dspace Embedded Success Greg Jankord Ph.D. Wilson Perez M.S.

Transcription

1 dspace Embedded Success Greg Jankord Ph.D. Wilson Perez M.S. 1

2 Overview What is EcoCAR? Vehicle Architecture Guided by Model-Based Design xil Process Real Time Development and Data Analysis Future Work 2

3 What is EcoCAR 3? 3

4 EcoCAR 3 4-year Advanced Vehicle Technology Competition (AVTC) challenging 16 college teams to rebuild a 2016 Chevrolet Camaro Engineering Goals: Increase fuel economy Reduce emissions and energy consumption Maintain performance and consumer acceptability 4

5 History 5

6 Four Year Competition Year One: 0 Buyoff Design the car Choose engine, transmission, other key components Year Two: 50% Buyoff Build the car Received car in December 2015 Had three months to completely rebuild as a hybrid vehicle Year Three: 65% Buyoff Refine the car Work out all bugs and problems in car Begin to tweak vehicle and its systems to achieve maximum performance and efficiency Test emissions and energy usage Year Four: 99% Buyoff Refine and Optimize the car (cont.) Ensure car drives and feels as good as one just bought from a showroom Tweak vehicle and its systems to achieve maximum performance and efficiency 6

7 EcoCAR Competition Industry Benefits Increases interest in the automotive industry Gives students a hands-on experience to apply knowledge learned in the classroom, that better prepares them to be automotive engineers of the future Opportunity to work in a cross functional team High level understanding of how different subsystem and components work together within the vehicle Prepares students for full-time employment Works with Industry sponsored software (NX for Design, Simulink, dspace, etc) Instills troubleshoot and problem solving skills 7

8 Vehicle Architecture 8

9 Ohio State EcoCAR 3 Vehicle Architecture Parallel Series Plug-in Hybrid Electric Vehicle 18.9 kwh A123 Lithium Ion Battery Pack 32 kw Denso ISG Belted Alternator Starter 2.0L E85 Engine (119kW) 5-Speed Tremec Automated Manual Transmission P112 kw Peak Power Parker Hannifin Electric Machine 9

10 Vehicle Technical Specifications (VTS) Increase Fuel Economy 40MPGge 40 Miles of all electric range 250 Miles of total range Reduce Emissions Uses E85 Estimated 50-70% emissions reductions Maintain Performance 0-60 time of 6.6 seconds 340 horsepower 10

11 Guided by Model-Based Design 11

12 Core Concepts of Model-Based Design Define Requirements System-Level Specifications Continuous Engineering Complete Integration & Test System-Level Integration & Test Subsystem Design Subsystem Integration & Test Subsystem Implementation Time the development process centers around a system model from requirements capture and design to implementation and test. 12

13 Core Concepts of Model-Based Design Define Requirements Complete Integration & Test System-Level Specifications Continuous Engineering System-Level Integration & Test 99% mule vehicle by competition Requirements Traceability Finalize architecture design Physical Modeling, Algorithm Development, Simulation, etc. Subsystem Design Subsystem Implementation Time Subsystem Integration & Test Component testing Subsystem build and vehicle integration Model Coverage, Model Advisory, etc. Rapid Prototyping, Embedded Code Generation, etc

14 Line No. Description: OSU EcoCAR 3 transmission assembly Prepared By: Simon Trask Complete Date: Model Year: 2016 Key Date: Approver: Shawn Midlam-Mohler Vehicle: OSU EcoCAR 3 VPPS: Approver: FMEA #: Revision: Transmission: Manual 5 Speed Transmission FMEA Date: Engine: 2.0L i4 E85 Item / Function of the Part Potential Failure Mode (Loss of Function or value to customer) Design Failure Mode and Effects Analysis (DFMEA) Potential Effect(s) of Failure S E V Potential Cause(s) / Mechanism(s) of Failure O C C Current Design Controls (Design actions planned or completed to prevent or reduce occurrence of failure, provide details and Best Practices used) Prevention Current Design Controls (Analytical or physical validation method planned or completed) Detection D E RPN T Recommended Action(s) [1] Clutch transfers engine [1.1] Clutch does not engage Engine power not transfered [1.1.1] Controller Engine and transmission speed [ ] Attempt 1 torque to transmission when requested to transmission 7 error 7 Controller tested on HIL sensors 2 98 engagment again [1] Clutch transfers engine [1.1] Clutch does not engage Engine power not transfered [1.1.2] Damaged Engine and transmission speed [ ] Attempt 2 torque to transmission when requested to transmission 7 electrical wiring 4 Controller tested on HIL sensors 2 56 engagment again Unintended engine start or [ ] Shut down front [1] Clutch transfers engine [1.2] Clutch engages without incorrect engine speed [1.2.1] Controller Engine and transmission speed powertrain and shift 3 torque to transmission request match 7 error 7 Controller tested on HIL sensors 2 98 transmission into neutral Unintended engine start or [ ] Shut down front [1] Clutch transfers engine [1.2] Clutch engages without incorrect engine speed [1.2.2] Voltage Regular charging and Fault monitoring from master powertrain and shift 4 torque to transmission request match 7 supply out of range 2 monitoring of battery voltage cylinder 2 28 transmission into neutral Less power transfered from [1] Clutch transfers engine [1.3] Clutch slips between engine to transmission and [1.3.1] Controller Frequent check of clutch Engine and transmission speed 5 torque to transmission input and output possible clutch damage 7 error 7 material and actuator sensors [ ] Disengage clutch Less power transfered from [1] Clutch transfers engine [1.3] Clutch slips between engine to transmission and [1.3.1] Insufficient Frequent check of clutch Engine and transmission speed 6 torque to transmission input and output possible clutch damage 7 Clutch Pressure 8 material and actuator sensors [ ] Disengage clutch Less power transfered from [1.3.2] Damaged [1] Clutch transfers engine [1.3] Clutch slips between engine to transmission and clutch friction Frequent check of clutch Engine and transmission speed 7 torque to transmission input and output possible clutch damage 7 material 6 material and actuator sensors [ ] Disengage clutch Less power transfered from [1] Clutch transfers engine [1.3] Clutch slips between engine to transmission and [1.3.3] Damaged Frequent check of clutch Engine and transmission speed 8 torque to transmission input and output possible clutch damage 7 clutch actuator 4 material and actuator sensors 3 84 [ ] Disengage clutch Less power transfered from [1.4.1] Sudden high Impose torque limits on clutch [1] Clutch transfers engine engine to transmission and input torque (from inputs, ramp torque during 9 torque to transmission [1.4] Clutch input shaft yields possible clutch damage 7 electric machine) 2 electric start Torque feedback from inverter 3 42 [ ] [1] Clutch transfers engine [1.5] Clutch catastrpohic Engine cannot transmit [1.5.1] Engine speed Impose speed limits on clutch 10 torque to transmission failure power to transmission 7 exceeds clutch limit 2 inputs Transmission speed sensor 2 28 [ ] [1.6.1] Excessive power input at high [1] Clutch transfers engine ambient Measure temperature [ ] Shift transmission 11 torque to transmission [1.6] Clutch over heats Internal components fail 7 temperature 3 frequently Master cylinder temperature sensor 3 63 into neutral [2] Transmission applies [2.1.1] Incorrect reduction ratio from input speed torque and transfers [2.1] Shift dogs and synchronization HIL simulation of speed 12 torque to the wheels synchronizers wear or yield Transmission inoperable 7 during shifting 3 sychronization Subsystem testing [ ] [2] Transmission applies reduction ratio from input 14 torque and transfers [2.2.1] Excessive Electric motor and transmission [ ] Shift transmission 13 torque to the wheels [2.2] Input shaft yields Transmission is inoperable 7 input torque 2 Controllers tested on HIL speed sensors 3 42 into neutral

15 System Safety Requirements 15

16 xil Process MIL, SIL, HIL/CIL, VIL 16

17 Regression Testing Validation through xil phases Integration of three software suites Regression Testing Ensure eliminating one bug doesn t create others Thorough validation of logic before in vehicle testing Made easier by automated testing Ensure validation through increasing fidelity levels Ensure logic robustness and catch bugs before being implemented on vehicle 17

18 Modular Structure The full vehicle model is setup in a modular manner Setup is easy to transfer from MIL to SIL/PIL/HIL/VIL: The Inputs and Outputs layer are completely separated from the Algorithm part of the models to separate out Electrical and CAN interfacing Communication between supervisory, GCM and the powertrain/components in MIL/SIL: From-goto block-set Vehicle Network Toolbox (allows use of.dbc files in MIL phase) Communication between supervisory and the powertrain/components in HIL: RTI block-set, Motohawk block-set is used for the GCM and other controllers 18

19 Plant model structure Electrical Rx RTI Multi I/O Blocks CAN Rx RTI CAN Rx/Unpack Blocks I N P U T S SPINE O U T P U T S Electrical Tx RTI Multi I/O Blocks CAN Tx RTI CAN Pack/ Tx Blocks COMMUNICATIONS INTERFACE LOGIC INPUTS CONTROLLER / PLANT MODEL OUTPUTS 19

20 MIL to HIL Transition MIL Controllers (MABx + GCM) Powertrain + Driver Step 1: Conversion using an.m file Controllers (MABx + GCM) Powertrain + Driver 1 Simulink Model 3 Simulink Models Step 2: Build Code for controllers using Simulink coder SIL HIL Step 2: Build Code using rti1401, motohawk rpc and rti1006 C-code within simulink (MABx) Model Within Simulink Code Within MABx II C-Code within Midsize HIL Simulator C-code within simulink (GCM) Code Within GCM 20

21 Emulated Soft ECUs The SMS team is emulating all the ECUs that are either team developed or team added in their full vehicle model Hybrid Supervisory Controller (MABX II) FPTCAN 500 kbaud HVCAN 500 kbaud RPTCAN 500 kbaud GMLAN 500 kbaud ECM (Engine) BAS Inverter (BAS Motor) Cooling Loop Pumps HVAC BMS (ESS) Brusa (HV Charger) APM (DC/DC) EM Inverter (Electric Motor) PSCM (Power Steering) EBCM (Brakes) CGM (Serial Gateway) GCM (Transmission) Team Developed Controller (Function) Team Added Controller (Function) Stock Camaro Controller (Function) Added GM Controller (Function) Legend External Terminating Resistor Internal Terminating Resistor Network Name baud rate CCM (Chassis) DLC BCM (Body) 21

22 SMS Testing Procedure MIL/SIL Matlab/ Simulink Simulink Coder Built Code PIL/HIL ControlDesk Hardware Software Interface Recorded Data Experiment Setup IBM Rational Doors Requirements AutomationDesk Test Case Generation and Execution Recorded Data Execution Plan Initation Requirements Generation/ Refinement Verdict/Results Synect Test Case/Verdict Management 22

23 Test Case Example 23

24 Real Time Development and Data Analysis 24

25 Rapid Prototyping Plant models validated through component and vehicle level testing Component Level Validation Friction clutch characteristic maps Clutch Line pressure Transmission Shift times 25

26 Control Desk NG 26

27 PTU Thermal Testing and Analysis Sought to better understand the effects of the high speed operation of the PTU on oil temperatures Instrumented the PTU and differential with in oil sensor and recorded temperatures over the EEC drive cycles Data collected via Arduino interfaced with matlab 27

28 Data Analysis: Acquisition MIL HIL VIL Excel data sheets, etc. ControlDesk NG MABx Vector gl100 data logger Matlab Script (Read/ Post-Process) Matlab Workspace 28

29 CD Mode (MIL Simulation vs. Test data) Energy Consumption from HIL Simulation 6382 Wh 29

30 Data Analysis Dates Test 3/ /1-2 4/7 4/7-9 4/ /21 4/19 4/ / /1-3 5/1 5/4 TRC VDA TRC VDA TRC Emissions Lab TRC VDA TRC VDA TRC Emissions Lab TRC HS Oval TRC VDA TRC VDA TRC VDA TRC Emissions Lab TRC Emissions Lab Total Hrs Hrs

31 Future Work 31

32 ADAS Algorithms Steps: 1. Setup parameters Line detection Object detection 2. Capture stereo images 3. Rectify stereo images 4. Detect lanes 5. Detect objects 6. Estimate distance to objects 7. Overlay detection boxes and labels on output image 8. Log data 9. Display output image 10. Repeat steps

33 MotionDesk Exploring MotionDesk for ADAS Testing 33

34 Thank You 34

35 Questions 35