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A modernization of tools and processes is vital to develop more innovative products that will integrate complex technologies and comply with ever stricter standards. The upcoming Euro 6 and Euro 7, the European emission standards that define acceptable exhaust emissions limits for new vehicles have increased the workload of engine design and control design engineers. They now have to integrate complex engine actuation and control systems, required to optimize engine performance, while keeping emissions at the lowest level possible. The growing number of systems driven by controls, as well as the multiple interactions between them, makes the engineering tasks more complex as engineers need to take a higher number of degrees of freedom into account. This has a direct impact on costs and times. In a quest of rationalization, the deployment of system simulation for plant modeling permits substantial gains in process efficiency all over the development process.

In the automotive industry simulation represents an essential tool for the development process of the functions designed and integrated within the Engine Control Unit (ECU). This approach applies to each stage of the development cycle to establish the possible physics which are modeled accordingly. The particular stage which relates to the validation of the Engine Control Unit uses test benches called Hardware In the Loop (HIL) systems. They simulate both engine and vehicle by means of integrated models. The characteristics of these benches represent the constraints for the real-time computation of these models, in particular when the Engine Control Unit test requires a highly detailed physical model. This paper attempts to treat the introduction of plant models based on a more accurate physical representation of the internal combustion engines into a Hardware In the Loop target.