SESSION 2 Powertrain. Why real driving simulation facilitates the development of new propulsion systems

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Muriel Maxwell
6 years ago
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1 SESSION 2 Powertrain Why real driving facilitates the development of new propulsion systems

2 CO 2 /Fuel Consumption, Pollutant Emissions, EV Range The real driving values are more and more in the public eye 2

3 Load Which Parameters Influence Real Driving? The load of the powertrain system heavily depends on many boundary conditions 100 Time lots of variations Simulation is needed 3

4 CO 2 /Fuel Consumption, Pollutant Emissions, EV Range What can be done to improve real driving values sustainably? On-road release test? 4

5 CO 2 /Fuel Consumption, Pollutant Emissions, EV Range What can be done to improve real driving values sustainably? Virtual development & test On-road release test Powertrain development process Integration of real driving into the entire development process! VIRTUAL TEST DRIVING 5

Virtual Test Driving for Powertrain Applications Virtual test driving is real driving Driver characteristics Skills Mood Attention level Driver Vehicle Vehicle characteristics Vehicle dynamics

6 Virtual Test Driving for Powertrain Applications Virtual test driving is real driving Driver characteristics Skills Mood Attention level Driver Vehicle Vehicle characteristics Vehicle dynamics Powertrain performance Operating strategy CLOSED LOOP Environment Traffic situation Ambient conditions Scenery/surroundings Traffic/ Environment Road Road characteristics Course of the road Surface Traffic lights/traffic signs 6

7 How to Use Real Driving Simulation in Powertrain Development Development process integration Driver Vehicle How to use real driving in daily business? Traffic/ Environment Road 7

8 Real Driving Simulation Vehicle model / virtual prototype Driver Vehicle Traffic/ Environment Road 8

9 Real Driving Simulation Vehicle Where can the vehicle model be obtained? Vehicle Option 1 Use of existing virtual prototypes Ask your colleagues/customers! Option 2 Use of vehicle data set generator Just create it yourself! Option 3 Set up new virtual prototype based on measurements Ask IPG Automotive! Add-on for vehicle data set generator: coast down adaption tool Tool to automatically adapt driving resistances to coast down measurements Obtaining a virtual prototype is not time-consuming! 9

10 Live Demo: Coast Down Adaption

11 Real Driving Simulation Vehicle Which powertrain for the virtual prototype vehicle? Vehicle Vehicle body Vehicle model Bodies Engine Suspensions Steering Tires Brake Option 1 CarMaker real-time powertrain models Option 2 High-fidelity 3 rd party powertrain models Powertrain Aerodynamics Sensors Misc. Option 3 Real powertrain components/systems hardware-in-the-loop Different options to integrate a powertrain into the virtual prototype 11

12 Real Driving Simulation Vehicle New transmission models and example vehicle data sets Vehicle Continuously variable transmission - CVT Dual-clutch transmission - DCT Example vehicle data sets Source: Bosch Source: Daimler Continuously variable transmission model with TCU Single track and speed envelope mode Dual-clutch transmission model with TCU Default and extended mode (with engine control request during shifting) New hybrid electric vehicle (HEV) examples Example vehicle models with DCT and CVT New transmission and TCU models and example vehicle data sets available 12

Real Driving Simulation Vehicle GT-SUITE

Trailer(s) Road / environment Scenario /

13 Real Driving Simulation Vehicle GT-SUITE interface now also available with GT-SUITE 2017 as master Vehicle CarMaker/TruckMaker GT-Suite Vehicle Chassis (suspension, steering, ) Body (masses, aerodynamics, sensors) Trailer(s) Road / environment Scenario / traffic Driver Brake Powertrain Mechanical system Electrical system Powertrain controls Thermal system (cooling/heating) Hydraulic system Integration of high-fidelity powertrain models incl. thermal, electrical and hydraulic systems Integrated solver handling for combined mechanical and thermal system models 13

14 Real Driving Simulation Road model Driver Vehicle Traffic/ Environment Road 14

Real Driving Simulation Road How can the road model be

Road Neu: Example roads/ scenarios Scenario Editor Road

KML data Road import using ADAS RP Road import from

Definition of the road, static and dynamic 3D objects

import Elevation data, traffic signs / speed limits have

signs and speed limits included Import of complete road

15 Real Driving Simulation Road How can the road model be obtained? Road Neu: Example roads/ scenarios Scenario Editor Road generation based on GPS measurements Road import using KML data Road import using ADAS RP Road import from detailed measurements New example roads and test tracks available in CarMaker 6.0 GUI-based drag & drop road and scenario generation Definition of the road, static and dynamic 3D objects Road generation using GPS measurements Pure x/y route import Elevation data, traffic signs / speed limits have to be added manually Elevation/incline data, traffic signs and speed limits included Import of complete road networks IPG Automotive s partners provide services for detailed road measurements and data processing Multiple options to use/create/import a road in the environment 15

16 Real Driving Simulation Road New example scenarios available in CM 6.0 Real road examples RDE route Karlsruhe AMS CO 2 test route Bernina Pass Stelvio Pass Extended test track examples City/rural/highway Nardo high-speed track Nardo handling track Off-road proving ground 16

17 Live Demo: RDE Route

18 Real Driving Simulation Road Cooperation with atlatec for RDE track measurements Road Record RDE track Process data Simulate Accuracy of the data tailored to RDE tests focus on relevant aspects Data export to ROAD5 format for direct use in CarMaker Integrated video player for parallel replay during the 18

19 Real Driving Simulation Driver model Driver Vehicle Traffic/ Environment Road 19

20 Real Driving Simulation Driver Comprehensive driver model with different operating modes IPGDriver Driver 1. Performing conventional 2. Retracing speed profile driving cycles from measurement data v Input + t v t 3. Performing free driving Driver 20

21 Real Driving Simulation Driver Operating mode speed profile driving Driver 2. Retracing speed profile from measurement data v t Variation options Allowed range of speed tolerance Driver reaction times relaxed nervous Energy-optimized driving within the speed tolerance limits Vehicle and payload Main use cases Exact repetition of measured speed profiles validation of model/test setup System robustness check in critical driving situations Tunable driver behavior in operating mode speed profile driving New options for driver behavior variation 21

22 Live Demo: Driver variations in operating mode speed profile driving

Real Driving Simulation Driver Operating mode free driving Driver 3.

Autonomous speed and course planning Intelligent reaction to traffic signs/lights and traffic objects Variation

of realistic real driving speed profiles depending on scenario Full reproducibility in combination with high variation

23 Real Driving Simulation Driver Operating mode free driving Driver 3. Performing free driving Driver model controls longitudinal and lateral dynamics incl. Autonomous speed and course planning Intelligent reaction to traffic signs/lights and traffic objects Variation options Driver behavior Traffic light timing Traffic conditions Vehicle and payload Benefits and use cases Generation of realistic real driving speed profiles depending on scenario Full reproducibility in combination with high variation flexibility Comprehensive real driving investigations with random traffic behavior Intelligent driver model reacts to road and environment Traffic object integration or phenomenological traffic approach 23

24 Real Driving Simulation Traffic/environment model Driver Vehicle Traffic/ environment Road 24

Real Driving Simulation Traffic Three different

Traffic objects controlled by IPGTraffic 2.

Phenomenological traffic approach Autonomous

and predictable behavior Co- with highfidelity

25 Real Driving Simulation Traffic Three different ways of traffic Traffic/ environment Traffic 1. Traffic objects controlled by IPGTraffic 2. Traffic objects controlled by traffic tool 3. Phenomenological traffic approach Autonomous traffic with stochastic traffic object positioning and predictable behavior Co- with highfidelity traffic tool PTV VISSIM Stochastic traffic Traffic situation without traffic objects 25

Real Driving Simulation Traffic Phenomenological traffic approach for RDE optimization Traffic/ environment Input Output 1. RDE route incl.

26 Real Driving Simulation Traffic Phenomenological traffic approach for RDE optimization Traffic/ environment Input Output 1. RDE route incl. all real traffic signs & traffic lights RDE test generation method Parameter settings for desired traffic density and weather conditions on road segments 2. database With representative speed profile characteristics for different road types various traffic situations/densities Automatic generation of random traffic behavior Road surface definition depending on weather conditions Multiple RDE test scenarios according to parameter settings Generation of speed profiles with virtual test driving Usable online and offline RDE test generation method with phenomenological traffic representation and intelligent driver Provided by IPG Automotive as engineering service 26

Real Driving Simulation Traffic New PTV VISSIM co-

CarMaker/TruckMaker (vehicle, driver, scenario)

maneuver (ego vehicle) synchronized co- PTV VISSIM

27 Real Driving Simulation Traffic New PTV VISSIM co- interface Traffic/ environment Preparation Simulation CarMaker/TruckMaker (vehicle, driver, scenario) Scenario generation in CarMaker Vehicle, driver, maneuver (ego vehicle) synchronized co- PTV VISSIM (traffic) Automatic road import from CarMaker Traffic situation definition 27

28 Live Demo: Coupling CarMaker with PTV VISSIM

Real Driving Simulation in the Entire Development Process

of multi-domain models in a virtual prototype Integration of

prototype VIRTUAL TEST DRIVING / real driving All real

29 Real Driving Simulation in the Entire Development Process Virtual development & test On-road release test Integration of multi-domain models in a virtual prototype Integration of ECU(s), powertrain components and entire systems in a virtual prototype VIRTUAL TEST DRIVING / real driving All real driving functions mentioned can also be used seamlessly on test benches! 8

30 Powertrain Testing Applications on the test bench We thank all our partners for the great collaboration! Dyno Interface the powerful solution for all types of powertrain test benches New features and variants are now available 30

31 Dyno Interface New features and variants Dyno Interface engine Dyno Interface powertrain & roller New test bench variants KIT-IFKM Silke Voss Fotografie IAV KS ENGINEERS Stop/start with and without decoupling clutch Simulink powertrain model integration Coast down and test bench adaption tool Driving robot parameterization GUI E-motor and EV test benches Coupling with battery emulators 31

32 Real Driving Simulation Facilitates the Development of New Propulsion Systems Driver Vehicle Traffic/ Environment Road Virtual test driving shortens the development time, lowers costs and increases product quality 32

Testing with Virtual Prototype Vehicles on the Test Bench

DEVELOPMENT Real Driving Emissions Testing with Virtual Prototype Vehicles on the Test Bench IPG Automotive AUTHORS Dipl.-Ing. Christian Lensch-Franzen is Head of Engineering at APL Automobil-Prüftechnik