Fault Insertion for Controller Calibration in a Range of Engine Models

This document explores the use of detailed crank-angle resolved engine models within VeSyMA–Engines to simulate and analyse abnormal engine operating conditions for ECU calibration and fault detection.

The study introduces a range of realistic engine faults, including air leaks, clogged injectors, stretched timing chains, and throttle sensor short-circuits, to evaluate how a software-based ECU can detect faults using sensor signals and respond through protective limp-home strategies. By combining multidomain mechanical, hydraulic, pneumatic, and electrical modelling, the research demonstrates how high-fidelity Modelica simulations can support advanced controller validation, onboard diagnostics development, and future Hardware-in-the-Loop testing for engine management systems.