ESC-HIL TEST SYSTEM SOLUTIONS FOR VIRTUAL TEST DRIVING

ESC-HIL TEST SYSTEM SOLUTIONS FOR VIRTUAL TEST DRIVING

Table of Contents Motivation 3 System at a Glance 4 General Description 5 Block Diagram (example configuration) 6 Use Cases 7 Verification and Validation of ESC Systems Variant Testing, Validation and Homologation Best-in-Class Features 8 Add-ons and Integration Potential 9 Synergy Effects Using CarMaker / HIL platform Integration of Further ECUs and the FailSafeTester Integration of Further Mechanical Components Scope of Delivery 10 Appendix: Test Bench Results 11 2

Motivation The key objective of developing electronics in automotive development projects is to ensure the reliability of the individual components in any situation. Therefore, the increasingly complex development processes and interlinking of the components require supporting simulation techniques. They assist in shortening development cycles and in detecting sources of faults in the interaction of the components at an early stage. This is a challenge faced by both automotive OEMs and suppliers. Hardware-in-the-loop simulation (HIL simulation) is a major element of optimizing the development process. Global Vehicle Requirements Released Vehicle Integration of multi domain models from different development tools in a virtual prototype Powertrain Vehicle Dynamics Validation against global vehicle target Integration of ECU(s) or complete vehicle systems in a virtual prototype ADAS Virtual Test Driving Figure 1: Early validation of components and systems along the V-model Real-world electronic vehicle control units and prototypes such as the electronic stability control (ESC) unit are connected with real-time simulation models of the vehicle and the vehicle s environment, or with a complete simulation environment (CarMaker). HIL simulation allows users to perform tests under real-word conditions in a laboratory environment. This not only makes it possible to test electronic components in any conceivable failure mode, but to also conduct tests which are often difficult to implement in real-world conditions. In the simulation environment, risk-free and reproducible testing of dangerous worst-case scenarios is possible with just a minimal investment of effort and expense. Due to this approach, final test driving can be accomplished with a significantly reduced effort. This ultimately leads to major time and cost savings, as well as substantial quality improvement. The correct functionality of ESC systems is important not only due to their mandatory use in all newly registered passenger cars and trucks within the EU. In addition, ESC, as an interacting electronic control unit for numerous other applications in the vehicle (e.g. ADAS, energy efficiency, steering systems), plays a central role and has long ceased to be defined strictly as a vehicle dynamics control system. The HIL method has long become established as the standard and essential technique that makes it possible to manage the immense testing requirements of diverse functionalities. 3

System at a Glance Delivery of the fully functional test system in a 38 rack housing (see picture) is standard. This ensures ease of integration and maximum future extensibility by further components and upgrades. However, if required, the setup can also feature smaller test benches through to portable desktop cases. Standard 19 Rack Housing In different heights and preconfigurations customized for every use case. Xpack4 Real-Time System Including CarMaker/HIL and relevant I/O-devices. Power Supply Fully programmable, optionally with Car Start functionality. FailSafeTester State-of-the-art solution for automatic fault insertion without manual patching cables. Plug-in Test Boxes Connected customer ESC- ECU(s) as device under test. Test boxes can be exchanged easily by Plug & Play. 4

General Description The ESC-HIL test system is a turnkey solution for testing and validating realworld ESC units enabling all ESC functionalities to be tested with a single HIL system. The main components include: CarMaker simulation software Xpack4 realtime system with ESC-specific I/O Electrical, mechanical and functional integration of the customer s ESC ECU Optional coupling with FailSafeTester Integration in a standard 19 rack with power supply unit The ESC ECU is integrated as a real-world component, where the hydraulic system including the hydraulic pump is modeled. The resulting elimination of mechanically moved components reduces power requirements and noise development during operation. The vehicle model with the corresponding driver and brake model generates the steering wheel angle, wheel speed, yaw rate, lateral acceleration and primary brake pressure. Thanks to specifically developed tools, the ECU residual bus simulation is automatically generated directly from the database (e.g. the DBC file) for commonly used field bus systems such as the CAN bus. The valve activities are measured by a special-purpose, high-precision analog signal acquisition box and fed back to the hydraulic model (virtual valves). Due to the high quality of the valve position measurement, the IPG SignalAcquisitionBox, makes it possible to run all performance tests in addition to functional and fail-safe tests. Quick calibration and no need for re-calibration after reinstalling the ECU, is a further advantage that saves time and costs. In addition, the CarMaker/HIL environment offers extensive possibilities for ECU diagnosis directly from the Car- Maker GUI. Access to and processing of internal ECU parameters is possible even during runtime thanks to CCP/ XCP access. 5

Block Diagram (example configuration) User Interfaces (CarMaker Host-PC) Ethernet Simulation Framework (CarMaker Xpack4) Road Model Roadway Information Driver Model Steering Wheel Pedals Tire Model Vehicle Model Cockpit PCI Bus Engine / Hybrid Model Hydraulic Brake Model Xpack4 I/O FailSafeTester Yaw Rate Wheel Speed Lateral Acceleration Primary Pressure Trq Request Vehicle Bus Hydraulic Pump Pressure Magnetic Valve Positions Power Supply Device Under Test (Plug-in Test Box) ESC ECU Sensor Box Power Control Software Components Hardware Components 6

Use Cases Verification and Validation of ESC Systems ESC-HIL test systems by IPG Automotive cover the entire range of ESC-related tests: Fail-safe tests, functional tests and performance tests. While simulation-based fail-safe testing has become well established due to low requirements regarding simulation model quality and maneuver setup flexibility, simulation-based functional testing and performance testing requires high model quality and a versatile way of setting up maneuvers, evaluation criteria, postprocessing routines and reporting functionality. Obviously, all of these requirements are covered by the CarMaker product family. Performance tests make it possible to quantify the operational quality of a function and whether the resulting vehicle performance matches the brand s image (also frequently referred to as brand DNA). Fail-Safe Tests Function Tests Performace Tests Sensor defect Backup mechansim Communication Diagnostic... ABS/ASR/VSC Steering support Hill-hold control ACC functions... Inlet speed Stability value Threshold consumption Braking distance... fotolia.com Variant Testing, Validation and Homologation Utilization of the ESC-HIL test system fully supports simulation-based ESC homologation according to ECE-R 13H. As a result, the high correlation between measurement and simulation makes it possible to already validate the growing number of variants and derivatives in vehicle development in simulation and HIL. Consequently, the number of real-world vehicle tests can be significantly reduced. 7

Best-in-Class Features The CarMaker software environment not only provides an open and flexible platform for integrating the user s own models but also a state-of-the-art vehicle dynamics environment that enables physically correct behavior up to the limit. Thanks to the modern FailSafeTester concept, electrical faults can be generated in fully automatic mode with free selection of the failure modes. As a result, it is possible to reliably conduct targeted investigations even in worst-case scenarios. The maneuver- and event-based approach to testing enables uncompromising transfer of test cases from the SIL or even the MIL stage. Even highly complex closed-loop driving instructions can be easily executed and fully reproduced assisted also by the highly sophisticated IPGDriver model. The ESC-TestWare option combines the knowledge and expertise from more than 30 years of experience in the vehicle dynamics environment in bundled test catalogs. Linking with the Test Manager makes it possible to fully automatically run complete test series and test catalogs for hours and even days at a time. Further Advantages at a Glance Open and robust architecture consisting of off-the-shelf industry components Extremely high computer and communication performance (5-10 times faster than the benchmark) Intuitive use on PCs Stable test automation and test management Exact reproducibility of the results across extended periods of time Unrivaled turnaround times thanks to interaction between real-time node and host PC Support of all automotive-specific I/O interfaces such as CAN (FD), Ethernet, FlexRay, LIN, DAC, AD, PMW, etc. Vehicle-specific I/O modules for Chassis, Powertrain, ADAS and Body Control applications Matlab/Simulink-based modeling possible but not imperative 8

Add-ons and Integration Potential Synergy Effects Using the CarMaker / HIL Platform Use of open integration opportunities on the highest level: Simulation of the test vehicle and environment in hard real-time conditions Easy use and integration of validated model libraries (e.g. tires, suspension, MBS axles) and users own models via C-Code, FMI, Simulink and other interfaces IPGDriver model for sophisticated closed-loop driving tasks Integration of Further ECUs and the FailSafeTester The Xpack4 Integration HIL system provides possibilities for further plug-in test boxes extending the range of test cases of the entire system. Functional tests and interactions between the ESC system and other components of any kind such as active dampers or electric power steering are possible at the highest levels of reproducibility even in complex settings. The FailSafeTester provides opportunities for testing all kinds of electrical faults such as in power supply, (wheel speed) sensor signals and CAN signals. Integration of Further Mechanical Components For the interaction of ESC with EPB functions the real-world EPB brake calipers can be integrated as mechanical components as well. The ESC test system, with mechanical integration of the brakes in their true locations at the front and rear axle, can be extended to create a full-fledged dual circuit braking system test bench. 9

Scope of Delivery Test systems by IPG Automotive are turnkey solutions. Following the complete integration of the customer s DUT, the system is delivered in fully operational condition. After on-site commissioning, assistance by specialists who are familiar with the system will be available to customers at any time. A possible configuration looks as follows: HIL rack environment Software HIL / DUT Engineering Customer Services Real-time system Xpack4 for ESC 19 subrack Carrier board and dual or quadcore CPU I/O modules M410 CAN M32 Digital in M36 Analog in M43 Relay out M62 Analog out M400 wheel speed generator M409 Power Supply Control CarMaker / HIL pro IPGGUI IPGCar IPGTrailer IPGTire IPGDriver IPGRoad IPGTraffic ManeuverControl IPGControl IPGInstruments IPGMovie Test Manager ScriptControl FailSafeTester Tool Plug-in test box for ESC Electrical and mechanical level Software level Functional level of integration Integration in turnkey HIL Planning Construction Implementation Start-up On-site installation Customer instruction Training CarMaker / HIL training for ESC Support Support and maintenance by qualified experts worldwide Cabinet peripherals 80V / 100A Power supply with car start option Diagnostic Tool support CCP/XCP and Flash Tool CAN/FlexRay/LIN Tools Cabinet 24 or 38 units Configured host PC 10

Appendix: Test Bench Results Hydraulic brake model performance Braking pressures while braking on µ-split (ABS function) 200 175 150 125 Pressure (bar) 100 75 50 25 0 12 13 14 15 16 17 18 19 20 Time (s) Pressure master cylinder simulated Wheel pressure font left Wheel pressure rear left Pressure master cylinder measured Wheel pressure font right Wheel pressure rear right Vehicle model performance Double lane change (ESC function) Vehicle Velocity (km/h) 68 66 64 62 60 58 56 54 Corr.: 99% 8 Corr.: 92% Accel. Lat. (m/s²) 6 4 2 0-2 -4-6 -8 300 310 320 330 340 350 360 Position x (m) 300 310 320 330 340 350 360 Position x (m) CarMaker simulation Real measurement 11

Simulation Software Real-time Hardware Test Systems Engineering Services IPG Automotive GmbH, Karlsruhe 2016 China France Germany India Italy Japan Korea Malaysia Sweden Turkey UK USA Solutions for virtual test driving As an innovation driver for virtual test driving, the company is a leading global provider of software and hardware products for the automotive and supplier industry. With the areas Simulation Software, Real-time Hardware, Test Systems and Engineering Services, IPG Automotive supports its customers in creating innovations and improving their development process efficiently. The simulation solutions CarMaker, TruckMaker, and MotorcycleMaker, as open integration and test platforms, facilitate great savings in time and cost for customers, in a continuous development process of Model-, Software- and Hardware-in-the-Loop, all the way to the Vehicle-in-the-Loop method. The application ranges from the general vehicle dynamics simulation, developing and testing of chassis control systems, as well as interconnected systems such as chassis, powertrain, and steering in full electric and hybrid vehicles. Another strength of IPG Automotive is the development of future-oriented solutions for the integration and testing of advanced driver assistance systems. IPG Automotive GmbH Bannwaldallee 60 76185 Karlsruhe Tel.: +49 721 98520 0 ipg-automotive.com