GENERIC EPS MODEL Generic Modeling and Control of an Electromechanical Power Steering System for Virtual Prototypes

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2 GENERIC EPS MODEL Generic Modeling and Control of an Electromechanical Power Steering System for Virtual Prototypes Dipl.-Ing. Roman Mannale, Volker Ewald, Dr.-Ing. Markus Bauer Adam Opel AG, Control Systems & Brake CAE Karlsruhe, Apply & Innovate, 20 September

3 AGENDA 1. Introduction 2. EPS tool chain 3. Generic EPS model 4. Summary 3

4 VARIANT DIVERSITY Astra Senator Chassis & ADAS ABS, ESC, AWD, CDC ABS ABS & ESC Increasing development, tuning and validation effort 4

5 ROAD LAB MATH STRATEGY (RLM) ROAD LAB MATH??? Manöver 1 1 [stwhl_ang] 1/z stwhl_ang 1 1 1/z [gas_gear_clutch] 1/z gas_gear_clutch Straßenanregung Adam MatCar Opel AG 1 EngRngSt_value 1 [BLS] CDC [man_mcp] man_mcp Demux ESP / ABS / TCS IVCS IVCS Test drives System tuning Random testing Validation Hardware in the loop simulation (HiL) Diagnosis Failsafe Performance Model/Software in the loop simulation (MiL/SiL) Architecture development System integration Parameter optimization Ressource optimized development & validation 5

6 SIMULATION TOOL CHAIN OVERVIEW Component Data Component Database Control Systems Master Model (CSMM) SiL Measurements Design Data ASCII (CM-Infofile) Parameters CarMaker (CM) vehicle infofiles CSMM HiL Multi Body Simulation (MBS) Master Model Axle Full vehicle DiL 6 Component Models CM-Models Simulink Models S-functions c-code fkfs.de

7 MASTER MODEL APPROACH Library 1 Library m Master Model Master Model Master Model 7 User 1 User 2 User n

8 RLM EXAMPLES Architecture phase Prototype phase Tuning & Validation Develop Test Mule Elimination HiL ESC Homologation Vehicle ROAD LAB MiL SiL MATH 8

9 RLM TOOL CHAIN FOR EPS SYSTEMS Architecture phase Prototype phase Tuning & Validation Develop Test Generic EPS model (MiL) Supplier EPS model (SiL) Power pack bench (HiL) EPS system bench (HiL) Vehicle ROAD HiL LAB MiL SiL MATH Virtual steering test bench Support all development phases 9

10 EPS TOOL CHAIN APPLICATIONS Tasks Analysis Architecture phase Design of the steering system Define requirements for suppliers Predict the interaction with chassis components Sensitivity analysis Prototype phase Tuning & Validation E-Motor Tie rod Torsion bar Steering lever arm Wheel 10

11 EPS TOOL CHAIN APPLICATIONS Tasks Analysis Architecture phase Prototype phase Detailed analysis of the interaction with chassis components Dampers Bushes Mounting ECU functional testing Tuning & Validation 11

12 EPS TOOL CHAIN APPLICATIONS Tasks Analysis Architecture phase ECU testing Functional testing Performance testing according to internal spec. Pre-calibration of control functions Prototype phase Tuning & Validation Power pack bench (HiL) EPS system bench (HiL) 12

13 RLM TOOL CHAIN FOR EPS SYSTEMS Architecture phase Prototype phase Tuning & Validation Develop Test Generic EPS model (MiL) Supplier EPS model (SiL) Power pack bench (HiL) EPS system bench (HiL) Vehicle ROAD HiL LAB MiL SiL MATH Virtual steering test bench 13

14 VIRTUAL STEERING TEST BENCH Measurement data (from MBS or real system) Measurement data (from MBS or real system), steering model Steering model Automatic identification Validation Analysis Model parameters Validated steering model Controlability, observability, modal/stability/sensitivity analysis EPS model A EPS model C EPS model D 14 One tool for all models (Opel/Supplier) EPS model B Virtual steering test bench

15 RLM TOOL CHAIN FOR EPS SYSTEMS Architecture phase Prototype phase Tuning & Validation Develop Test Generic EPS model (MiL) Supplier EPS model (SiL) Power pack bench (HiL) EPS system bench (HiL) Vehicle ROAD HiL LAB MiL SiL MATH Virtual steering test bench 15

16 GENERIC EPS MODEL COMPONENTS Controller model Reference model for target behaviour Model based approach: Internal Model Control Motor model Mechanical steering model Non-linear friction 2 degrees of freedom Non-linear friction 16

17 REQUIREMENTS FOR GENERIC EPS MODEL Model in the loop Available for early development Modular concept Cover all basic EPS functions Physically-based self-adjusting controller setup EPS target values Vehicle parameters Generic EPS model 17

18 INTERNAL MODEL CONTROL APPROACH - G R (s) = 1/G M (s) u F(s) G R (s) G (s) Filter Controller System Disturbances y d G M (s) Model - d Model error Controller parameters reflect physical parameters of the system 18

19 GENERIC EPS MODEL OVERVIEW Steering wheel torque Observers Generate reference intermediate shaft angular speed Disturbance compensator Controller (IMC) Mech. system Friction compensator Model (IMC) 19

20 GENERIC EPS REFERENCE GENERATION Steering wheel torque Reference intermediate shaft angular speed Stationary model - Define desired steering support (Boost Curve) Dynamic model - Ideal dynamic reference behaviour - Tunable damping 20

21 GENERIC EPS EXAMPLE RESULT Test run: 100 km/h Slowly increase steering wheel angle (quasi stationary) Two vehicle models: Middle class Compact class Middle class Target behaviour Compact class Steering wheel torque Two vehicles classes, similar steering wheel torque Lateral vehicle acceleration 21

22 SUMMARY RLM strategy for ressource optimized development & validation Model/software in the loop (Math) Hardware in the loop (Lab) Test drives (Road) EPS tool chain as one part of RLM covers all development phases Architecture phase Prototype phase Tuning & Validation Generic EPS model allows early analysis & system understanding Available for early development (MiL) Modular concept Covers all basic EPS functions Physically-based self-adjusting controller setup 22

23 Roman Mannale THANK YOU

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