Maneuver based testing of integrated vehicle safety systems

Maneuver based testing of integrated vehicle safety systems Rudolf Ertlmeier 1 Kathrin Sattler 1, Andreas Raith 1, Thomas Brandmeier 1 Daouda Sadou 2, Christian Schyr 3 1 Institute for Applied Research (IAF); Ingolstadt University of Applied Sciences 2 Continental Automotive GmbH 3 IPG Automotive GmbH " apply & innovate 2012" - IPG Technology Conference 18. / 19. September 2012

Agenda / Contents 1 Motivations Networking of automotive systems Integrated safety systems New test concept 2 Test system Realisation Example of continuous testing 3 Crash data feeding Selection and feeding Crash data scaling 4 Outlooks

Networking of automotive systems Development of system complexity development in recent years The number of various control units in vehicles is expanding extremely since the last few years system complexity is increasing constantly testing is getting more and more extensive FlexRay MOST CAN LIN Gateway CAN CAN CAN CAN Diagnosis... source: Kiesewetter T.: Der VW Touareg - Karosserieelektronik und Infotainment ATZextra, Nr. 2010-02, page 47, 2010

Integrated safety systems New safety system concept (e.g. SCU - Safety Control Unit) see hear e.g. ACC e.g. CISS (Crash Impact Sound Sensing) e.g. ESC feel communicate e.g. Car-2-X

New test concept Idea of a new test concept for safety systems idea of the new test concept combination of: - vehicle simulation - environment simulation - crash data feeding for MiL, SiL and HiL test environment project: VISAPS vehicle- and environment simulation SCU crash data modular flexible system for development and production release of networked systems (MiL, SiL, HiL - test environment) consistency and automation of testing project partners:

Realisation Concept software vehicle & environment simulation environment sensors chassis sensors car2x communication GPS/navigation laboratory crashes simulated crashes other relevant situations (misuses) HiL(real time system) SCU signals trigger crash data base interfaces (e.g. bus systems) sensor signals hardware SCU (safety control unit) algorithms (with vehicle dynamics, object properties, ) SCU signals actuators (e.g. airbags, belt tensioners)

Realisation 1 st Generation: CAN-Tester Testing of CAN based algorithm in an electronical control unit: Data sources Replay of CAN-Traces Rest bus simulation CarMaker simulation CAN data manipulation Cyclic Redundancy Check (CRC) Message counter Data Length Code (DLC) Timeout Data field (including init- and error-values)

Realisation 2 nd Generation: Airbag HiL-system programming, calibration, fault memory Crash DB crash parameters velocity coverage impact angle Safety Control Unit crash signals CarMaker vehicle environment current measurement SPI PSI5 analog bus systems (CAN, LIN, FlexRay) intelligent IO

Example of continuous testing Collision in front of traffic lights New test system enables a continuous testing throughout all phases of driving: Normal Driving, PreCrash and InCrash t -3 = -2s v -3 = 60km/h t -2-0,8s v -2 = 60km/h t -1-0,75s v -1 = 60km/h t 0 = 0s v 0 40km/h Normal Driving belt tensioner emergency brake PreCrash airbag InCrash t

Selection and feeding Feeding test system with required crash data 1 Normal Driving / PreCrash: crash trigger at collision time specify crash parameter by using simulation parameter SCU is being fed with vehicle dynamics and environmental sensor data from IPG CarMaker simulation 2 InCrash:? Angular 30 43 km/h looking for corresponding real driven crash data and feeding into SCU SCU real driven crash data crash data base

Crash data scaling Artificial generation of crash data What can we do if there are not enough or exactly the required real driven crash data in the database? search for best fitting data set generate crash data by using FEM inaccurate testing results not feasible in almost real time generate data out of existing real driven crash data by scaling and interpolation angular 30 32 km/h scaling / interpolation angular 30 43 km/h angular 30 51 km/h longitudinal acceleration [g] integrated velocity [km/h] 0-10 -20-30 front 30 right angle, v = 43km/h reference signal generated signal 0 10 20 30 40 50 60 70 0 v reference -20 v generated -40 0 10 20 30 40 50 60 70 time [ms]

Next generation test system project: VISAPS 2 1 further development of current scaling and interpolation algorithm 2 realisation of secondary accidents simulation within CarMaker 3 further development of the new VISAPS test system: implementation of AUTOSAR - requirements ISO 26262 certification integration of power measurement to measure the ignition circuit currents exactly 4 test strategies development of an efficient test strategy for highly networked safety systems by combining different test methods such as maneuver-based or evolutionary tests

If you have any questions, please do not hesitate to contact us: Dipl.-Ing. (FH) Rudolf Ertlmeier Dipl.-Ing. (FH) Kathrin Sattler Istitute for Applied Research (IAF) Istitute for Applied Research (IAF) Ingolstadt Universty of Applied Sciences Ingolstadt Universty of Applied Sciences Esplanade 10 Esplanade 10 85049 Ingolstadt 85049 Ingolstadt phone: +49 (0)841/9348-648 phone: +49 (0)841/9348-646 Email: rudolf.ertlmeier@haw-ingolstadt.de Email: kathrin.sattler@haw-ingolstadt.de Dipl.-Ing. (FH) Andreas Raith Prof. Dr.-Ing. Thomas Brandmeier Istitute for Applied Research (IAF) Istitute for Applied Research (IAF) Ingolstadt Universty of Applied Sciences Ingolstadt Universty of Applied Sciences Esplanade 10 Esplanade 10 85049 Ingolstadt 85049 Ingolstadt phone: +49 (0)841/9348-723 phone: +49 (0)841/9348-384 Email: andreas.raith@haw-ingolstadt.de Email: thomas.brandmeier@haw-ingolstadt.de Dipl.-Ing. Daouda Sadou Dr.-Ing. Christian Schyr Continental Automotive GmbH IPG Automotive GmbH Siemensstraße 12 Bannwaldallee 60 93055 Regensburg phone: +49 (0)721/98520-43 phone: +49 (0)941/790-6280 Email: christian.schyr@ipg.de Email: daouda.sadou@continental-corporation.com

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