dspace GmbH Rathenaustr Paderborn Germany dspace Technology Conference Workshop #2

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2 dspace Engineering - Mechatronic Test Benches Matthias Deter Group Manager Engineering E-Drive Applications dspace Technology Conference 2017 Workshop #2 dspace GmbH Rathenaustr Paderborn Germany 2

3 Agenda Mechanical Test Stands and Model Environment Motivation dspace Solutions ASM Tool Suite Application Examples Sensor Stimulation Simple Load Machine Steering Systems Braking Systems Radar Sensor 3

4 Mechanical Test Stands and Model Environment Motivation 4

5 Motivation Increasing integration level trough light weight and tight construction as cost optimization Exhaustive HIL testing within laboratory condition includes stimulus of all interfaces Integrated sensors and actuators requires more than the traditional electrical interface dspace is well known as provider of custom specific turn-key HIL systems Test benches are a mandatory step to serve our customers as a single source supplier Extensive experience in RCP and a suitable product chain assures best results Highest control dynamics and accuracy through drive PWM synchrony real-time control 5

6 Key Features Advantage of HIL Testing with Mechanical Test Benches Effects of mechanical components included in tests Integrated sensors included in tests Supports testing of real mechanical limits Hardware quality assurance Requirements Entire HIL environment (Software & Hardware) High performance low latency HIL coupling Application specific load actuator dynamics Electrical setup with low noise connection of measurement signals 6

7 Target Applications Main Applications Electronic power steering (EPS) Electric brake booster Additional Applications Rear wheel steering Integrated sensors Radar sensor Mechanical load to real pump Radiator fan Reversible belt tensioner Fuel door or trunk operation 7

8 Mechanical test stands and Model Environment dspace Solutions 8

9 Available interfaces for Industrial Drive Inverters CANopen Master Solution Compatible to automotive CAN Supported by nearly all HIL-Simulator Low dynamics (1ms) achievable Fieldbus Solution Standard industrial bus interface Supported by nearly all drive suppliers Medium dynamics (0.5ms) achievable TWINsync Solution Supplier specific interface for parallel drives PWM synchronous control and measurement High dynamics (0.125ms) TWINsync 9

10 TWINsync Solution At a Glance High dynamic control of LTi Motion ServoOne Drives out of a model-based real-time application High-performance, low-latency connection, range of up to 100 m Decentral use possible, no own processing unit needed Communication in fast 125 µs Simulink task, synchronized with the drive PWM IO Interface 2 x LTi ServoOne TWINsync interfaces 2x galvanically isolated digital IO groups 4x Digital in 3x Digital out 2x TTL Encoder processing 10

11 TWINsync Solution Transfer Module Function and Interface orientated transfer element for the SCALEXIO TwinSync Solution Two interfaces for standard TwinSync cables (LTi) provided as Sub-D 9 Capability to connect components via easy to use spring-type terminals Specifically designed to connect one or more Remote Sensor Interface Boxes (RSI) Enhanced signal integrity assured by using standard RJ45 patch cables Power supply for RSI already integrated on RJ45 11

12 TWINsync Solution Remote Sensor Interface (RSI) High fidelity measurement of analogue signal sources, e.g. torque sensors Advanced test bench control loops performance due to better signal quality High transfer rate for low latency control loop embedding (T SAMPLE = 125µs) Assured signal integrity avoids problems due to distortions, e.g. EMC Reduced wiring efforts: Wiring of analog signal through the whole test bench can be avoided Included sensor supply enables single wire access through RJ45 patch cable Generic interface supports configuration and calibration access as well as function test 12

13 TWINsync Solution LTI Motion Servo One Family Servo drives from 2 to 450 A Single axis modules with AC mains input Multi axis modules with DC inputs for active frontend connection High-performance motor control for precise, dynamic movement Linear and rotary motor systems supported Integrated functional safety ensures personal protection directly in the drive controller Compact size for optimum cabinet utilization 13

14 TWINsync Solution Principle Wiring Example LTi TwinSync cable LTI Servo One motor controller TwinSync Solution Transfer Module RJ45 cables Position Sensor cables IOCNET Load Motor Motor cables RSI Torque Sensor Force Sensor Analogue signal cable RSI Load Motor 14

15 Mechanical test stands and Model Environment ASM Tool Suite 15

16 ASM Tool Suite MotionDesk ModelDesk Truck TurboCharger Engine Gasoline Basic Trailer DrivetrainBasic Diesel Exhaust Engine Gasoline Engine Gasoline In-Cylinder Engine Diesel Engine Diesel In-cylinder Electric Components Environment Traffic Pneumatics Brake Hydraulics Vehicle Dynamics 16

17 Vehicle Motion Multi body system with 5 bodies (chassis, wheels) 11 independent degrees of freedom (DoF) for chassis, wheels and steering Easy to extend with additional bodies for truck and trailer simulation 17

18 Traffic ASM Traffic is the model for simulating vehicles, traffic participants, traffic objects, and vehicle sensors. It allows to efficiently develop and validate driver assistance systems in virtual environments. Environment simulation for ADAS controllers Road networks Traffic maneuvers Traffic signs, buildings, pedestrians, objects 18

19 Application Examples Sensors Stimulation 19

20 Test Benches for Sensor Stimulation Preconditions for external senor tests Smart sensors with bus interface (e.g. CAN, LIN) Entire integration tests with all network members Target Sensors Types Position sensors (e.g. shift lever) Angle sensors (e.g. steering angle) Application Example: Steering Robot Flexible due to CANopen control interface Small size easy to integrate in HIL environment Mechanical limitation of rotation range possible 20

21 Integrated Sensors The number of ECUs with integrated sensors grows due the last years In modern ESP systems the traditional external sensors cluster are replaced by internal sensors for cost reduction Testing such ECUs requires external injection of the relevant physical behavior, e.g. yaw rate and/or acceleration Complexity depends on the required degree of freedom Challenges for test environment Perform network tests and fail-safe tests with a production ECU Realistic driving maneuvers should be performed in laboratory 1D or 3D sensors need to be test 21

22 Test Bench Examples for Integrated Sensors Rocker 1 Degree of Freedom 3D Motion Platform 3 Degree of Freedom ECU Actuator 22

23 Test Bench for Integrated Sensors - Rocker Target Application EPB Electronic Parking Brake e.g. for hill holder function testing Technical Details Harmonic Drive Motor and Inverter Max. Speed 120rpm Max. Torque 3.3Nm Shaking Motion +/-90 Static Control Precision Position +/- 1 Dynamic Control Max. Frequency 5Hz at 2 23

24 Integrated Sensors 3D Motion Platform (1) Customers Supplier in Germany OEM in Germany OEM in China OEM in South Korea dspace Service Turnkey solution Dimensions L x W x H Electrical connection 2 m x 1 m x 2,2 m (500kg) 3-phase, 6kW 24

25 Integrated Sensors 3D Motion Platform (2) Features at a glance Real time coordinate transformation and EtherCAT interface (1kHz) Provides 3 degree of freedom Simulation of lateral & longitudinal acceleration turning the ESP ECU in two axes stimulates the internal g sensors max. ± 90 degree, acceleration max. 0.7g Simulation of the Yaw Rate freely turnable ±, yaw rate 180 /s electrical connections by a high performance slip ring system Yaw stimulation by turning the entire platform with ECU 25

26 Application Examples Simple Load Machine 26

27 Simple Load Machine HIL Testing Reasons Electronic commutation becomes standard ECU and motors are frequently designed in one housing Such power packs frequently used for various applications Function orientated testing becomes mandatory Application Examples Electronic steering Electronic fuel pumps Hydraulic pumps Radiator fans 27

28 Simple Load Machine Exemplary HIL System (1) Customers Supplier in Germany OEMs in Germany OEMs in China OEMs in South Korea OEMs in North America dspace Service Turnkey solution Dimensions L x W x H Electrical connection Depend on integration 3-phase, 6kW 28

29 Simple Load Machine Exemplary HIL System (2) Features at a glance: Several integration options for mechanical setup 19 drawer 19 subrack Separat rig Several communication interfaces possible CANopen interface EtherCAT interface TWINsync interface Specification: Several customer specific design in engineering projects 29

30 Application Examples Steering Systems 30

31 Steering Systems Electronic Power Steering (EPS) Replacing hydraulic assist with a computer-controlled electric motor Power on demand enable fuel efficient steering Higher steering dynamics Allow actuation for driver assistance systems and automated driving User feel oriented assist logic including force feedback Challenges for test environment Motor control algorithms need to be test ECU and motor are designed in one housing Multitude of vehicle configurations Highly dynamic interaction with track and driver Combination with other ECUs (e.g. ESP) to test distributed functions Picture: 31

32 Steering Systems Exemplary HIL Setup Vehicle-Simulator ASM Driver, Maneuver and Scheduler; ASM Traffic ASM Vehicle Steering System MDoF Vehicle Dynamics F Rod T Steer i Steer x Rod ε Steer i Steer T Column ε SteeringWheel Torque Sensor (Driver Side) ECU Motor Load Motor Gear Mechanical Bench for EPS Position Sensor (Rod Side) Load Motor IO for EPS IO for Testbench 32

33 Steering Systems Column Drive EPS (1) Customers Supplier in Germany OEM in Germany OEM in North America OEM in China OEM in South Korea dspace Service Turnkey solution Dimensions L x W x H Electrical connection 4 m x 1 m x 1.8 m (1500kg) 3-phase, 10kW 33

34 Steering Systems Column Drive EPS (2) Features at a glance Prepared for closed loop operation of AFS and column drive EPS Combination with other ECUs (e.g. ESP) to test distributed functions ASM Vehicle dynamics model including interfaces for external steering systems Model based control of drive inverter (8kHz) Exemplary steering motor specification Maximum torque: 11 Nm Maximum speed : 3000 rpm Exemplary load motor specification Maximum torque: 120 Nm Maximum speed : 1200 rpm 34

35 Steering Systems Exemplary HIL Setup Vehicle-Simulator ASM Driver, Maneuver and Scheduler; ASM Traffic ASM Vehicle Steering System F Rod x Rod Mechanical Bench for EPS MDoF Vehicle Dynamics IO for EPS ε SteeringWheel T Column Torque Sensor Torque Sensor ECU Motor Load Motor Driver Side Steering Column Force Sensor Steering Rod Wheel Side (Linear Actuator) IO for Testbench Gear Load Motor 35

36 Steering Systems Complete steering system example #1 (1) Customers Several OEMs in Germany OEM in North America OEM in South Korea dspace Service Turnkey solution Dimensions L x W x H Electrical connection 3 m x 1 m x 2,2 m (ca. 900 kg) 3-phase, 15kW 36

37 Steering Systems Complete steering system example #1 (2) Features at a glance Motor connected to the real steering column Model based control of drive inverter via TWINsync (8kHz) Configureable steering shaft mounting position Specification Maximum torque: Maximum speed: Maximum frequency: Control precision: Control precision: 50Nm 500 rpm 30Hz +/- 0,2 (Steady State) +/- 0,5 Nm (Steady State) 37

38 Steering Systems Complete steering system example #1 (3) Features at a glance: Ball screw actuator one-sided connected to the tie rod Model based control of drive inverter via TWINsync (8kHz) Force control loop using force sensor Specification: Maximum force: Maximum speed: Maximum frequency: Moving mass: Control precision: Control precision: 20kN 400 mm/s 5Hz 500kg +/- 100 N (Steady State) +/- 0,2 mm (Steady State) 38

39 Steering Systems Exemplary HIL Setup Vehicle-Simulator ASM Driver, Maneuver and Scheduler; ASM Traffic ASM Vehicle Mechanical Bench for EPS Steering System F Rod x Rod ε SteeringWheel MDoF Vehicle Dynamics IO for EPS T Column x Rod F Rod Load Motor Wheel Side (Linear Actuator) Force Sensor Torque Sensor Torque Sensor ECU Motor Gear Load Motor Driver Side Steering Column Force Sensor Steering Gear Wheel Side (Linear Actuator) Load Motor IO for Testbench 39

40 Steering Systems Complete steering system example #2 (1) Customers OEM in Germany Supplier in North America Supplier in Germany dspace Service Turnkey solution Dimensions L x W x H Electrical connection 5 m x 3 m x 2,5 m (ca kg) 3-phase, 25kW 40

41 Steering Systems Complete steering system example #2 (2) Features at a glance Realistic forces and torques from ASM vehicle dynamics for closed loop tests Real test scenarios with the real steering system Two sided actuation of the steering gear by means of linear drives Generic concept with Active Front End (AFE) for energy recovery 41

42 Steering Systems Complete steering system example #2 (3) Features at a glance Model based control of drive inverter via TWINsync (8kHz) Interface for integrating the real steering wheel Torque control using torque sensor Realistic steering shaft and cardan mounting Specification Maximum torque: Maximum speed: Maximum frequency: Control precision: Control precision: 50Nm 500 rpm 30Hz +/- 0,2 (Steady State) +/- 0,5 Nm (Steady State) 42

43 Steering Systems Complete steering system example #2 (4) Features at a glance Model based control of drive inverter via TWINsync (8kHz) Air cooled dspace linear motor Force measurement at tie rod Specification Maximum force: Maximum speed: Maximum frequency: Moving mass: Control precision: Control precision: 20kN 1000 mm/s 30Hz 150kg +/- 20 N (Steady State) +/- 0,2 mm (Steady State) 43

44 Application Examples Braking Systems 44

45 Braking Systems Electric Brake Booster This brake boosting system is no longer working with the vacuum, but electromechanical. Through intelligent control system adapts the braking pressure depending on driving modes. Main advantages: Increased braking force (up to 300 %) Energy recovery in electric vehicles Autonomous braking (Congestion Assistant ) Challenges for test environment High level control algorithms need to be test Integrated mechatronic design Test in prototype vehicles are very expletive Highly dynamic interaction with track and driver 45

46 Load Motor Assembly Types of Brake Booster Benches Linear Load Motor Vertical Assembly One load actuator Rotatory actuator with ball screw Test including the brake booster Brake Booster Linear Load Motor Horizontal Assembly One load actuator Linear actuator Rotatory actuator with ball screw Test including entire brake system (brake hydraulics can be also simulated) Optionally with driver s seat Load Motor Force Sensor Brake Booster 46

47 Brake Booster Test Bench with Spindle Actuator - Vertical Assembly Example Features Spindle actuator directly mounted to brake booster Motor and Inverter from LTi Ball screw spindle from Raco Details Dimensions: L x W x H: 1m x 0,5m x 1,3m Electric Supply: 3~400V / 16A Spindle Actuator for Brake Pedal Actuator maximum force: Maximum speed: Maximum distance : 2500N 150 mm/s 100 mm 47

48 Braking Systems Exemplary HIL Setup (Horizontal Assembly) Vehicle-Simulator ASM Driver, Maneuver and Scheduler; ASM Traffic ASM Vehicle Steering System Mechanical Bench for Brake Booster Optional MDoF Vehicle Dynamics IO for EPS F x Brake_Pedal Load Motor Force Sensor Brake Booster Brake Hydraulics Electrical Brake IO for Testbench 48

49 Braking Systems Wet bench Customers OEM in Germany OEM in China dspace Service Turnkey solution Dimensions L x W x H Electrical connection 3 m x 2 m x 1.8 m (900 kg) depending on actuation unit 3-phase, 15kW 49

50 Braking Systems Wet bench, Modular Concept Features at a glance: Modular concept with real parts unit and actuation unit Integration of real brake hydraulics possible Different actuation units available Driver seat module Ball screw actuator Linear actuator 50

51 Braking Systems Wet bench, Ball Screw Actuator Features at a glance: Model based control of drive inverter via TWINsync (8kHz) Ball screw actuator at pressure point of brake pedal Simulation of pedal position Specification: Maximum force: Maximum speed: Maximum frequency: Moving mass: Control precision: Control precision: 2500N 150 mm/s 5Hz 200kg +/- 10 N (Steady State) +/- 0,2 mm (Steady State) 51

52 Braking Systems Wet bench, Linear Actuator Features at a glance: Model based control of drive inverter via TWINsync (8kHz) Optimized dspace linear motor to enable realistic actuation Simulation of pedal position and pedal force (using driver's leg model) Specification: Maximum force: Maximum speed: Maximum frequency: Moving mass: Control precision: Control precision: 2000N 1000 mm/s 30Hz 20kg +/- 10 N (Steady State) +/- 0,2 mm (Steady State) 52

53 Application Examples Radar Sensor 53

54 Radar Sensor Aside from cameras, radar sensors are the most important sensors in advanced driver assistance systems (ADAS). They are essential for safety and comfort functions Different types available Short-Range Radar Sensor Mid-Range Radar Sensor Long-Range Radar Sensor Challenges for test environment Radar sensor component tests High level control algorithms need to be tested Overarching ADAS function tests Simulation of defined NCAP scenarios 54

55 Radar Sensor Over-the-Air Radar-in-the-Loop Test Bench Customer Various customers dspace Service Turnkey solution Dimensions L x W x H Electrical connection 1,8m x 0,9m x 1,05m (280 kg) 400V, 16A, 3-phase 55

56 Radar Sensor Over-the-Air Radar-in-the-Loop Test Bench, Mechanical Setup Features at a glance Complete system test including radar sensor ECU and RF front end Impact evaluation of, material and paint due to radar sensor s original mounting position in the vehicle e.g. bumper Effective absorption no ghost targets Compact and mobile design Wide angle range High reproducibility and 24/7-testing State-of-the-art drive inverters Multi axis, high precision positioning system Energy recovery due to power supply unit EtherCAT interface for position set points 56

57 Radar Sensor Over-the-Air Radar-in-the-Loop Test Bench, miro sys ARSG Features at a glance Fully digital concept, flexible configuration Compact converter modules for angle simulation Support of 24, 77 and 79 GHz radar sensors For almost all ADAS scenarios such as ACC, AEB and more Integrated component test capability 57

58 Radar Sensor Over-the-Air Radar-in-the-Loop Test Bench, Real Time Simulation Features at a glance Real-time integration into HIL simulation of ARSG Radar Simulator for synchronous closed loop testing in 1ms Powerful toolchain (accurate simulation models and easy graphical editor) Automotive Simulation Models for very accurate real-time simulation with many scenarios 58

59 Radar Sensor Exemplary HIL System Over-the-Air Radar-in-the-Loop Test Bench, Simulation Performance Feature Details 4 independent targets with variable parameters: Radar targets Update rate Distance Speed Signal strength (RCS) Azimuth angle 1ms Distance range step size 2 *) 1000m 5.6cm Digital Speed range step size ± 700km/h 4mm/s Angle range step size ± 100 0,1 Simulated area 100 Angle positioning speed Max. 200 /s Radar under test Radar Frequency 24, 77, 79 GHz and higher *) under development 59

60 Thank you for listening! 60

61 Important Information! 2017, dspace GmbH All rights reserved. Written permission is required for reproduction of all or parts of this publication. The source must be stated in any such reproduction. This publication and the contents hereof are subject to change without notice. Benchmark results are based on a specific application. Results are generally not transferable to other applications. Brand names or product names are trademarks or registered trademarks of their respective companies or organizations. 61

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