Brake-by-Wire system development
Technology and development process
Davide Colombo Vehicle Systems - Active Control Systems Head of Advanced Brake & Steering System Group
Torino, 18 Gennaio 2007 Mod. 25-P02-00 Contents
• Introduction on by-Wire Technology
• Focus on CRF Brake-by-Wire Project
• System architecture
• Main components
• Control development and Validation (Brake-by-Wire Application)
• Application development process
• Software-in-the-Loop
• Hardware-in-the-Loop
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 2 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF X-by-Wire (XBW) – The Origins
• Systems for electronic control of vehicles • Replace mechanical linkages with wires • Originally Fly-by-Wire
Fly-by-wire Airplane : There is no mechanical or hydraulic connection between the pilot controls and the control surfaces.
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 3 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF XBW in automotive – Why?
XBW represent a great opportunity to improve:
• Safety • Fuel Consumption and Emission • Performance • Driving Pleasure • Ergonomics • Costs through modularity Ref.: http://www.crf.it/B/B1_2.html
Brake-by-Wire Application – Fiat Panda Improving Area
Fixed F.d.T.
Systems Integration
Fixed F.d.T. Flexbile F.d.T. x BBW V ECU
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 4 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF XBW in automotive – Where?
In a vehicle a lot of mechanical links can be substituted by electronics. Some X-by-wire applications are already present in our vehicle and other are under development.
iat ers F oth GM nd C, a Re C h nau evy lt , D ,… od ge
Under d evelopment, …
Un der de Fi vel a at opm nd ent o ,… th er s iat F s and other
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 5 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF X-by-Wire (XBW) – Fiat experiences and applications
Throttle-by-wire • Drops mechanical connection between gas pedal and the throttle;
Clutch and Gearbox -by-wire (Selespeed) ALREADY on the MARKET
• Drops mechanical connection between: FAIL SAFE REQUIREMENTS (Low Redundancy Requirements) • Clutch actuator and Pedal; • Gearbox and gear lever. • Single Fail Safe Actuator • Single Fail Safe ECU • Double Fail Safe Sensor (Driver Req) • No Power Redundancy Needed Throttle-by-wire Selespeed
(Actuator)
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 6 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF X-by-Wire (XBW) – Fiat experiences and applications
Steer-by-Wire & Brake-by-Wire • Drops mechanical connection between steering wheel and the wheels; • Drops hydraulic connection between brake pedal and UNDER DEVELOPMENT the actuators FAIL OPERATIONAL REQUIREMENTS (High Redundancy Requirements) Steer-by-wire & Brake-by-Wire Architecture • Single Fail Operational Actuator (SBW); • Double Fail Safe ECU (SBW) • Triple Fail Operational Sensor (Driver Req) • Power Redundancy Needed
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 7 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Full by Wire vehicle
Main Aim : New vehicle architectures, interiors and HMI By- Wire: Enabling Technology allowing Driving Controls Architecture reconfigurations • Gas, Brake, Clutch Pedal and Steering Column dropped; • HMI with all Controls on Steering Wheel;
• Others advantages from By-Wire • Vehicle Dynamic: • Vehicle Control Integration • Ergonomics : • Adjustable HMI • Fuel Consumption and Emissions • Engine, Gearbox and Brake Integration • Driving Pleasure • Automatic Gear Box • Steering system with variable steering ratio • Integrated EPB for Hill Holder and Drive Away Functions • Ready for ADAS systems • Parking AID
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 8 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Full By Wire - Design and development process
THE IDEA BY WIRE New Vehicle Concepts An Enabling Technology • Architecture and Interiors • Complex system (Redundancy) • Ergonomics • Safety and Reliability to be guaranteed • Driving Pleasure • Costs • Performance PROS CONS
Design, Development, Validation Process
PRODUCT
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 9 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Contents
• Introduction on by-Wire Technology
• Focus on CRF Brake-by-Wire Project
• System architecture
• Main components
• Control development and Validation (Brake-by-Wire Application)
• Application development process
• Software-in-the-Loop
• Hardware-in-the-Loop
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 10 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF System over view: architecture
Local Layer Vehicle Layer Local Layer
WSpeed HMI WSpeed RHF RHR EMB2_RHF EMB4_RHR
BRK2 VCS BRK4 RHF BCU2_RHF BCU4_RHR RHR
TT-Network Power POWER
BCU1_LHF BCU3_LHR POWER
EMB1_LHF BRK1 BRK3 EMB3_LHR WSpeed WSpeed LHF LHF LHR LHR
Local Layer Local Layer
Main Characteristic Power and Network Components • TT Network • 1 VCS, Vehicle Control System • C-CAN Service Network; • 4 BCU, Brake Control Unit • Double Power Supply (12 V); • 1 HMI, Human Machine Interface
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 11 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF System over view: main components
Electro-Mechanical Caliper Brake by Wire Brake Pedal Control ECU
• Supply Voltage 12 V • Position sensors: 3 • MPC555 controller
• Max current 15 A • Force feedback: passive • On board BLDC driver (25A @ 12 Volt) • Clamping Force 13 KN • Time Triggered Network
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 12 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Contents
• Introduction on by-Wire Technology
• Focus on CRF Brake-by-Wire Project
• System architecture
• Main components
• Control development and Validation (Brake-by-Wire Application)
• Application development process
• Software-in-the-Loop
• Hardware-in-the-Loop
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 13 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF V-cycle: By Wire System Development Process
Architecture & System System Design Calibration
Modeling & Identification
Safety assessment System Control (eg. Fault injection) Target Design SIL (Software In the Loop) Setting Tuning Diagnosis Design Revision phase Risk Assessment System CIL (Component In the Recovery Design Set-up & Debug Loop) Constraints HIL (Hardware In the Loop) (Cost, Power,...)
“Rapid Prototyping” Code generation
Design Flow Target ECU Code Generation (fixed point, ..
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 14 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Controlled systems Validation methods
• Test on track Seganli di misura Comandi • Software in the Loop Simulation : COMPONENTE DA TESTARE • System Hardware Model; • Real Hardware (ECU, • Vehicle Model. actuators, …); • Real Vehicle. Sensori Attuatore
From WorkSpace: • Simulazione manovre; From Revision phase Grandezze da misurare • SimulazioniWorkSPace Fault; Attuazione
Revision phase BBW_System Simulink Model Vehicle Simulink Model
Libreria CAE di Sistemi Controllo Autotelaio
To WorkSpace: • Risultati;To WorkSPace
Seganli di misura Comandi COMPONENTE DA TESTARE • Hardware in the Loop Attuatore
HARDWARE Attuazione • Real Hardware (ECU, Revision phase actuators, …); Emulazione Sensori Sensori HDW to SFW • Vehicle Model (emulated in
Software Real-Time real-time simulation); Output simulatore Input simulatore
SOFTWARE DI SIMULAZIONE
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 15 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Application development process: validation methods pros and cons
Seganli di misura Comandi COMPONENTE Seganli di misura Comandi DA TESTARE COMPONENTE From WorkSpace: DA TESTARE • Simulazione manovre;From • SimulazioniWorkSPace Fault; Attuatore
HARDWARE Attuazione
BBW_System Simulink Model Sensori Attuatore
Vehicle Simulink Model Emulazione Sensori Sensori HDW to SFW Libreria CAE di Sistemi Controllo Autotelaio
Software Real-Time Output simulatore Input simulatore To WorkSpace: Grandezze da misurare • Risultati; Attuazione To WorkSPace SOFTWARE DI SIMULAZIONE
Simulation in the Loop Hardware in the Loop Test on track
Environment Simulated -- Real HW - Real +
Test Flexibility Hign + High + Low -
Data reliability Low -- Good - High +
Timing and costs Low ++ Low + High -
Test repeatability High ++ High + Low -
Scene simulation No limits ++ Low limits + High limits -
Operators Safety High ++ High + Low -
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 16 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Contents
• Introduction on by-Wire Technology
• Focus on CRF Brake-by-Wire Project
• System architecture
• Main components
• Control development and Validation (Brake-by-Wire Application)
• Application development process
• Software-in-the-Loop
• Hardware-in-the-Loop
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 17 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Simulation-in-the Loop phase
Software in the Loop validation method needs a platform to simulate manoeuvres and fault injections.
This platform is made by:
• Vehicle Model;
• Brake-by-Wire System Model;
• Fault Injection Generator Box Model.
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 18 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF SIL – Brake-by-Wire System Simulink Functional Model
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 19 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF SIL Example: Sensor fault while bending
Active EBD – Fault on LHF Wheel Speed – NO DIAG Active EBD – Fault on LHF Wheel Speed – DIAG
Fault Fault Diag
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 20 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Contents
• Introduction on by-Wire Technology
• Focus on CRF Brake-by-Wire Project
• System architecture
• Main components
• Control development and Validation (Brake-by-Wire Application)
• Application development process
• Software-in-the-Loop
• Hardware-in-the-Loop
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 21 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF Brake-by-Wire System HIL Bench
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 22 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF HIL Example: BBW ABS tests
• To verify: • Vehicle Speed Estimation Algorithm • ABS modulation capability • Safety of the ABS Algorithm • EMB modulation capability Full ABS on High Friction Full ABS on Low Friction
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 23 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF HIL Benchmark: ABS comparing - BBW versus conventional
• Simulations are done using the same vehicle (model) • The control law are similar (slip regulation)
or m at te ul ys d S o e m ir lic W u y - ra -b yd e H k o - ra tr B ec El
Initial Vehicle Speed : 60 km/h
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 24 the information contained herein shall be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written consent CRF