Digital Automotive Development - Electronic systems as ...€¦ · Digital Protoype 7.0 Summary From boundary conditions to an engineering tool environment • The development of

EI Electronic systems as significant contributers and challenge of dealing with complexityErstelldatum: 28.05.2008

Änderungsdatum: 30.05.2008Seite 1

2.0Products3.0Requirements

1.0Initial situation

4.0Complexity Management5.0Fields of action6.0Digital Protoype7.0Summary

Digital Automotive Development -Electronic systems as significant contributers and challenge of dealing with complexityArmin Müller, Director Innovations, Concepts; Dr. Ing. h. c. F. Porsche AG






From boundary conditions to an engineering tool environment

• The development of a vehicle is influenced by competition, differentiation, legal requirements and trends in a global society as well as by customers.

• These complex and partly contradictory requirements have to be balanced for an exeptional product and have to be integrated in the vehicle. This results in a high complexity in the car developing process.

• The process of managing the complexity is organized by a systematic model. Theapplication of this model foucusses on the organizational and technical aspects.

• One of the main focus concerns the application of digital prototypes. Vehicleengineering needs further development and extension of current tools.

1.0Initial Situation






The automotive market demands attractive products and leads to a permanently rising variety of model versions.

2.0Products






Beyond the variety of model versions, each vehicle has to meet additionalrequirements.

• The automotive overall system has to meet all legal demands, requirements of consumer protection and inhouse demands.

• The automotive overall system has to meet trends of interest in a global society forat least the product life cycle.

• The automotive overall system gets its distinguishing by the styling of the overallsystem and the integrated innovations. The value of the the overall system therebyis higher than the value of the addition of its subsystems.

• The automotive overall system accomplishes the economical competitiveness.

3.0Requirements






The amount of safety requirements to be fullfilled has tenfold since 1980.

3.0Requirements

Amou

ntof

cra

shco

nfig

urat

ions

InhouseConsumerU.S. lawsRoW laws






The characteristics of a brand are also designed by inhouse demands.

Porsche Engineeringnew technologies and innovations

Social responsibiltyand acceptanceresponsible consumption

Performanceoriented towardsuncompromising, purposeful sport

Costumerssport-tuned, performance-oriented as well as efficient and comfortable, quality, reliabilty

Women as customerssport-tuned, performance-oriented, fun by driving, ergonomics, aesthetics, operations

Harmony with environmentconsumer electronics, informationtechnology

Safetyminimisation of risks by applyinglatest technology

Feel Porscheemotions, wellbeing, preciousmoments, fun by driving, relaxtion, pleasure

Performance orientedcostumerssport-tuned, performance-oriented, fun by driving, individualisation, motorsport up to professional racing

3.0Requirements






Essential global trends drive the change and generate additionalrequirements for the vehicle.

Environment Information Society Traffic & Mobility

• need for resources• CO2 emissions• petroleum dependancy/

market-price

• assistance systems &integrated safety

• tracking systems• tele service

• customers in best age• cultural differences

• overcrowded areas• infrastructure

3.0Requirements






The start-stop-system is an innovation to reduce fuel consumption with high requirements for implementation.

3.0Requirements

Partitioning of the „Start-Stop“-function

Chassis

All-wheel-drive Axle-differential-lock

Level Wheel anglesensor

Front side door(2x)

Back side door(2x)

Seat

Trailer Rear view camera

Steering-column-switch

Assistancesystems 1

Assistancesystems 2

Parking assistance Independantcar heating

Infotainment

Bodycontroller (front)

Gear box

Battery sensor

Engine

Bodycontroller (back)

Air-conditioncontrol unit

Reinforced starterCooled generator RPM transmitter

Dash board

DC/DC transmitter AGM battery

Airbag Occupantclassification

Gateway

Sensor cluster

RDK

PSM

Power Lift Gate






The partially contradictory requirements result in a high complexity for theautomotive development.

4.0Complexity Management






Integrating the requirements in the overall vehicle requires the contentrelated synchronisation of the development‘s core processes.

oper

ativ

e co

repr

oces

ses

Definition Concept

Overall vehicle

Chassis

Body


production-vehicledevelopment

Engine/transmission

Electric/electronics






An early project evaluation minimizes project risks and increases the scopeof action.


Concept Production-vehicle development ProductionDefinition

Degr

eeof

free

dom

for

chan

geDecision stage and basic concept

Product optimisation, problemanalysis and trouble shooting

• low degree of specification• high degree of variety• forecast as good as possible• short response time

• high degree of specification• several small modifications• high forecast precision• short/medium response time






The process of managing complexity follows the V-model used in electronicsdevelopment.

The model is valid for both real vehicles and digital vehicles.

Status of requirements metRequirements

Evaluation and interpretation

Evolution and assembly

Parts, modules & systems testingExecutable specification

Change management

Configuration management

Quality managementSupp

ort

proc

esse

s4.0Complexity Management






Main processes are model build up, assembly and operation of digital prototypes and support processes.

Digital prototype

5.0Fields of actions

Anforderungen

Model build up

Anforderung Erfüllungsstatus

Evolution and assembly

Change management

Configuration management

Quality managementSupp

ort

proc

esse

s

Status of requirements metRequirements

Evaluation and interpretation

Parts, modules, systems testingExecutable specification






The requirements are realized by executable specifications.

Project specifications

• Product and project descriptions

Executable specifications

• design models

• geometry data design

• surface models

• geometry data styling

• functional models

• technology data

5.0Fields of action






Data of model set up and digital prototypes are organized in the datamanagement.

Material list

Geometrydata

Technology data

…DPTdata

Data management

Task/Requirement Working process Results

Documentation

Supp

ort -

Proc

esse

s

5.0Fields of action

Digital Prototypes

…

…… …






Depending on the use of digital prototypes, the results are presentedin different ways.

Topside

110

120

130

140

150

160

500.00 1000.00 1500.00 2000.00Frequenz [Hz]

TOTAL MASS OF MODEL0.3478844

LOCATION OF THE CENTER OF MASS OF THE MODEL35.99744 -17.04400 -27.03432

MOMENTS OF INERTIA ABOUT THE ORIGINI(XX) I(YY) I(ZZ)

17315.49 45066.08 54812.02

PRODUCTS OF INERTIA ABOUT THE ORIGINI(XY) I(XZ) I(YZ)

-182.4164 -3299.566 15.63359

MOMENTS OF INERTIA ABOUT THE CENTER OF MASSI(XX) I(YY) I(ZZ)

16960.18 44361.04 54260.17

PRODUCTS OF INERTIA ABOUT THE CENTER OF MASSI(XY) I(XZ) I(YZ)

-395.8575 -3638.116 175.9293

5.0Fields of action

haptics3D stereo interactive3D stereo3D mono animation3D mono2D animationx/y plotsnumber sequence






In order to develop a product by using analogy models, significant aspectshave to be considered.

• Model build up towards executable specification with different data models fromdifferent domains like CAD and electronics

• Suitable representation of results - e. g. visualization

• Data management for models, digital prototypes, support processes and supplierintegration for digital prototypes

• Build up and operation of digital prototypes5.0Fields of action






Steps for experimental validation are mostly transferable to the virtualworld.

6.0Digital Prototype

Preparation Build up Execution Evaluation

virtual

real

11 22 33 44






MATLAB and Simulink can be used to run digital prototypes on completevehicle level.


Digital Prototype

Results/Test-Suite

Function 1Input

Output

Module

With an organized process and modularised structure the digital prototype is„easy“ to handle and use.






For electronic systems a full test environment exists including a digital prototype.

Porsche

Supplier

overall vehicle test/digital prototypeOverall vehicle/digital prototype

real vehiclereal environment real driving conditionclose to customer use ...

vehicle integrationand vehicle test

vehicle

Sensorik actuatorcontrol unit network real „regular“ track ...

complete network integrationand complete network testing

ECU network

part system bus segmentbus segment ... part system

system/bus segmentintegration and part network test

system and bus management

control unitcontrol unit control unit control unit ...

software-/hardware integrationand control unit test

ECU

CPU software component I/Osoftware component ...

software module integrationand software component test

software component

foo.c ...foo.c foo.mdl foo.c

software module testsoftware module

foo.c


actuator technologysensor technology






Non-electronic based systems are used in a individual test environment. They are based on mechanics and hydraulics.







The influence of electronic functions on full vehicle level has to beorganized by co-simulation.

Function 1Input

Output

Function 2Input

Output

Function 3Input

Output

Function xInput

Output

…

Interdisciplinary

Digital Prototypes

CrashCrashStiffnessStiffness Pedestrian protect.Pedestrian protect. Restraint systemsRestraint systemsTrimmed-bodyTrimmed-bodyFatigue strength

(BIW)Fatigue strength

(BIW) FMH/GreenhouseFMH/Greenhouse

1 2 3 4 5 6 7

Performance/fuel consumption

Performance/fuel consumptionThermal modelThermal modelMKSMKS CFDCFDelastic MKSelastic MKSNVH/AcousticNVH/Acoustic

Wheel speed sensor

ABS

LSD

Con

trol

uni

t

Con

trol

uni

t

Hyd

raul

icun

itLS

D: L

imite

d sl

ip d

evic

e

al-a

q

Accelerationsensors

BLS

Brake lightswitch

Traction switch

Info lamp

LSD

: Lim

ited

slip

Control & regulationsystem

Wheel speed sensor

ABS

LSD

Con

trol

uni

t

Con

trol

uni

t

Hyd

raul

icun

itLS

D: L

imite

d sl

ip d

evic

e

al-a

q

Accelerationsensors

BLS

Brake lightswitch

Traction switch

Info lamp

LSD

: Lim

ited

slip

Control & regulationsystem

8 9 10 11 12 13 14







Interactions of digital prototypes causes a lot of time to build up the digital prototype.

Cpl.-car responsemodels

1 D to 3 D

Control & regulationsystem models

Brake loadsCooling requirements

Functions of cpl. car with-regulation systems

Thermal modelsbrake, cooling circuit

Virtual flow body

Flow about componentsheat dissipation

3D

1,5 D

CAD

SFE concept

CFD

Geometry

GeometryFEM

MKS

Flowaerodynanics

Stiffness model

Resistance,lift , air forces

Occupant loadsvehicle deformationintrusions, sensors

MKS-body

MKS power train

MKS chassis

MKS cpl.-car model

eMKS-Gsfz.-Modell NVH < 50 Hz

Air-borne noise

NVH > 50 Hz

Digitalcpl-vehicleprototype

Collective loadsexcitation functions

Damages

Stiffnesses/frequences

Pedestrian protectsion

FMHFMH/Greenhouse

Crash model

Trimmed-Body

NVH legislation model

Treasuri

Fatigue strength

Pedestrian protection

Madymo model

Occupant loads

Driving performancesconsumption, lap times

Temperatures, fluids,components, brakesPerformance &

consumption model

3

4

14

101

9

8

13

11

12

2

5

6

7

Actuators

Supplier model

Test data







The integration environment should support the set up, configuration and operation of the digital prototypes.

integration environment

digital prototype,

set up

results,visuali-sation

environ-ment,

test trackprofile

data manage-ment,

supportprocesses

test cases,drivingcycle


Central goals for the digital prototype are short build up time and easy to use.






In the next step the integration environment offers a complete integrationplatform for the build up of the digital prototypes.

Integration environment digital prototypes

CrashCrash

4

StiffnessStiffness

2

The digital prototype has to be build up in an autonomized work flow. Additionally a digital concept prototype will be integrated.







Based on the integration environment the validation of the digital prototypeswill be managed.

CrashCrash

4

Integration environment easy to use on full vehicle level

The validation will be automated by a workflow and dedicated user interfaces.The complexity in this stage increases especially by the execution and test datamanagement. The test cases will be key for product quality in the future.



Digital Prototype






Digital Automotive Development - requirements to an engineering tool

• Increasing complex requirements and legal regulations evolve extensive demandson the overall vehicle system.

• In addition to the complexity management tools, models and methods to developan overall vehicle can be used in analogy to the electric/electronic process.

• Improvement potentials for faster processes can be seen in the data management, support process, in new problem solving methods of co-simulation of digital prototypes and in the improvement of calculation speed.

• Long term goal is an integration environment on complete vehicle level that allowsto build up and work on a digital prototype with various technologies in early stageand seamless structure. Additionally the environment has to be automated and easy to use.

7.0Summary






Thank you very muchfor your attention

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Digital Automotive Development - Electronic systems as ...€¦ · Digital Protoype 7.0 Summary From boundary conditions to an engineering tool environment • The development of