maneuver based validation of bmw xdrive variants by … · outlook. • frontloading. •...
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Freude am Fahren
MANEUVER BASED VALIDATION OF BMW xDRIVE VARIANTS BY
USING VIRTUAL VEHICLE INTEGRATION AND HIL TEST METHODS.
IPG TECHNOLOGY CONFERENCE, SEPTEMBER 18 -19, KARLSRUHE.
19.09.2012
Matthias Prebeck, Dr. Peter Rissling; BMW Group
Michael Folie; IPG Automotive
Page 2
• Basics xDrive.
• Testsystem.
• Integration engine-model.
• Maneuver based tests.
• Testautomation.
• Benefits and Outlook.
AGENDA.
MANEUVER BASED VALIDATION, 19.09.2012
Page 3
BASICS xDRIVE. ACTIVE 4X4-SYSTEM.
MANEUVER BASED VALIDATION, 19.09.2012
Com. Bus
LMV (Actuator):
Receive target torque and actuate clutch.
Securing torque accuracy over temperature and lifetime.
DSC (Master):
Computation target torque with respect to the driving sit.
Send-out target torque on communication bus.
ECU: DSC
ECU: LMV
All advantages of a 4x4 car without the typical disadvantages.
Requirements xDrive:
Maximum traction.
BMW-typical driving characteristics.
Reduced fuel consumption deficite.
Page 4
BASICS xDRIVE. 4X4 FUNCTIONS IN LMV-ECU.
MANEUVER BASED VALIDATION, 19.09.2012
Abrasion-
model
(oil, coating)
Guardmodel
(thermal impact) Degradation
and fail-safe
logics
Bussignals:
Target torque,
Wheel speeds, …
Sensors, Terminals
(Current, Ubat, GND)
Bussignals:
Actual torque,
…
Control:
current + mechanics
Signal
conditioning
Computation
of internal
variables
Diagnostics
Torque
controller
Page 5
BASICS xDRIVE. LATEST MODELS WITH xDRIVE.
MANEUVER BASED VALIDATION, 19.09.2012
2009 2010 2011 2012 2013
09/2009 7-Series
09/2009 X1
06/2010 5-Series GT
09/2010 5-Series
09/2010 X3
09/2011 6-Series
07/2012 3-Series
11/2012 1-Series
Page 6
TESTSYSTEM. HIL-PLATTFORM.
MANEUVER BASED VALIDATION, 19.09.2012
Main Switch
Power Supply 1
(Engine Start)
Power Supply 2
Realtime Computer
Patch Panel
FlexRay
CAN
Plug-In TestBox 1
DSC
Plug-In TestBox 2
LMV
LMV-ECU + Actuator
Page 7
TESTSYSTEM. INTEGRATED TOOLS AND MODELS.
MANEUVER BASED VALIDATION, 19.09.2012
Engine-model CarMaker TestManager
Diagnostic
Flash Tool
XCP on FlexRay
FlexConfig
INCA
Page 8
TESTSYSTEM. COMBINATION OF ECUS AND MODELS.
MANEUVER BASED VALIDATION, 19.09.2012
CarMaker-model (vehicle-dynamics-model)
Transfer case
(mounted LMV-ECU) DSC-ECU
BMW engine-environment-model
+ engine control
Residual-bus-simulation
Flexray Gateway
Behaviour model (LMV/DSC)
Gateway for signal-manipulation on flexray.
Residual-bus-simulation to provide all necessary bus signals.
Behaviour model (LMV/DSC): simplified model if one of the ECUs is not connected to the bus.
Page 9
INTEGRATION ENGINE-MODEL. BMW ENGINE-MODEL.
MANEUVER BASED VALIDATION, 19.09.2012
Compiled Simulink-
model for CarMaker:
Layer:
Communication via
physical signals.
Physical
environment-
model oft the engine.
Soft-
ECU
Page 10
INTEGRATION ENGINE-MODEL. GENERATION ECU-MODEL.
MANEUVER BASED VALIDATION, 19.09.2012
C-Code
Matlab/ Simulink
*.c
…
Code-Generator
*.h
GCC-Compiler
Generated C-
Code
Sources for ECU
Compiler for ECU
Soft-ECU: simulation-
model for Simulink
(based on Simulink S-
functions and CarMaker
specific librarys)
Page 11
MANEUVER BASED TESTS. CATALOG.
MANEUVER BASED VALIDATION, 19.09.2012
Typical maneuvers:
Different levels of grip.
Understeering.
High axle load.
Page 12
MANEUVER BASED TESTS. DEVELOPING A MANEUVER.
MANEUVER BASED VALIDATION, 19.09.2012
Global settings:
Setting global start values.
Script-Control call for interaction
with 3rd party tools.
Global maneuver commands.
Maneuver step settings:
Teststeps (mini-maneuver).
Realtime expressions (state
observer, end condition, operation
functions).
Page 13
MANEUVER BASED TESTS. DEVELOPING A TRACK.
MANEUVER BASED VALIDATION, 19.09.2012
2D view:
3D view:
Creating a track step by step.
Import track data.
Import GPS data.
Page 14
MANEUVER BASED TESTS. TEST-EXECUTION.
MANEUVER BASED VALIDATION, 19.09.2012
IPGMovie: Starting on a hill with different levels of grip.
Page 15
MANEUVER BASED TESTS. ANALYSIS.
MANEUVER BASED VALIDATION, 19.09.2012
Instruments
IPGMovie
IPGControl
Page 16
TESTAUTOMATION. TESTMANAGER.
MANEUVER BASED VALIDATION, 19.09.2012
passed
failed
Test-report: XLS
Test-results:
Realtime-expression for signal evaluation criteria's .
TestLog function to collect and display results (passed / failed).
TestManager can be remote controlled and modified from ScriptControl or TCP/IP socket.
Page 17
BENEFITS.
MANEUVER BASED VALIDATION, 19.09.2012
OUTLOOK.
• Frontloading.
• Functional and system-tests.
• Regression tests for new software.
• Testautomation.
• Fewer resources needed (cars, test-track).
• Documentation of test results.
• Prepare test-system for the next generation of the xDrive-systems.
• Integration of the ECU model as AUTOSAR-component.
• Integration of DSC functions in CarMaker (no more ECU hardware is needed).
Page 18
THANK YOU FOR YOUR ATTENTION. QUESTIONS?
MANEUVER BASED VALIDATION, 19.09.2012