This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

In the rapidly evolving field of automotive engineering, calibration is crucial for optimizing a vehicle'™s control systems to achieve peak performance, efficiency, and regulatory compliance. Traditionally, calibration has been a time-consuming, manual process. However, as modern powertrain systems become more complex and interconnected, there is a growing need for innovative approaches to keep pace with technological advancements. Powertrain Calibration Engineers are increasingly adopting virtual environments to conduct these processes, marking a pivotal shift from traditional methods. Virtualizing the calibration process offers numerous advantages for OEMs and suppliers. By reducing reliance on physical prototypes, companies can significantly cut down on costs and enhance time efficiency. Virtual calibration provides unprecedented flexibility and scalability, allowing engineers to navigate vast parameter spaces with improved accuracy and data utilization. Additionally, this approach opens up new opportunities for enhancing safety and achieving comprehensive integration of diverse systems and subsystems. In this talk, Morgan Jenkins, Chief Product Officer of Secondmind, will explore the transformational impact of artificial intelligence and more specifically advanced machine learning techniques on the calibration process. Machine learning models, which can predict outcomes and suggest optimal calibration settings, act as powerful tools to streamline and refine calibration tasks. The talk will delve into how optimization algorithms efficiently explore calibration spaces without the need for physical testing, bolstered by integrating advanced simulation tools to create hybrid models that accelerate the calibration timeline. Furthermore, the presentation will discuss the use of transient and global machine learning models that extend their utility into the vehicle verification and validation phases of development. By drawing on real-world examples from EV powertrain calibration, this talk will showcase how such cutting-edge approaches dramatically accelerate development cycles, thus supporting the industry's drive for innovation and alignment with environmental goals. Ultimately, the adoption of these virtualized strategies sets a new standard for performance optimization, positioning the industry for continued advancement and success in a digital-first landscape.