Upload
others
View
7
Download
0
Embed Size (px)
Citation preview
SOLUTIONS FOR VIRTUAL TEST DRIVING
ESC-HIL TEST SYSTEM
2
Table of Contents
Motivation 3
System at a Glance 4
General Description 5
Block Diagram (example configuration) 6
Use Cases 7
Verification and Validation of ESC Systems
Variant Testing, Validation and Homologation
Best-in-Class Features 8
Add-ons and Integration Potential 9
Synergy Effects Using CarMaker / HIL platform
Integration of Further ECUs and the FailSafeTester
Integration of Further Mechanical Components
Scope of Delivery 10
Appendix: Test Bench Results 11
Virtual Test Driving
Vehicle Dynamics
Global Vehicle Requirements Released Vehicle
Integration
of ECU(s) or complete vehicle systems
in a virtual prototype
Powertrain
Integration
of multi domain models from different development tools in a virtual prototype
ADAS
Figure 1: Early validation of components and systems along the V-model
Validation against global vehicle target
The key objective of developing electronics in automotive development projects is to ensure the reliability of the
individual components in any situation. Therefore, the increasingly complex development processes and interlinking
of the components require supporting simulation techniques. They assist in shortening development cycles and in
detecting sources of faults in the interaction of the components at an early stage. This is a challenge faced by both
automotive OEMs and suppliers. Hardware-in-the-loop simulation (HIL simulation) is a major element of optimizing
the development process.
Motivation
3
Real-world electronic vehicle control units and prototypes such as the electronic stability control (ESC) unit are
connected with real-time simulation models of the vehicle and the vehicle’s environment, or with a complete
simulation environment (CarMaker).
HIL simulation allows users to perform tests under real-word conditions in a laboratory environment. This not only
makes it possible to test electronic components in any conceivable failure mode, but to also conduct tests which
are often difficult to implement in real-world conditions. In the simulation environment, risk-free and reproducible
testing of dangerous worst-case scenarios is possible with just a minimal investment of effort and expense.
Due to this approach, final test driving can be accomplished with a significantly reduced effort. This ultimately
leads to major time and cost savings, as well as substantial quality improvement.
The correct functionality of ESC systems is important not only due to their mandatory use in all newly registered
passenger cars and trucks within the EU. In addition, ESC, as an interacting electronic control unit for numerous
other applications in the vehicle (e.g. ADAS, energy efficiency, steering systems), plays a central role and has long
ceased to be defined strictly as a vehicle dynamics control system.
The HIL method has long become established as the standard and essential technique that makes it possible to
manage the immense testing requirements of diverse functionalities.
4
Delivery of the fully functional test system in a 38” rack housing (see picture) is standard. This ensures ease of
integration and maximum future extensibility by further components and upgrades. However, if required, the setup
can also feature smaller test benches – through to portable desktop cases.
System at a Glance
Power Supply
Fully programmable,
optionally with Car Start
functionality.
Xpack4 Real-Time System
Including CarMaker/HIL and
relevant I/O-devices.
FailSafeTester
State-of-the-art solution
for automatic fault insertion
without manual patching
cables.
Plug-in Test Boxes
Connected customer ESC-
ECU(s) as device under test.
Test boxes can be exchanged
easily by “Plug & Play”.
Standard 19” Rack Housing
In different heights and pre-
configurations customized for
every use case.
5
The ESC-HIL test system is a turnkey solution for testing and validating real- world ESC units – enabling all ESC functionalities to be tested with a single HIL system.
The main components include:
� CarMaker simulation software
� Xpack4 realtime system with ESC-specific I/O
� Electrical, mechanical and functional integration of the customer’s ESC ECU
� Optional coupling with FailSafeTester
� Integration in a standard 19” rack with power supply unit
The ESC ECU is integrated as a real-world component, where the hydraulic system including the hydraulic pump
is modeled. The resulting elimination of mechanically moved components reduces power requirements and noise
development during operation.
The vehicle model with the corresponding driver and brake model generates the steering wheel angle, wheel
speed, yaw rate, lateral acceleration and primary brake pressure.
Thanks to specifically developed tools, the ECU residual bus simulation is automatically generated directly from
the database (e.g. the DBC file) for commonly used field bus systems such as the CAN bus. The valve activities
are measured by a special-purpose, high-precision analog signal acquisition box and fed back to the hydraulic
model (virtual valves).
Due to the high quality of the valve position measurement, the IPG SignalAcquisitionBox, makes it possible to run
all performance tests in addition to functional and fail-safe tests. Quick calibration and no need for re-calibration
after reinstalling the ECU, is a further advantage that saves time and costs.
In addition, the CarMaker/HIL environment offers extensive possibilities for ECU diagnosis directly from the Car-
Maker GUI. Access to and processing of internal ECU parameters is possible even during runtime thanks to CCP/
XCP access.
General Description
Block Diagram (example configuration)
User Interfaces (CarMaker Host-PC)
Simulation Framework (CarMaker Xpack4)
Driver ModelRoad Model
Vehicle Model
Ethernet
Engine / Hybrid Model
Hydraulic Brake Model
Trq
Re
qu
est
Tir
e M
od
el
Roadway Information
Steering Wheel
Pedals
Cockpit
Xpack4 I/O
FailSafeTester Power Supply
Ve
hic
le B
usYaw Rate
Wheel Speed
Lateral Acceleration
Primary Pressure
Ma
gn
eti
c V
alv
e
Po
sit
ion
s
Power Control
PCI Bus
ESC ECU Sensor Box
Device Under Test (Plug-in Test Box)
Hyd
rau
lic
Pu
mp
P
ressu
re
6
Software Components
Hardware Components
Fail-Safe Tests Function Tests Performace Tests
7
Verif ication and Val idation of ESC Systems
ESC-HIL test systems by IPG Automotive cover the entire range of ESC-related tests:
Fail-safe tests, functional tests and performance tests.
While simulation-based fail-safe testing has become well established due to low requirements regarding
simulation model quality and maneuver setup flexibility, simulation-based functional testing and performance
testing requires high model quality and a versatile way of setting up maneuvers, evaluation criteria, post-
processing routines and reporting functionality. Obviously, all of these requirements are covered by the CarMaker
product family. Performance tests make it possible to quantify the operational quality of a function and whether
the resulting vehicle performance matches the brand’s image (also frequently referred to as brand DNA).
Variant Testing, Val idation and Homologation
Utilization of the ESC-HIL test system fully supports simulation-based ESC homologation according to ECE-R
13H. As a result, the high correlation between measurement and simulation makes it possible to already validate
the growing number of variants and derivatives in vehicle development in simulation and HIL. Consequently, the
number of real-world vehicle tests can be significantly reduced.
Use Cases
� Sensor defect
� Backup mechansim
� Communication
� Diagnostic
� ...
� ABS/ASR/VSC
� Steering support
� Hill-hold control
� ACC functions
� ...
� Inlet speed
� Stability value
� Threshold consumption
� Braking distance
� ...
© fotolia.com
8
� The CarMaker software environment not only provides an open and flexible platform for integrating the user’s
own models but also a state-of-the-art vehicle dynamics environment that enables physically correct behavior
up to the limit.
� Thanks to the modern FailSafeTester concept, electrical faults can be generated in fully automatic mode with
free selection of the failure modes. As a result, it is possible to reliably conduct targeted investigations even in
worst-case scenarios.
� The maneuver- and event-based approach to testing enables uncompromising transfer of test cases from the
SIL or even the MIL stage. Even highly complex closed-loop driving instructions can be easily executed and
fully reproduced – assisted also by the highly sophisticated IPGDriver model.
� The ESC-TestWare option combines the knowledge and expertise from more than 30 years of experience in the
vehicle dynamics environment in bundled test catalogs. Linking with the Test Manager makes it possible to fully
automatically run complete test series and test catalogs for hours and even days at a time.
Best-in-Class Features
Further Advantages at a Glance
� Open and robust architecture consisting of off-the-shelf industry components
� Extremely high computer and communication performance (5 -10 times faster than the benchmark)
� Intuitive use on PCs
� Stable test automation and test management
� Exact reproducibility of the results across extended periods of time
� Unrivaled turnaround times thanks to interaction between real-time node and host PC
� Support of all automotive-specific I/O interfaces such as CAN (FD), Ethernet, FlexRay, LIN, DAC, AD, PMW, etc.
� Vehicle-specific I/O modules for Chassis, Powertrain, ADAS and Body Control applications
� Matlab/Simulink-based modeling possible but not imperative
9
Synergy Effects Using the CarMaker / HIL Platform
Use of open integration opportunities on the highest
level:
� Simulation of the test vehicle and environment
in hard real-time conditions
� Easy use and integration of validated model
libraries (e.g. tires, suspension, MBS axles) and
users’ own models via C-Code, FMI, Simulink and
other interfaces
� IPGDriver model for sophisticated closed-loop
driving tasks
Integration of Further ECUs and the Fai lSafeTester
� The Xpack4 Integration HIL system provides
possibilities for further plug-in test boxes extending
the range of test cases of the entire system.
Functional tests and interactions between the ESC
system and other components of any kind such
as active dampers or electric power steering are
possible at the highest levels of reproducibility even
in complex settings.
� The FailSafeTester provides opportunities for testing
all kinds of electrical faults such as in power supply,
(wheel speed) sensor signals and CAN signals.
Integration of Further Mechanical Components
� For the interaction of ESC with EPB functions the
real-world EPB brake calipers can be integrated as
mechanical components as well.
� The ESC test system, with mechanical integration
of the brakes in their true locations at the front and
rear axle, can be extended to create a full-fledged
dual circuit braking system test bench.
Add-ons and Integration Potential
10
Scope of Delivery
Test systems by IPG Automotive are turnkey solutions.
Following the complete integration of the customer’s DUT, the system is delivered in fully operational condition.
After on-site commissioning, assistance by specialists who are familiar with the system will be available to custo-
mers at any time.
A possible configuration looks as follows:
HIL rack environment
Software HIL / DUT Engineering
Customer Services
Real-time system –
Xpack4 for ESC
� 19” subrack
� Carrier board and dual
or quadcore CPU
� I/O modules
� M410 – CAN
� M32 – Digital in
� M36 – Analog in
� M43 – Relay out
� M62 – Analog out
� M400 – wheel speed
generator
� M409 – Power Supply
Control
� Cabinet peripherals
� 80V / 100A Power supply
with car start option
� Cabinet 24 or 38 units
� Configured host PC
CarMaker / HIL pro
� IPGGUI
� IPGCar
� IPGTrailer
� IPGTire
� IPGDriver
� IPGRoad
� IPGTraffic
� ManeuverControl
� IPGControl
� IPGInstruments
� IPGMovie
� Test Manager
� ScriptControl
� FailSafeTester Tool
� Diagnostic Tool support
� CCP/XCP and Flash Tool
� CAN/FlexRay/LIN Tools
Plug-in test box for ESC
� Electrical and
mechanical level
� Software level
� Functional level of
integration
Integration in turnkey
HIL
� Planning
� Construction
� Implementation
Start-up
� On-site installation
� Customer instruc-
tion
Training
� CarMaker / HIL
training for ESC
Support
� Support and main-
tenance by qualified
experts worldwide
Appendix: Test Bench Results
54
56
58
60
62
64
66
68
300 310 320 330 340 350 360
Ve
hic
le V
elo
cit
y (
km
/h)
Position x (m)
-8
-6
-4
-2
0
2
4
6
8
300 310 320 330 340 350 360
Position x (m)
Ac
ce
l. L
at.
(m
/s²)
CarMaker simulation
Real measurement
Pressure master cylinder simulated
Wheel pressure font left
Wheel pressure rear left
Pressure master cylinder measured
Wheel pressure font right
Wheel pressure rear right
Pre
ssu
re (
ba
r)
Time (s)
1220
1314 15 16 17 18 19
200
175
150
125
100
75
50
25
0
Corr.: 99% Corr.: 92%
11
Hydraulic brake model performance
Braking pressures while braking on µ-split (ABS function)
Vehicle model performance
Double lane change (ESC function)
As an innovation driver for virtual test driving, the company is a leading global provider of software and hardware products
for the automotive and supplier industry. With the areas Simulation Software, Real-time Hardware, Test Systems and
Engineering Services, IPG Automotive supports its customers in creating innovations and improving their development
process efficiently. The simulation solutions CarMaker, TruckMaker, and MotorcycleMaker, as open integration
and test platforms, facilitate great savings in time and cost for customers, in a continuous development process of
Model-, Software- and Hardware-in-the-Loop, all the way to the Vehicle-in-the-Loop method. The application
ranges from the general vehicle dynamics simulation, developing and testing of chassis control systems, as
well as interconnected systems such as chassis, powertrain, and steering in full electric and hybrid vehicles.
Another strength of IPG Automotive is the development of future-oriented solutions for the integration and testing of
advanced driver assistance systems.
© IP
G A
utom
otiv
e G
mb
H, K
arls
ruhe
| 20
16
Simulation Software • real-time Hardware • teSt SyStemS • engineering ServiceS
SOLUTIONS FOR VIRTUAL TEST DRIVING
IPG Automotive GmbH • Bannwaldallee 60 • 76185 Karlsruhe • Tel.: +49 721 98520 0 • ipg-automotive.com
China | France | Germany | India | Italy | Japan | Korea | Malaysia | Sweden | Turkey | UK | USA