EMS Calibration



Target vehicle

  • Gasoline
  • Diesel
  • Hybrid
  • EV


  • Emission
  • OBD-II
  • Driveability
  • After treatment system

Emission calibration

  • SULEV, EURO 6 / 7, China 6 and Tier 4 (Industrial)
  • Emission related hardware and component selection
  • Optimization of logic and calibration for leaner cold fueling
  • UREA-SCR application
  • DPF calibration

Drivability calibration

  • Optimum calibration for high drivability index fuel
  • Logic development for high drivability index fuel
  • Drivability calibration over -30 ˜ 50。... ambient temperature

OBD-II calibration

  • OBD-II, EOBD and KOBD regulation

Vehicle benchmarking

  • Emission related hardware, logic and calibration
  • Fuel economy related hardware, logic and calibration
  • Drivability related logic and calibration

Fuel economy analysis

  • Energy Flow-Down Method

Development of advanced fuel economy system and logic

Catalyst bench aging and vehicle durability cycle development corelated with in-use DF


SULEV application

Fast light-off control

  • H / W side
    • Place the catalyst as close as possible to exhaust manifold
    • Increase catalyst cell density
  • Calibration side to increase heat flux
    • Increase Idle engine speed
    • Spark timing calibration
    • Waste-gate position open control

Reduce engine-out raw emissions
: optimum catalyst heating point and cold start

  • Intake / exhaust VVT control
  • Injection strategy calibration
    : SOI, EOI, fuel pressure, split injection calibration

NOx conversion efficiency increase

  • Fuel cut off condition calibration
  • Catalyst purge calibration to increase NOx conversion efficiency
  • Lambda control calibration with downstream O2 sensor feedback

filter control

GPF model calibration

  • DP soot mass with clean filter model
  • Engine out soot model
  • Soot burning rate model
  • GPF temperature model

GPF control

  • Passive / active regeneration control
    (Lambda, temperature control)
  • Fuel cut off conditon calibration during regeneration
  • Soot mass validation (model vs actual mass)
  • Soot burning efficiency test
  • Service regeneration strategy
  • GPF regeneration strategy (duration, coordinator)
  • GPF OBD (efficiency) strategy

GPF validation test

  • GPF failure check through uncontrolled burning test (DTI, DTO)
    : CT scanning confirmed
  • Environment test (cold, hot, altitude)
  • Ash calibration with fleet test

Diesel SCR control

SCR model calibration

  • Raw NOx, NO / NO2 ratio modeling
  • NOx conversion efficiency modeling
  • NH3 loading / slip modeling
  • SCR temperature model
  • SCR efficiency model

SCR Control

  • Heat-up
  • NH3 loading target
  • Urea dosing schedule
  • SCR defrost calibration in cold condition
  • Strategy for improvement of emission(RDE, WLTC, NEDC, etc.)
  • SCR OBD strategy(efficiency, incorrect urea, consumption, etc.)

SCR validation test

  • Environment test(cold, hot, altitude)
  • Validation of model accuracy
  • Robustness of NOx conversion efficiency in real driving

filter control

DPF model calibration

  • DP soot mass with clean filter model
  • Engine out soot model
  • Soot burning rate model
  • DPF temperature model

DPF control

  • Heat-up / active regeneration control (air control, post injection control)
  • Open & closed loop temperature control
  • Transient conditon check and calibration
  • Soot mass validation (model vs actual mass)
  • Soot burning efficiency test
  • Service regeneration strategy
  • DPF regeneration strategy (duration, coordinator)
  • DPF OBD (PM sensor, efficiency) strategy

DPF validation test

  • DPF failure check through uncontrolled burning test (DTI, DTO)
    : CT scanning confirmed
  • Environment test (cold, hot, altitude)
  • Oil dilution & ash check with fleet test

EURO 7 / China 6

Additional challenge for better fuel consumption

  • Thermal management
    • Integrated thermal management 3-way valve control(block, radiator, heater)
    • Split cooling circuit
    • Optimized temperature of each part
  • Weight reduction
    • Aluminum cylinder block
  • Friction reduction
    • Piston & ring design optimization
    • Crankshaft balance weight optimization
    • Variable oil pump integrated with vacuum pump
    • Timing belt instead of chain system
    • Camcarrier-camshaft module
    • Crank offset
    • Roller rocker arm
    • Switchable water pump or electrically controlled thermostat

After treatment system

  • SCR system will be in multiple locations and the total size will be larger
  • Urea injection will be multi-point injection.
  • DPF would not need active regeneration any more, only passive type would be enough.
  • Electrically heated catalyst could be used for cold start emission.

Combustion system

  • With enhanced SCR system, engine developmint could be focused only on better thermal efficiency and on reducing PM, no longer on reducing NOx emission as before.
  • Compression ratio would be raised to around 18 from current 15~16.
  • EGR would be used limitedly or the system even may be deleted.
  • High swirl would be required less than before, therefore port could be optimized for more flow.


  • 48V mild hybrid system will used.(P0~P2)
  • EHC could be effective by 48V system

Fuel Economy

Principle of Energy Flow-Down Method

To improve fuel economy of your car, understanding of engine + T / M + vehicle interaction and control strategy (ECU, TCU) are very Important

Benets of Energy Flow-Down Method

  • Energy Flow-Down Method can analyze the fuel consumption and contribution of each component and ECU / TCU control data through systematic approach.
  • Client can have the whole view for the quantitative fuel consumption and contribution of each component.
  • Client can recognize the weak and strong points against target vehicle.
  • Client can understand how top maker optimizes every component and control data to improve fuel economy.
  • Client can make catch-up plan of short, mid, long term in the most efcient cost.

How we do,
What you can get!

Measurement items

  • Combustion pressure
  • Ignition signal
  • Engine speed
  • Vehicle speed
  • Manifold absolute pressure
  • Air / Fuel ratio
  • Battery voltage & current
  • Alternator current
  • Cooling fan current
  • Brake pedal signal
  • Accelerator pedal signal
  • Throttle angle signal
  • Coolant temperature
  • Engine oil temperature
  • Injection pulse
  • Fuel rail pressure
  • Fuel temperature
  • Exhaust gas temperature
  • Turbine rpm
  • Output shaft rpm
  • Engine inertia @ lift
  • Drivetrain friction @ lift
  • Drivetrain inertia @ lift
  • Engine friction @ bench
  • Torque converter
    characteristics @ MAD
  • Injector characteristics @ rig
  • Power steering friction @ rig
  • Each gear driving resistance
    @ test load (if necessary)
  • Shift pattern & lockup area @ MAD


  • Indicated thermal efficiency
  • Incomplete combustion loss
  • Pumping loss
  • Engine friction loss
  • Alternator loss
  • Power steering loss
  • Engine inertia loss
  • Torque converter base loss
  • Torque converter slip loss
  • Braking loss
  • Drive train friction loss
  • Drive train inertia loss
  • Clutch loss
  • Vehicle inertia loss
  • Rolling resistance loss (f0)
  • Aerodynamic resistance loss (f2)
  • Pilot / Main injection timing (diesel)
  • Spark timing (gasoline)
  • Idle RPM
  • Total fuel cut time
  • Total cycle number
  • Cooling fan loss
  • Total part load full lockup time
  • Part load speed ratio distribution
  • Total driving time at each gear
  • Shift pattern
  • Energy management system logic
  • Neutral control logic
  • Deceleration lockup logic
  • Ne elevation logic


  • Logic & calibration strategy
  • Engine hardware strategy
    • Friction improvement
    • System application strategy
      (Intake CVVT, Dual CVVT, Turbo, GDI, etc.)
  • Characteristic of engine
    (BSFC, mechanical friction, pumping friction, engine inertia)
  • Transmission hardware strategy
  • Shift pattern & lockup zone strategy
  • Torque converter selection strategy
  • Gear ratio selection strategy
  • Transmission related loss
    (Drivetrain friction loss, slip loss, fuel consumption at each gear)
  • Vehicle thermal management strategy
  • Vehicel electrical load strategy
  • Vehicle energy save strategy
  • Rolling resistance reduction strategy
  • Aerodynamic resistance reduction strategy