Embodiments of the present disclosure present technological improvements as solutions to one or more of the above-mentioned technical problems recognized by the inventor in conventional practices and the existing state of the art.
The invention particularly describes an automation system to integrate, monitor and control online electronic control unit data with on-road data to the accurate correlation of performance and emissions in road-to-rig methodologies of vehicle testing and for powertrains testing, electric motor levels, battery levels and their systems, subsystems with replication trials.
The system comprises a plurality of sensors, at least one processing unit, at least one memory, at least one database, at least one server module, at least one web application, at least one central automation unit, vehicle powertrains, electric motor and battery. The system and method of the present invention comprise inspection of the vehicle and their powertrains testing, electric motor levels, battery levels and their systems, subsystems which includes checking for any physical damage to the vehicle, powertrains, electric motor and battery or any essential component of the testing equipment. The method includes checking engine oil, fuel level, filters, etc, or other consumables which are basic necessary requirements for the trial run or test run. The method includes measurement of devices for installation feasibility and checking the battery status and checking necessary communication workings of a communication module, at least one central automation unit, and dynamometer controllers to control. The method further includes exporting data to the web-based application which includes recording test data and many other required data for accurate correlation. The system checks the given inputs and checks the logic. If the logic check fails, then necessary manual actions with the test sample to match the condition same as on road and repeat from the earlier stage. If the logic check passes then go to the next step “start test”. In the last stage after finishing the test, the obtained data may be analyzed for future test analysis.

BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments can be better understood with reference to the following drawings and descriptions. The components in the figures are not necessarily to scale, the emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, the figures, like reference numerals designate corresponding parts throughout the different views.
Reference will be made to embodiments of the invention, examples of which may be illustrated in the accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
The above and other objects, features, and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
Figure 1 illustrates the various graphs wherein different parameters are referred to the typical diesel engine of the existing testing system.
Figure 1a illustrates a typical diesel engine exhaust system of an existing testing system of vehicle.
Figure 2 illustrates schematic of the system or device of communication on-road testing of system and method to enhance accurate correlation of attributes and characteristics in road to rig methodologies according to one of the embodiments of the present invention.
Figure 3 illustrates a functional flow diagram of the on-road test according to an exemplary implementation of one of the embodiments of the present invention.
Figure 4 illustrates different exhaust system parameters of BS-6 Diesel engine which plays a major role in controlling emissions
Figure 5 illustrates different devices of exhaust systems which explain the importance in replication trials to achieve good replication according to one of the embodiments of the present invention.
Figure 6 illustrates a graphical user interface that explains logic conditions in an automation web-based application to execute replication trials according to one of the embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments.
As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
In the following description, for the purpose of explanation, specific details are set forth in order to provide an understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these details. One skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into a number of systems.
The various embodiments of the present invention provide a system and method to enhance the accurate correlation of various attributes or characteristics in road to rig methodologies for vehicle testing. vehicles and for powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level Therefore, the disclosed system provides an accurate correlation for testing fuel-powered or electrified vehicles in test laboratories by using all kinds of dynamometers and testing stands. As well as powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level
Furthermore, connections between components and/or modules within the figures are not intended to be limited to direct connections. Rather, these components and modules may be modified, re-formatted or otherwise changed by intermediary components and modules.
The systems/devices and methods described herein are explained using examples with specific details for better understanding. However, the disclosed embodiments can be worked on by a person skilled in the art without the use of these specific details.
Throughout this application, with respect to all reasonable derivatives of such terms, and unless otherwise specified (and/or unless the particular context clearly dictates otherwise), each usage of
“a” or “an” is meant to read as “at least one.”
“the” is meant to be read as “the at least one.”
References in the present invention to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Embodiments of the present invention include various steps, which will be described below. The steps may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, steps may be performed by a combination of hardware, software, firmware and/or human operators.
Various methods described herein may be practiced by combining one or more machine-readable storage media containing the code according to the present invention with appropriate standard computer hardware to execute the code contained therein. An apparatus for practicing various embodiments of the present invention may involve one or more computers (or one or more processors within the single computer) and storage systems containing or having network access to a computer program(s) coded in accordance with various methods described herein, and the method steps of the invention could be accomplished by modules, routines, subroutines, or subparts of a computer program product.
In some embodiments, the systems may be configured as a distributed system where one or more components of the system are distributed across one or more networks in the testing system.
If the specification states a component or feature "may", "can", "could", or "might" be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
As used in the description herein and throughout the claims that follow, the meaning of "a'', ''an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.
Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this invention will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
While embodiments of the present invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claim.
In existing working models of the system the accurate emulation and simulation of performance and emissions from on-road to test laboratories is not so precise because of following reasons: 1. Different initial boundary conditions of the vehicle system as well as powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level 2. The testing of the vehicle is conducted by using different chassis dynamometer, engine dynamometer and powertrain dynamometer according to the requirement of the testing standards or the according to the desired output/results. 3. The purpose of testing is different as the main purpose of road-to-rig methodologies is to perform complete vehicle performance and emission development within the laboratory and de-linking with on-road trials which is more time and effort-consuming etc.
There are several road-to-rig solutions available like road load simulation with gradients, and torque matching methods. The abovementioned method is used for testing performing tests only for showing the standards are obtained in limiting conditions and they are performed on ideal conditions which are not necessarily true at all times in standard working conditions of the vehicles and powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level Therefore, it may not provide accurate results in vehicle testing systems, thereby leading to no precision and the test results differ from the actual results.
Due to complex vehicle architecture and to meet future and advanced regulatory requirements, OEMs need much more development to obtain more precise results which requires more time and effort for vehicle programs to develop advanced testing systems which can provide better as well as error-free or more accurate results. The current available Road to Rig solutions are capable to replicate work done/loads/torques accurately only from an engine perspective. Since different vehicles have complex Exhaust After Treatment Systems (hereinafter referred to as EATS) which include DOC, Heated DOC, LNT, SCR, sCRF, cDPF, sDPF, ASC, etc.) It is very essential to monitor the status of EATS to ensure accurate replication of tailpipe emissions for internal combustion engine, especially diesel-powered vehicles. The readings provided by the testing systems for the above parameters are important because the whole result is depending on these abovementioned parameters. If there is a difference between ideal conditions and testing rig conditions, then the entire testing provides faulty results and the ultimate aim and objectives of the testing system may not be achieved which is not considered for the better accuracies by the ultimate standards. In case of Electrified vehicles or electric motors or in batteries, it is also essential to monitor the status of any hardware components of the vehicle like Battery SOC, Thermal management of battery and motor, battery management system and its status, E-motor status, Inverter, any other accessory loads, etc., and need to ensure that the same can be correlated in replication of test cycles inside the laboratory.
FIG. 1, illustrates the various graphs wherein different parameters which are not limited but it can be referred in to typical diesel engine testing in which challenges faced by internal combustion engine during emulation or simulation from on-road to the laboratory. In this figure the vehicle speed, engine speed, gear positions, and pedal operations are described which are ensured the same as on road tests, there is a high variation in the status of EATS which makes vehicle performance and emission replication very poor or not appropriate according to standards. This graphs shows different levels of on road test data and data of replication trials in different levels.
FIG. 1a illustrates the typical architecture of a diesel vehicle system, the exhaust system which is connected to the engine. Various sensors are provided to calculate various emissions parameters which provides calculated data of the engine and control unit. In advanced diesel engines, there is mandatory to use a diesel exhaust fluid in vehicles with Selective Catalytic Reduction (SCR) technology to reduce harmful gases being released into the atmosphere. This fluid is a 32.5% solution of high-purity, synthetically manufactured urea in de-mineralized water. If this fluid is not used in diesel engines, then it will not be able to meet the latest emissions standards. The engine will emit significantly higher levels of nitrogen oxide (NOx) than allowed limit which is set by the regulating emission authorities. There is frequent dosing is used of this fluid to reduce the level of emissions. The dosing status depends upon the exhaust temperature which leads to the initiation of this fluid Injection and hence the resulting variation in tailpipe NOx emissions. There are different soot load levels that might lead to higher variations in PN, and different exhaust temperature levels before the start of replication tests lead to different operating modes within the engine management system and hence the higher variations of the performance and emissions. This results in differences in actual test results and lab test results which is not appropriate way to conduct tests and can provide inaccurate results. Therefore, to enhance the accurate replication of vehicle emissions and performance, it is required to monitor the status of EATS in case of diesel vehicles and must be within tolerance acceptable criteria.
Similarly, in electric vehicles the output of the battery pack is important because in every scenario the performance of the vehicle may not be ideal due to which it may not provide the ideal efficiency of the given battery packs. The range is considered as a key parameter of electric vehicles. Therefore, battery capacity is the main parameter influencing electric vehicles' range. In order to batteries are the most expensive part of electric vehicles due to is it suitable to focus on other parameters such as weight, aerodynamic drag coefficient or correct size of the motor. The range is not influenced only by the design parameters such as battery capacity but also important is driver influence. Therefore, in electric vehicles Battery SOC (State of Charge) estimation status, Motor performance Torque and Power status, Motor load status, Battery and Thermal management system parameters, Regenerative braking status, Battery Management System Parameters for Temperature, Current, Voltage, etc, Inverter status, PDU-Power Distribution Unit status, and Vehicle driving modes need to be considered for obtaining accurate test results.
Referring to FIG. 2 illustrates a device communication schematic of on-road testing of a System and method to enhance accurate correlation of various attributes or characteristics in road to rig methodologies according to one of the embodiments of the present invention. The system comprises a plurality of sensors, at least one processing unit, at least one memory, at least one database, at least one server module, at least one web application, a vehicle for testing, at least one ECU(or) any xCU, a communication module, at least one central automation unit, dynamometer controllers to control.
1. Vehicle: Test sample which is under development. In case of an engine dynamometer, the test sample can be an engine and powertrain dynamometer. In case of an electric vehicle the sample will be powertrain or electric motor, battery attached to different transmission components.
2. ECU(or) any xCU: The controllers of the vehicle/engine/powertrain/ electric motor which is reading and recording data from different sensors which can be programmed to perform necessary actions based on sensors' feedback received from the controllers. for example, interlocking of operations, executing programs for safety reasons etc.
3. Communication modules: This special purpose module that converts data of one controller into an electric signal which can be recognized and read by another controller. To establish successful communication between two different controllers.
4. Host (Optional): Intermediate controller between central automation and ECU(or) any xCU, communicate, read and write data to ECU and xCU, also communicate with central automation system work as a slave controller and follows commands sent by central automation to ECU or xCU to execute necessary logics and programs.
5. Central Automation: An automation system is needed to ensure that all devices inside the test cell like chassis dynamometers, emission measurements systems like motor exhaust analyzer, dilution tunnel, particulate mass, particulate number measurement devices, and other test cell peripherals are integrated to one central host system from which operator controls, give demands, receive feedback, and log all available parameters to generate data reports as and when required. This automation system is also configured to monitor instrument boundary conditions, test limits and health status checks of all integrated equipment. By using a communication module, it can communicate directly with the vehicle/powertrain / engine xCU by using these tools which can interface an automation system to monitor and record all xCU data which will help to match conditions during lab replication trials same as the on-road conditions. Multiple communication can be possible using this device for example from xCU to automation directly or xCU to automation via a host communicating device which includes a storage module, memory module, and processing module for processing different inputs and thereafter by providing different output for controlling the controller.
Figure 3 illustrates the functional flow diagram of the on-road test according to an exemplary implementation of one of the embodiments of the present invention. The system comprises a plurality of sensors, at least one processing unit, at least one memory, at least one database, at least one server module, at least one web application, at least one central automation unit, vehicles and powertrains testing, electric motor levels, battery levels and their systems, subsystems at component level. The system and method of the present invention comprise inspection of the vehicles, powertrains and electric motors which includes checking for any physical damage to the vehicle powertrains and electric motors or any essential component of the testing equipment. The method includes checking engine oil, fuel level, filters, etc., or other consumables which are basic necessary requirements for the trial run or test run. The method includes measurement of devices for installation feasibility and checking the Battery status and checking necessary communication workings of a communication module, central automation unit, and dynamometer controllers to control.
The method further includes conducting on-road tests and data recording with an ECU data logger, data acquisition system etc. Further, it includes preparing test cycles and uploading to the central control system for establishing vehicle ECU and xCU communication with the central automation system. The method includes exporting data to the web-based application which includes recording test data and many other required data for accurate correlation. After that, it includes checking logic. If the logic check fails it instructs to do all necessary manual actions with test sample to match the condition same as on-road and repeat from the earlier stage. If the logic check pass then go to the next step “start test” i.e. start the replication trail in test facility. In last stage after finishing test the obtained data may be analyzed for future test analysis. The system may be repeating or conducting tests /trails for different combinations or configurations for any further validation.
Referring to FIG. 4, illustrates graphs that explain about different parameters of (BS-6 Diesel Vehicles) which include Temperature, pressure and status of such systems that play a major role in road-to-rig replication. This data is already being monitored, stored and controlled by different vehicle/engine/powertrain xCUs. All parameters must be within some acceptable limit to achieve good replication in the lab. This disclosed figure illustrates different graphs which explain the importance of tolerance limits in replication trials to achieve good replication. As shown in plots for Internal Combustion Engine the diesel particulate filter temperature (T5), the synthetic liquid additives status and its dosing, selective catalytic reduction temperature, Soot load %, Engine OP mode, etc. is not the same as the on-road test (On road test indicated by Blue line). In this situation, if the replication trial is performed in the lab it may impact on final emission result and performance. For better correlation, this parameter needs to be within condition block (tolerance) limits. These limits are automatically calculated by the communication module used in web applications. Therefore, it becomes very easy to monitor all vehicle xCU parameters during the on-road trial and keep the same or within tolerance during replication for correlation.
Referring to FIG. 5 different parameters of exhaust systems which explain the importance in replication trials to achieve good replication. In this figure different parameters not limited to the provided parameters or any other parameters included in test chamber cell which are essential for testing. For better correlation this parameter should be within the condition limits.
Referring FIG. 6, illustrates a graphical user interface that explains logic conditions in an automation web-based application to execute replication trials, automation web-based application is able to check the status and parameters of vehicle xCU’s or any test cell parameters and it can compare with the on-road status and tolerance which can allow executing test if all test conditions are “OK” Therefore, the disclosed system and method narrow down this gap between the method of monitoring & process which ensures the accurate replication of vehicle attributes and characteristics during the road to rig methodologies for all kind of motilities (ICE, HEV, EV, FCEV, etc.)
Advantages of the invention
• The disclosed system provides a vehicle testing or powertrain testing/ electric motor/ battery system for accurate correlation of all functional attributes from on road to the Laboratory to rapidly develop vehicles and minimize the time and efforts required to complete vehicle development.
• The disclosed system provides a vehicle testing or powertrain testing/ electric motor/ battery system that saves time and effort are equivalent to savings of development costs.
• The disclosed system can be implemented in the existing module of the testing module because of this the disclosed system provides more accurate results.
The processes, methods disclosed herein may be deliverable to or implemented by a processing device, controller, or computer, which may include any existing programmable electronic control unit or dedicated electronic control unit. Similarly, the processes, methods, or algorithms may be stored as data and instructions executable by a controller or computer in many forms including, but not limited to, information permanently stored on non-writable storage media such as ROM devices and information alterably stored on writeable storage media such as floppy disks, magnetic tapes, CDs, RAM devices, and other magnetic and optical media. The processes, methods, or algorithms may also be implemented in a software executable object.
Further, while one or more operations have been described as being performed by or otherwise related to certain modules, devices or entities, the operations may be performed by or otherwise related to any module, device or entity.
Further, the operations need not be performed in the disclosed order, although in some examples, an order may be preferred. Also, not all functions need to be performed to achieve the desired advantages of the disclosed system and method, and therefore not all functions are required.
While selected examples of the disclosed system and method have been described, alterations and permutations of these examples will be apparent to those of ordinary skill in the art. Other changes, substitutions, and alterations are also possible without departing from the disclosed system and method in its broader aspects.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, thereby enabling others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention. , Claims:1. A system to enhance accurate correlation of attributes in road-to-rig methodologies, the system comprising
a plurality of sensors; at least one processing unit; at least one memory; at least one database; at least one server module; at least one web application; at least one central automation unit; dynamometer controllers to control the operations of dynamometer; driving robot; vehicle or the test sample; power analyser
characterised in that said web application aligns the data from the data central automation module, correlates the parameters by checking the given inputs and logic
and wherein
if a logic check fails, then the system instructs to do the necessary manual actions with the test sample to match the condition same as on road and repeat the test from the earlier stage.
if a logic check is pass then system proceed with the test.

2. The system as claimed in claim 1 wherein the plurality of sensors are configured for correlation of performance and emissions in road-to-rig methodologies of fuel-powered and or electrified vehicles for all parameters of the internal combustion engine in a fuel-powered vehicle or electric vehicles, for Exhaust After Treatment Systems parameters which includes DOC, Heated DOC, LNT, SCR, sCRF, cDPF, sDPF, ASC or Motor performance Torque and Power status, Motor load status, Battery and Thermal management system parameters, Regenerative braking status, Battery Management System Parameters for Temperature, Current, Voltage, Inverter status, PDU-Power Distribution Unit status and Vehicle driving mode.
3. The system as claimed in claim 1 wherein the plurality of sensors configured to detect and/or measures the plurality of parameters, convert the measured plurality of parameters into proportionate electrical signals and communicate said electrical signals to the processing unit.

4. The system as claimed in claim 1 wherein the processing unit comprises at least one processer and at least one memory communicatively coupled to it, the processing unit electrically coupled to the plurality of sensors, said processing unit configured to communicate with the plurality of sensors to receive the captured parameters in the form of proportionate electrical signals in real-time and analyze and process them.

5. The system as claimed in claim 1 wherein at least one database is configured to act as a real-time database, said database communicatively coupled to at least one processing unit to fetch the processed signal information of the data from the sensor through the processing unit, store the received signal information and communicate it through the Web Base Application to the data central automation module.

6. A method to enhance accurate correlation of attributes in road-to-rig methodologies comprising steps of:
• inspecting vehicle powertrain / electric motor/ battery condition and checking engine and battery parameters to conduct a test;
• installing measurement sensors to obtain Emission data, and battery status;
• conducting on-road tests and data recording with ECU data logger, data acquisition system;
• preparing test cycle and uploading to the central control system to establish vehicle ECU and xCU communication with a central automation system.
• checking logic:
a. If logic check fails then ask to perform manual actions with the test sample for matching the condition same as on road by repeating the test.
b. If logic check pass then go to the next step for starting the test
• repeating or conducting tests for different combinations or configurations for further validation and development of vehicle engine, powertrains, components in vehicle system