connect simulation & test

connect simulation & test

Model Based Development

Engelbert Loibner

Electrification Techday, October 25

E.Loibner, AVL List GmbH | IODP | Oct, 2017 | 2AVL Integrated and Open Development Platform

… bridging the gap between the virtual and real world

Motivation


VEHICLE DEVELOPMENT PROCESS

Project start

Integration Step X SOP

Vehicle Development

Process (VDP)

Power-train

Electrics & Electronics

Hard- & Software Integration

Hard- & Software

Mixed IntegrationSimulation +

Hard- & Software

Virtual IntegrationSimulation

Only

Chassis

Require-

ments

http://img-new.cgtrader.com/items/4461/injection_system_of_a_v8_engine_3d_model_bed7807c-a776-4184-945f-2754dc86f4be.jpg



VIRTUAL DEVELOPMENT APPROACHE

Benefits: Reduction of prototypes, cost and time reduction

SOP

Planning Pre-concept Vehicle Series DevelopmentVehicle Concept

Simulation Vehicle testingStrategy Dyno testing

250.000 €100 € 50.000 € Cost per prototype

Optimisation via testingIn the past

Optimisaiton via virtual testingVirtual approach

Frontloading


TODAY’S LIMITATIONHETEROGENEOUS TOOL LANDSCAPE

Project start


Vehicle Development

Process (VDP)

Power-train


Chassis

Require-

ments




TODAY’S LIMITATION HETEROGENEOUS TOOL LANDSCAPE

Project start


Vehicle Development

Process (VDP)

Power-train


Chassis

Require-

ments




Consistent Models Same Test Procedures Seamless Data Management

AVL Integrated and Open Development Platform

Same results in different environments

Efficient Methods

AVL INTEGRATED AND OPEN DEVELOPMENT PLATFORM - VISION

Jumping between different environments – Free choice – use the best suitable environment for individual development tasks

CONNECT virtual and real components to Combined VIRTUAL – REAL Prototypes

ROADOFFICE VIRTUAL Lab BATTERY Lab POWERTRAIN Lab


… only advanced methodology allows for increasing the number of iterations along the

development process and in the end achieve a better product maturity in less development time

Road testingSimulationVirtual

testingBattery testing

E-Drive

testingChassis dyno testingPowertrain testing

Faster

Better

“Achieving more iterations for

fast and sound decisions”

WHAT’S THE VALUE OF IODP?

Product

target

achievement


WHAT’S THE VALUE OF IODP?

Simulation Virtual

Test Bed

Component

Test Bed

E-Motor

Test Bed

Powertrain

Test Bed

Chassis

Dyno

Road

Testing

today

future

Development Tasks

Costs …

Time…

Quality…

REDUCE

By making sound decisions earlier

By shifting tasks in cheaper environments

By increasing system knowledge earlier

• Making early, fast and sound decisions• Bridge the best from virtual & real world• Reuse & Ease of use • Bringing together versatility and flexibility• Collaboration and knowledge sharing

Virtual part of the prototype

Physical part of the

prototype

Unit

under

test

REDUCE INCREASE

Classical

AVL Approach


VIRTUAL DEVELOPMENT EXAMPLE:BEV DEVELOPMENT

BenchmarkingTarget Setting & Specifications

1. Benchmarking

• Competitive analysis

• Efficiency & fun-to-drive

• Highlights & weaknesses

• Deep dive

Technology Scouting

• Battery

• Powertrain architecture

• Body / Chassis / Comp.

3. Virtual Optimisation

• Vehicle simulation concept study

• Simultaneous vehicle attribute assessment

• Determine influence of vehicle and powertrain variants on several attributes

4. Concept testing and definition

• Driver simulator

• Drive & experience different virtual vehicle prototypes

• Component adjustments on driver simulator

• Subjective vehicle concept evaluation

SimulationConcept Validation

2. Target Setting

• Electric range

• Efficiency

• Driving attributes

Component Specification

• Vehicle & Powertrain


EXAMPLE BEV: CHOOSE POSSIBLE TECHNICAL CONFIGURATIONS

> 100 system variants > 10.000 virtual prototypes


AVL USP AVL-DRIVE: OBJECTIVE ASSESSMENT OF RELEVANT DEVELOPMENT TARGETS


AVL APPROACH OF VIRTUAL VEHICLE DEVELOPMENT

Virtual target/attribute validation AVL-DRIVEVehicle simulation

Maneuver simulation &

optimisation

3 Mio. virtualvalidated kmsin 24 hours

E.Loibner, AVL List GmbH | IODP | Oct, 2017 | 14AVL Integrated and Open Development PlatformECONOMY PERFORMANCE DRIVEABILITYHANDLING

4. RESULT: BEST TECHNOLOGY COMBINATIONSTO ACHIEVE THE TARGETS

14.9

535

3.0 2.2

8.5

9.1

8.37.9 8.09.214.5

689

3.6

2.3

8.3

8.9 8.07.7

7.88.9

Battery 100kWh PT Topology: 2x Front, 2x Rear Gear ratio: 13:4 Total weight: 2020 kg Eco Tires Reduced Aero Resistance …

BEV Variant: Efficiency

Battery 80kWh PT Topology: 1 Front, 2x Rear Gear ratio: 16:4 Lightweight Technologies Total weight: 1820 kg Sport Tires Torque Vectoring …

BEV Variant: Driving Fun

10.000 variants



How to connect the heterogeneous tool landscape?


CONNECT SIMULATION AND TESTBED



Connect components; whether virtual or real

INDEPENDENT, OPEN,

TOOL / MODEL FREE

PHYSICALLY CORRECT

RESULTS

STABLE AND FAST

CO-SIMULATION


Virtual Prototype

CONNECT COMPONENTS

Virtualization of testbeds(Connect hardware & software, simulation & test)

Connect different simulation tools (Reuse existing models)

Tools specific interfaces (30+ software vendors) and interface standards (FMI)

Saber RD

Use case oriented (Flexible architecture supporting multiple tasks)

NEUTRAL and OPEN Integration Platform

https://www.google.at/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiHtvWR1KfNAhVMQBQKHdN3B8EQjRwIBw&url=https://www.fmi-standard.org/&bvm=bv.124272578,d.d24&psig=AFQjCNGLX32LiBMo9z1qbqEGtXJV7vAlSA&ust=1465998496473765



CUSTOMER REFERENCEJAPANESE CUSTOMER ENGINE DEVELOPMENT DEPARTMENT

Model-based driveability development

frontloading with co-simulation

ROAD PURE SIMULATION

Reuse of existing models

from different tools

(modeling time saving /

model: 2-12 month work).

Easy swap of simulation tools

• Avoid duplicate modeling

work (value / model: 20-

120 k€)

• Reduced time on

expensive test beds

• Higher system fidelity before

first hardware exists.

• Short improvement

iteration loops

Reduction of development

and testing time

$

.

.

Reduction of cost

Proven Benefits

Increased product quality

Source: AST User Conference Germany

October 25.-26.2016




Start in the Office extend with sim. ECU

ECU Software

… with Prototype ECU … with real ECU

• Stepwise approach• Start in pure office environment• Simulation models are running on a Windows

target (without compling to RealTime Target)• Simulation models could also be reused by

compiling to RT target (if possible)• No GAPS in the TOOLCHAIN

Production ECU

APPLICATION EXAMPLE: SOFTWARE DEV. START EARLY SOFTWARE DEVELOPMENT AND CALIBRATION



Make the testbed“simulation ready” by virtualizing the testbed


CONFIGURATION VIEW –MODELS & REAL COMPONENTS

Simulation Models

Virtualized Testbeds

CarMaker

AVL VSM

Testbed integration packages

Virtual Testbeds

VSM@ETB

VSM@PTTB

Cruise@ETB

Cruise@PTTB

CarM@ETB

CarM@PTTB

CarM@CD

…

EM-TB PTTB CD

EM-TB

VSM@TB

AVL VSM

VSM@ETB

Configure your

System

Architecture

together with real

testbed

Re

al te

stb

ed

vir

tua

lize

d in

M.C

Parametrize

your Testbed

Model.CONNECT

Makes the

testbed within

the simulation

visible

Connects

models and

models with real

components


CONNECT SIMULATION AND TESTBEDS

Testbed AVL Testbed with AVL PUMA Open2™

AVL Virtual Testbed™

Testbed.CONNECT™ Workstation

Testbed.CONNECT™

Simulation in the office Simulation on the testbed


CUSTOMER REFERENCE JAPANESE CUSTOMER ENGINE DEVELOPMENT DEPARTMENT

Correlation of 12

driveability operation

modes at different

operation points with

different ECU datasets.

High degree of automation

in comparison to road

• Lowered occupancy of

expensive vehicle

prototype

• Reduction of SOP shift

risks and related costs

• Reduced warranty costs

• Higher testing coverage

leading to higher product

quality

• More development

iterations possible before

SOP


and testing time

.

.

Reduction of cost

Proven Benefits


Driveability validation and model-based development

frontloading with co-simulation

ROAD ENGINE TESTBED

Real Engine

Vehicle Model

Powertrain

Model

TCU Control

Model


CUSTOMER REFERENCE HYBRID VEHICLE ENERGY MANAGEMENT ON TESTBED

Derating functions, high

performance track

behavior already on ETB

(full transient behavior)

Reduction of one week

testbed occupation for

cooling system installation

• SAVE expensive re-

design cycles

• Lowered occupancy of

expensive vehicle

prototype

• Reduction of SOP shift

risks and related costs



quality



SOP


and testing time

.

.

Reduction of cost

Proven Benefits


Impact of Hybrid operation strategy on thermal

management and component design

Office ENGINE TESTBED

Real

Engine

Real

E-Drive

Real Power

Electronícs

Powertrain Model

Cooling Model

Hybrid Operating

strategy Model


CUSTOMER REFERENCE US OEM HYBRID CALIBRATION ON POWERTRAIN TESTBED

Calibration started 6

months before first

vehicle was available

High degree of automation

in comparison to road

• Reduced use of

expensive vehicle

prototypes

• Calibration procedures

designed to specifically to

PTTB.



quality



SOP


and testing time

$

.

.

Reduction of cost

Proven Benefits


Calibration of hybrid functions before the first vehicle

including regen braking, starts and drive-away

ROAD POWERTRAIN TESTBED

VSM Vehicle

Model

Battery

Simulator

Real engine,

Transmission,

E-motor,

Driveline


RESEARCH PROJECT REFERENCE CONNECTED TESTBEDS

Engine and Drivetrain can

be commissioned in

parallel

In the electrification

component by

component integration

Reduce change times

• Avoid damage costs by

no mechanical coupling

during operation (misuse

and failure)

• Costs for altitude and

climatic chamber use

can be reduced



quality



SOP


and testing time

.

.

Reduction of cost

Proven Benefits


Pre-Implementation of vehicle functions through

Virtual CONNECTion – Virtual Integration

Com

ponents

Syste

m


DEMO: FUEL CELL IN THE LOOPCONNECTED TESTBEDS & MODEL.CONNECT

Fuel Cell System TB

E-Storage

Battery TB

HV-Bus

Virtual HV-Bus

Virtual PT-CAN

HV Battery

E-Storage

Fuel Cell

SystemBoost

HV-BusExample - FC Info DayVSM Model

Vehicle on the roadRoad profile

Cruise ModelVehicleE-MotorInverter

Simulink ModelPower Management

UDP-CAN I/OOut: Current DemandIn: Actual Voltage UDP - CAN

Current Demand

Actual VoltageCurrent Demand

Actual Voltage

PUMA OP 2 TB LYNX TB

Model.CONNECT



Electric Vehicle andADAS / Autonomous Driving –Two complementary technologies go together


APPLICATION AREA ADASDEVELOPMENT AND VALIDATION IN OFFICE ENVIRONMENT

*Source: Audi.de


AUTOMATED SYSTEMS –ENABLE-S3 (JOINT RESEARCH PROJECT)

71 partners

16countries

6industry

domains


DrivingCube DEMONSTRATOR INTEGRATION


SAFE & REPRODUCIBLE TESTING WITH DRIVER SIMULATOR

MOVIE

Traffic scenarios e.g. critical near crash situations with passengers or heavy traffic

Parameter/vehicle config changes e.g. speed, accelerations, payload, distances, sensor & vehicle configurations

HMI, human & machine take over maneuver


CONNECT SIMULATION AND TESTBED


CONNECT SIMULATION AND TESTBED AND DATA

Data.CONNECTTM

Opens the door from application to data world

Production

Data

Fleet

Data

Simulation

Data Testing DataBig Data analysis and

processing

Data Intelligence

KPI generation Data Mining Enterprise Search

Test order, workflow, scheduling

and planning

Virtualized Data.CONNECT Layer – through Data Model linkageVirtualized Data.CONNECT Layer – through Data Model linkage

Big

Data

Stack


IODP AS A SERVICE

We provide the connecting tools

We demonstrate how you can benefit – based on your specific landscape

Our team of experts can accompany you throughout the entire project …

… or carry out the task all together


Make early, fast and sound decisions

Bridge the best from virtual & real world

Reuse & Ease of use

WHAT’S THE VALUEFOR THE WHOLE ORGANISATION?

Collaboration and knowledge sharing


connect virtual and real worlds

Integrated and Open Development Platform

Documents

connect simulation & test