19.09.2012 Matthias Prebeck, Dr. Peter Rissling; BMW Group Michael Folie; IPG Automotive MANEUVER BASED VALIDATION OF BMW xDRIVE VARIANTS BY USING VIRTUAL VEHICLE INTEGRATION AND HIL TEST METHODS. IPG TECHNOLOGY CONFERENCE, SEPTEMBER 18 -19, KARLSRUHE. Freude am Fahren AGENDA. • Basics xDrive. • Testsystem. • Integration engine-model. • Maneuver based tests. • Testautomation. • Benefits and Outlook. MANEUVER BASED VALIDATION, 19.09.2012 Page 2 BASICS xDRIVE. ACTIVE 4X4-SYSTEM. DSC (Master): Computation target torque with respect to the driving sit. ECU: DSC Send-out target torque on communication bus. Com. Bus LMV (Actuator): Receive target torque and actuate clutch. ECU: LMV Securing torque accuracy over temperature and lifetime. Requirements xDrive: Maximum traction. BMW-typical driving characteristics. Reduced fuel consumption deficite. All advantages of a 4x4 car without the typical disadvantages. MANEUVER BASED VALIDATION, 19.09.2012 Page 3 BASICS xDRIVE. 4X4 FUNCTIONS IN LMV-ECU. Signal conditioning Bussignals: Bussignals: Target torque, Computation Actual torque, Guardmodel Wheel speeds, … of internal … variables Abrasion- Degradation Torque model (thermal impact) and fail-safe controller (oil, coating) logics Sensors, Terminals Diagnostics (Current, Ubat, GND) Control: current + mechanics MANEUVER BASED VALIDATION, 19.09.2012 Page 4 BASICS xDRIVE. LATEST MODELS WITH xDRIVE. 09/2009 06/2010 09/2010 07/2012 7-Series 5-Series GT 5-Series 3-Series 2009 2010 2011 2012 2013 09/2009 09/2010 09/2011 11/2012 X1 X3 6-Series 1-Series MANEUVER BASED VALIDATION, 19.09.2012 Page 5 TESTSYSTEM. HIL-PLATTFORM. Main Switch Power Supply 1 (Engine Start) Power Supply 2 Realtime Computer Patch Panel Plug-In TestBox 1 FlexRay DSC Plug-In TestBox 2 LMV CAN LMV-ECU + Actuator MANEUVER BASED VALIDATION, 19.09.2012 Page 6 TESTSYSTEM. INTEGRATED TOOLS AND MODELS. CarMaker TestManager Engine-model XCP on FlexRay FlexConfig Diagnostic INCA Flash Tool MANEUVER BASED VALIDATION, 19.09.2012 Page 7 TESTSYSTEM. COMBINATION OF ECUS AND MODELS. Flexray Gateway CarMaker-model (vehicle-dynamics-model) BMW engine-environment-model + engine control Residual-bus-simulation Transfer case DSC-ECU Behaviour model (LMV/DSC) (mounted LMV-ECU) 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. MANEUVER BASED VALIDATION, 19.09.2012 Page 8 INTEGRATION ENGINE-MODEL. BMW ENGINE-MODEL. Compiled Simulink- model for CarMaker: Soft- ECU Layer: Communication via physical signals. Physical environment- model oft the engine. MANEUVER BASED VALIDATION, 19.09.2012 Page 9 INTEGRATION ENGINE-MODEL. GENERATION ECU-MODEL. C-Code Matlab/ Simulink … Code-Generator *.c Generated C- *.h Code Compiler for ECU GCC-Compiler Sources for ECU Soft-ECU: simulation- model for Simulink (based on Simulink S- functions and CarMaker specific librarys) MANEUVER BASED VALIDATION, 19.09.2012 Page 10 MANEUVER BASED TESTS. CATALOG. Typical maneuvers: . Different levels of grip. Understeering. High axle load. MANEUVER BASED VALIDATION, 19.09.2012 Page 11 MANEUVER BASED TESTS. DEVELOPING A MANEUVER. Global settings: Setting global start values. Script-Control call for interaction rd with 3 party tools. Global maneuver commands. Maneuver step settings: Teststeps (mini-maneuver). Realtime expressions (state observer, end condition, operation functions). MANEUVER BASED VALIDATION, 19.09.2012 Page 12 MANEUVER BASED TESTS. DEVELOPING A TRACK. 2D view: 3D view: Creating a track step by step. Import track data. Import GPS data. MANEUVER BASED VALIDATION, 19.09.2012 Page 13 MANEUVER BASED TESTS. TEST-EXECUTION. IPGMovie: Starting on a hill with different levels of grip. MANEUVER BASED VALIDATION, 19.09.2012 Page 14 MANEUVER BASED TESTS. ANALYSIS. Instruments IPGControl IPGMovie MANEUVER BASED VALIDATION, 19.09.2012 Page 15 TESTAUTOMATION. TESTMANAGER. Test-results: passed failed Test-report: XLS 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. MANEUVER BASED VALIDATION, 19.09.2012 Page 16 BENEFITS. • Frontloading. • Functional and system-tests. • Regression tests for new software. • Testautomation. • Fewer resources needed (cars, test-track). • Documentation of test results. OUTLOOK. • 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). MANEUVER BASED VALIDATION, 19.09.2012 Page 17 THANK YOU FOR YOUR ATTENTION. QUESTIONS? MANEUVER BASED VALIDATION, 19.09.2012 Page 18 .