Maneuver based testing of integrated vehicle safety … based testing of integrated vehicle safety systems Rudolf Ertlmeier1 Kathrin Sattler1, Andreas Raith1, Thomas Brandmeier1 Daouda

Maneuver based testingof integrated vehicle safety systems

Rudolf Ertlmeier1

Kathrin Sattler1, Andreas Raith1, Thomas Brandmeier1

Daouda Sadou2, Christian Schyr3

1Institute for Applied Research (IAF); Ingolstadt University of Applied Sciences2Continental Automotive GmbH

3IPG Automotive GmbH

"‘apply & innovate 2012"’ - IPG Technology Conference18. / 19. September 2012

Motivations Test system Crash data feeding Outlooks

Agenda / Contents

1 MotivationsNetworking of automotive systemsIntegrated safety systemsNew test concept

2 Test systemRealisationExample of continuous testing

3 Crash data feedingSelection and feedingCrash data scaling

4 Outlooks

R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems


Agenda / Contents




4 Outlooks



Networking of automotive systems

Development of system complexity

development in recent years

The number of various control unitsin vehicles is expanding extremelysince the last few years

⇒ system complexity isincreasing constantly

⇒ testing is getting more andmore extensive

Gateway

CAN

Diagnosis

CAN

CAN

CAN

LIN

MOST

FlexRay

CAN

...

source: Kiesewetter T.: Der VW Touareg - Karosserieelektronik und InfotainmentATZextra, Nr. 2010-02, page 47, 2010



Integrated safety systems

New safety system concept (e.g. SCU - Safety Control Unit)

see hear

e.g. ACC e.g. CISS

(Crash Impact

Sound Sensing)

feel communicate

e.g. ESC e.g. Car-2-X



New test concept

Idea of a new test concept for safety systems

idea of the new test concept

combination of:

- vehicle simulation

- environment simulation

- crash data feeding

for MiL, SiL and HiL test environment

vehicle- and

environment

simulation

crash data

SCUSCU

project: VISAPS

• modular flexible system for development and production release ofnetworked systems (MiL, SiL, HiL - test environment)

• consistency and automation of testing

• project partners:



Agenda / Contents




4 Outlooks



Realisation

Concept

HiL (real time system)

vehicle &

environment

simulation

inte

rface

s (e.g

.

SCU

(safety control unit)

algorithms(with vehicle dynamics,

sensor signals

• environment sensors

software hardware

SCU signals

crash

data

base

(e.g

. bu

s system

s)

(with vehicle dynamics,

object properties, …)

actuators

(e.g. airbags,

belt tensioners)

• environment sensors

• chassis sensors

• car2X communication

• GPS/navigation

• laboratory crashes

• simulated crashes

• other relevant

situations (misuses)

trig

ge

r

SCU signals



Realisation 1st Generation:

„CAN-Tester“

Testing of CAN based algorithm inan electronical control unit:

Data sources

• Replay of CAN-Traces

• Rest bus simulation

• CarMaker simulation

CAN data manipulation

• Cyclic Redundancy Check (CRC)

• Message counter

• Data Length Code (DLC)

• Timeout

• Data field (including init- anderror-values)



Realisation 2nd Generation:

„Airbag HiL-system“

Safety Control Unit

programming, calibration, fault memory

crash parameters• velocity• coverage

anal

og

curr

ent m

easu

rem

ent

SP

I

PS

I5

bus systems(CAN, LIN, FlexRay)

intelligent IO

Crash DB

CarMakervehicle – environment

• coverage• impact angle• …

cras

h si

gnal

s



Example of continuous testing

Collision in front of traffic lights

New test system enables a continuous testing throughout all phases ofdriving: Normal Driving, PreCrash and InCrash

t0 = 0sv0 ≈ 40km/h

t-2 ≈ -0,8sv-2 = 60km/h

t-3 = -2sv-3 = 60km/h

t-1 ≈ -0,75sv-1 = 60km/h

PreCrashNormal Driving InCrashtttt

belt tensioner emergency brake airbag



Agenda / Contents




4 Outlooks



Selection and feeding

Feeding test system with required crash data

1 Normal Driving / PreCrash:

• SCU is being fed with vehicle dynamics

and environmental sensor data from

IPG CarMaker simulation

2 InCrash:

• looking for corresponding real driven

crash data and feeding into SCU

specify crash parameter by using simulation

parameter

crash trigger

at collision time

Angular 30° 43 km/h

?crash

data base

real driven

crash data

?SCU



Crash data scaling

Artificial generation of crash data

What can we do if there are not enough or exactly the required real driven crash datain the database?

• search for best fitting data set ⇒ inaccurate testing results

• generate crash data by using FEM ⇒ not feasible in almost real time

⇒ generate data out of existing real driven crash data by scaling andinterpolation

angular 30° 32 km/hangular 30° 32 km/h angular 30° 51 km/hangular 30° 51 km/h

scaling / interpolation

angular 30° 43 km/h

0 10 20 30 40 50 60 70

-30

-20

-10

0lo

ngi

tudi

na

l

acc

ele

ratio

n [

g]

front 30° right angle, v = 43km/h

0

reference signalgenerated signal

0 10 20 30 40 50 60 70

-40

-20

0

time [ms]

inte

gra

ted

velo

city

[km

/h]

vreference

vgenerated



Agenda / Contents




4 Outlooks



Next generation test system

project: VISAPS2

1 further development of current scaling and interpolation algorithm

2 realisation of secondary accidents simulation within CarMaker3 further development of the new VISAPS test system:

• implementation of AUTOSAR - requirements• ISO 26262 certification• integration of power measurement to measure the ignition circuit

currents exactly

4 test strategies• development of an efficient test strategy for highly networked

safety systems by combining different test methods such asmaneuver-based or evolutionary tests



If you have any questions, please do not hesitate to contact us:

Dipl.-Ing. (FH) Rudolf Ertlmeier Dipl.-Ing. (FH) Kathrin SattlerIstitute for Applied Research (IAF) Istitute for Applied Research (IAF)Ingolstadt Universty of Applied Sciences Ingolstadt Universty of Applied SciencesEsplanade 10 Esplanade 1085049 Ingolstadt 85049 Ingolstadtphone: +49 (0)841/9348-648 phone: +49 (0)841/9348-646Email: [email protected] Email: [email protected]

Dipl.-Ing. (FH) Andreas Raith Prof. Dr.-Ing. Thomas BrandmeierIstitute for Applied Research (IAF) Istitute for Applied Research (IAF)Ingolstadt Universty of Applied Sciences Ingolstadt Universty of Applied SciencesEsplanade 10 Esplanade 1085049 Ingolstadt 85049 Ingolstadtphone: +49 (0)841/9348-723 phone: +49 (0)841/9348-384Email: [email protected] Email: [email protected]

Dipl.-Ing. Daouda Sadou Dr.-Ing. Christian SchyrContinental Automotive GmbH IPG Automotive GmbHSiemensstraße 12 Bannwaldallee 6093055 Regensburg phone: +49 (0)721/98520-43phone: +49 (0)941/790-6280 Email: [email protected]: [email protected]



Thank youfor yourattention


Documents

Maneuver based testing of integrated vehicle safety … based testing of integrated vehicle safety systems Rudolf Ertlmeier1 Kathrin Sattler1, Andreas Raith1, Thomas Brandmeier1 Daouda