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Applied Collaboration for the Virtualization of Roads and Customer
Approval as Exemplified by a Brake Control System
Sven-Etienne Henschel, Rohan Deshetti
Introduction of Participated Business Divisions01
2
Applied Collaboration for the Virtualization of Roads and
Customer Approval as Exemplified by a Brake Control System
Goal of Collaboration02
Development of the Virtual Prototype 03
Mode of Operation in the Collaboration 04
Results of Collaboration05
Outlook for Collaboration06
07.09.2018
07.09.2018 3
Introduction of Participated Business Divisions
Robert Bosch GmbH
Audi Customer Team - Bosch
Customer Team VW Group
Project Management & SW
DevelopmentApplication Simulation
• PM & TPM
• Project controlling
• SW Management & development
• Vehicle/SW Planning with OEM
• ESP® Controller models
• Integration with vehicle models
• Virtual application
• Simulation Co-ordination
• Basic application
• Controller application
• VTC Maneuvers for SW release
• Analysis of maneuvers
ESP®/ESP®Hev
Integrated power brake
Wheel-speed sensor
Steering-angle sensor
iBooster
Yaw-rate sensor
Chassis Systems Control –
Active Safety
Mobility Solutions
Simulation environment
Environment
Simulation models
Models
Testing environment
Applied Testing
• Controller inclusion (SiL)
• Test field (HiL)
• Environment for virtual
functional development
• Customization of the
environment
• Driving dynamics:
• MBS model
• Carmaker
• Tires
• Validation of the
models
• Environmental sensing:
• Sensor models
• Development-related testing
• Requirements-based testing
• Virtual endurance run
• Real driving test
• Test management
Virtual Development
07.09.2018 4
Elektronische Fahrwerksysteme GmbH
Introduction of Participated Business Divisions
07.09.2018 5
Strategic Positioning of the Partner Businesses
Introduction of Participated Business Divisions
Mutual increase and protection of know-how at the same time!
07.09.2018 6
Goal of Collaboration
Introduction of the Pilot Project – Q7M4
CAE – To review the possibilities and constraints in “virtual validation methods” during the Development
phase of ESP, A Pilot Project (Q7 M4) between AUDI, EFS und Bosch is defined
Step 1
• Pilot Project Q7M4• Application support through Simulation e.g. Basic
Application, Check for Robustness
Step 2
• Less Prototype Vehicles• Virtual application & virtual cross-check for
Development-/Application baselines of SW
Step 3
• Worst-Case Validation• Virtual application & virtual cross-check for vehicle
variants considering vehicle dynamics aspects
Model validation
• Master Car
• Robustness check
Virtual application
• Use of master car
• SW proof-check for different baselines
Wide range usability
• Virtual application for variants
• Different wheelbase, engine, chassis
07.09.2018 7
Division of Responsibilities between EFS and Bosch
Goal of Collaboration
Verification of the driving physics
Development of a catalog for virtual driving
maneuvers
ABSEBVVDCASR…..
Functional test at the SiL
Development of a virtual prototype
Execution of the catalog for virtual driving maneuvers
Common validation
Evaluation of the catalog for virtual driving
maneuvers
Hardware/ECUs
Combined HIL
Development of a virtual prototype
07.09.2018 8
Development of Vehicle Model
Development of the Virtual Prototype
Virtual
prototype
Functional development
Piloted driving
Testing
EF
EA
TE
EG EKInput of data from test-bench measurement,
component checksIntegration checks
List of testing maneuvers:standstill, start, coast, braking, circular drive, …,Sine-With-Dwell
ISO standards19364 Steady-state circular 19365 Sine with dwell
Virtual prototype : A combined simulation model Vehicle model + ESP® system model
DCM parameters
from vehicle
ESP® System Interface:
• Act/Mod controller
• Brake system model
• Sensors & actuator models
• Test measurement
Complete Simulation Environment with ESP® System
Test measurement including traces from CM & ESP®
Inputs to
Controller:
Vehicle, Driver,
Environment etc.
Inputs to
Vehicle:
Controlled Act &
ESP® signals
Combined
signals for
analysis
CM
Traces
ESP®
Traces
Animation
Vehicle Interface:
• Vehicle, road, driver model
• Tire model
• Control systems(w/o ESP®)
• Test manager
• Flexray Restbus Signals
7-Sep-18 9
ESP® System Integration
Development of the Virtual Prototype
Key Points : Similar routine between App & Sim Same parameter format (DCM) + Same measurement format (MM6x)
7-Sep-18 10
Overall Interconnection SQ7
Development of the Virtual Prototype
Implementation of: ESC (ESP®) Air spring Damping control
11
Further Development Based on the example of Tires
Development of the Virtual Prototype
MF Tire
determined relaxation length reduced relaxation length
TMeasy
determined relaxation length
7-Sep-18
07.09.2018
Mode of Operation in the Collaboration
Simulation Workshop in Boxberg – Proving Ground
Vehicle Tests : Vehicle basic application & driving maneuvers to cover the vehicle response w.r.t. longitudinal & lateral
dynamics
Virtual Tests : SiL (for Application SW) & HiL (Remote HiL in Gaimersheim for complete SW)
Vehicle Tests
1. Basic application
2. Steering Characteristics
3. Longitudinal maneuvers
4. Lateral maneuvers
SiL Simulation (ASW)
1. Controller parameter
2. Maneuver duplication
3. Application SW test
4. Comparison with vehicle measurements
HiL Simulation (CSW)
1. Remote HiL access
2. Parameter adaption from SiL
3. Real-time simulation
4. Comparison with vehicle measurements & SiL
12
VPN
EFS
Network
Internet
Control from Boxberg
HiL Set-Up in Gaimersheim
Hardware/ECUs
Combined HIL
Aim & Steps : To use the validated simulation model & check the sensitivity of the model against different tires for ABS
07.09.2018
Mode of Operation in the Collaboration
Sensitivity Analysis
13
GoodYear Pirelli
Vehicle measurements
Tests:
• ABS Braking
• Partial braking
• Partial braking during
cornering
• Pos µ-Jump
CorrelationMeasurement based
simulation
Simulation-
model
Driver
Inputs
Steering
Brake
Velocity
Detailes of used tool:
• Software in the Loop (SiL) Environment
• Application Software
• Same controller parameter files as used in vehicle testsVehicle
measurements
Measurement based
simulation
CorrelationYes
Master Car Model
Driver
Inputs
Steering
Brake
Velocity
Real Vehicle
Virtual Vehicle
Results : For same tire pressure in tests & simulation Similar co-relation between Sim & tests as to in validated model
07.09.2018 14
Summary of Workshop Activities – Longitudinal dynamicsResults of Collaboration
Summary encompassing the real vehicle testing & SiL/HiL simulation activities during the workshop
☑ Basic application
☑ Parameter update in controller model
☑ Longitudinal maneuvers ABS: High-µ, Low-µ, µ-split, Pos µ Jump, Neg µ Jump
☑ Longitudinal & Lateral combined maneuver EBD cornering & braking
☑ Evaluation of vehicle measurements, simulation results and respective comparison Model parameter update
ABS- Braking
High - µABS- Braking
Low - µ
07.09.2018 15
Summary of Workshop Activities – Lateral dynamicsResults of Collaboration
Summary encompassing the real vehicle testing & SiL/HiL simulation activities during the workshop
☑ Vehicle & controller model with updated parameters
☑ Lateral dynamics VDC: Quasi static cornering, ISO lane change, Step steer
☑ Evaluation of VDC maneuvers, simulation & comparative analysis
☑ Constructive co-operative team work Knowledge exchange between application & simulation
Quasi static cornering
Lateral Acceleration [m/s²]
Ste
ering w
heel angle
[D
eg]
FL
FR
RL
RR
Lane change
Time [s]
Wheel P
ressure
[B
ar]
Late
ral A
ccele
ration [m
/s²]
Step steer
Time [s]
07.09.2018 16
Mode of Operation in the Collaboration
Project summary
Project time history : Work distribution & further steps during the project duration
Work steps : Work packets derived through workshop in PG-Boxberg & over the period of project
Workshop in
PG Boxberg
Tire SensitivitySensitivity, VTC
for ASW & CSW
Vehicle Test Catalogue
ABS VDC VAF
SiL for
ASWHiL for
CSW
Evaluation & comparison
SiL & HiL
Environment
Hardware/ECUs
Combined HIL
SiL Model
Project end
Project start
07.09.2018 17
Results of Collaboration
Outlook from Bosch
Maneuver distribution : Estimation of maneuver distribution between real vehicle & simulation
Future prospects : Prototype reduction
• Based on project activities & corresponding simulation results, following maneuver distribution between real vehicle
prototype & virtual prototype is realizable.
• Part of vehicle test catalogue (VTC) through simulation
• Rest through real prototype tests
Only vehicle
30%
Only simulation
40%
Vehicle + simulation 30%
• Future scope for following projects – Prototype reduction in early phase of project
• Virtual application for early prototypes – Basic application, basic controllers
• Detection of critical vehicle variants with respect to vehicle dynamics functions
• Cross check of low-µ application vs. high-µ banked curves
07.09.2018 18
ASW Cross-Check Low-µ vs. Banked curve High-µ
Results of Collaboration
Low-µ Application in Vehicle (Sweden)
Banked curve High-µ (PBx, PGN)
To analyze the effects of Low-µ Application on vehicle behavior on High-µ banked curves
Simulation is used during winter application
Banked curve detection No shutdown, no VDC-mis-
interventions on banked curveFailed: Retuning Passed:
Application Robust
Different banked tracks (PBx/PGN), driver (defensive,
normal, aggressive)
Parameter Set : DCM
07.09.2018 19
Virtual endurance run
Outlook for Collaboration
µ, GPS coordinates
Relevant FlexRay data
Data preparation
Mapping µ
Create CarMaker maneuver
Simulation
AUDI A6 (C7)
AUDI A7 (C8)
Raw data
07.09.2018 20
Benefit of Swarm Data in virtual Development
Outlook for Collaboration
Application
Data filtering
Stat. evaluation
Model validation
Modeling
Feature assessment
LogfilesVehicle: 4Number of Logfiles: 10Distance: 1000 km
Thank you for your attention!
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