functional testing of complex vehicle systems
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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
Tech Day AVL Nordiska, November 19th, 2014
Thomas R. WeckAVL Powertrain and Hybrid System
F. Illmeier / Engineering and Technology Powertrain Systems 2
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
OVERVIEW
1 – WHAT IS THE PROBLEM?
2 – FUNCTIONAL TESTING
3 – PROJECT EXAMPLE
4 – SUMMARY & OUTLOOK
F. Illmeier / Engineering and Technology Powertrain Systems 3
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
1 – WHAT IS THE PROBLEM?
Increasing ComplexityRising number of vehicle variantsHigh number of topologies & architecturesNew vehicle functionalities (e.g. E-Drive)
Divergent Vehicle TargetsPerformance vs. Fuel EfficiencyEmissions vs. DrivabilityDiversity of Market Demands
Heterogeneous Development EnvironmentCross Domain CollaborationDevelopment Quality & Risk
Product Lifecycle & Product DevelopmentReduced product lifecycle & product usageReduced development time & effort for single variant
VehicleDriver Interface
HV BatteryDC/AC 1
DC/DCHybrid Cooling
DC/AC 2HCU
Gasoline ENGEM1
GEN
EM2
MOT
DC/AC 3
EM3
VehicleDriver Interface
HV BatteryDC/AC
DC/DCHybrid Cooling
HCU
Diesel ENG
IL4 2,0 HSDI
AMT
Starter 12V
CL EM2
EM1:
BSG
TFSI
IL4; 1,4L; EU V
EM2
DCT7
VW Jetta
HybridCL
Starter 12V
el. Oil
Pump
VehicleDriver Interface
HV BatteryDC/AC
DC/DCHybrid Cooling
ECU /
HCU
F. Illmeier / Engineering and Technology Powertrain Systems 4
WORST CASE ... HOW DID THAT HAPPEN ?
Recall actions in US market (2012-2013)
increase from 15.5 to 20.5 Mio.CAM (Center of Automotive Management), March 2014
General Motor’s recalled 29 Mio. Vehicles in
the first half of 2014FORTUNE Magazine, August 15, 2014
HOW DOES CURRENT TESTING / VERIFICATION / VALIDATION
COVER ALL POSSIBLE OPERATING AND USAGE CONDITIONS ?
HAS THE COMPLEXITY OF THE VEHICLE SYSTEMS BEEN
CONSIDERED (PHEV/HEV, Driver Assist, Chassis Controls)?
IS THAT COMPLEXITY REFLECTED IN POWERTRAIN TESTING ?
DO TRADITIONAL USAGE PROFILES / TEST CYCLES COVER ALL
OPERATION CONDITIONS ?
WHAT IS THE TEST COVERAGE AND IS IT REPRESENTATIVE ?
HOW ARE AUTOMOTIVE STANDARD CONSIDERED (ISO 26262) ?
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
1 – WHAT IS THE PROBLEM?
F. Illmeier / Engineering and Technology Powertrain Systems 5
März 2009
???
Test Mileage:
2007: 24 Million km
2009: 36 Million km
2020: 250 Million km The biggest hurdle is validation to confirm that the system does not cause failures. One has to execute 250 million test kilometers states the Bosch executive director.
Source: Mercedes Benz
• Integrated functionalities between PT, ESP, Steering, Lighting, Suspension, Infotainment
• Autonomous Driving & Parking
• Car2Car (C2C) & Car2Infrastructure (C2I) for warning systems, early detection of traffic condition
Source: HEISE March 1st, 2014
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
1 – WHAT IS THE PROBLEM?
F. Illmeier / Engineering and Technology Powertrain Systems 6
Traditional View – Mechanical Focus (Durability)
Variation of driver profiles depending on customer usage
Mix of representative drive cycles (city, motorway,
mountain)
Consideration of environmental condition (humidity,
temperature, altitude)
BALANCED = components designed to meet customer needs
Definition of mechanical load profiles (e.g. speed, torque,
vibration) and affection of components
Limited operational interaction (consider breakdown to
component level)
Evaluation of damage relevant conditions
ComponentLoad/Stress
CustomerLoadProfile
Activates, operates and stress the PT system
Interacts with other vehicle systems
Reacts to changes in environmental conditions
Changes the load profiles for components
Prevents/reduces component damage
Provides additional limp home capabilities
Unforeseen interactions? -> undefined conditions
ComponentLoad/Stress
CustomerLoadProfile
Powertrain & VehicleSystem Operation
Mechanical Focus (Durability)NEW: Functional Focus (Coverage – Causal Dependence)
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
1 – WHAT IS THE PROBLEM?
7
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
2 – FUNCTIONAL TESTING
Product Definition,Test Methodology
Integration,Validation
SoP(Vehicle Launch)
System (Vehicle)Targets & Boundaries
Synergies
PT Design/Specification
Definition of Targets & Usage
Definition of Interactions
(Vehicle, System, Environment)
Systematic Planning of Integration,
Verification and Validation
Definition of Preventive Action
PT Test Specification Definition of Use and Test Cases Definition of Test Systems and Test
automation Systematic Execution, Documentation
and Proof Support of Corrective Action
AVL Know-how in Hybrid Development, Tools and Methodologyto improve Integration and Testing
F. Illmeier / Engineering and Technology Powertrain Systems 8
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
2 – FUNCTIONAL TESTING
Product Definition
Test Bed
VIR
TU
AL
Quality
History
Hybrid
SystemEnvironment &
Drive Cycles
Definition of Routes
Data Conversion
Data Export
Analyze of physical Structure,
Components and Functions
Find operating States/Transitions
Define Test Cases
Finalize Test Plan
& Confirm
in Simulation
Test
Requirements
Test Plan
F. Illmeier / Engineering and Technology Powertrain Systems 9
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
2 – FUNCTIONAL TESTING
WHERE is the Information
Generated & Managed ?
&
HOW is the Information
Used ?
Information
Usage
Component
-Parameters
-Functions
System States
Control
Factors
Vehicle
Targets
Test Cases
RequirementsSystem Model
Test View
… in Definition
… in Preparation
… in Execution
*Model Based Systems Engineering for PT Testing
F. Illmeier / Engineering and Technology Powertrain Systems 10
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
2 – FUNCTIONAL TESTING
Battery
Emulator
+ -
CAN
xCU
CAN
Diagnostic System
InO
ut
Failure
Insertion
Unit
Sensors
Actuators
FIU CAN
Test Bed
Automation
and Test
Management
Limit Observation
Additional actuators & cameras to observe and input into the driver interface
Battery conditioning to speed up the test initialization (achieve SOC faster)
Interaction with vehicle diagnostic system to analyze test results and re-initialize after failures
Stress- & failure insertion on test bed, to confirm system reaction with E/E failures
New
Automation...
Test Initialization,
Test Execution,
Data Recording,
Test Confirmation,
Re-Initialization
On the Test Bed
Failure Insertion Unit
Electrical Load Unit
Cameras
Test Environment
F. Illmeier / Engineering and Technology Powertrain Systems 11
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
3 – PROJECT EXAMPLE: Series Production Support
Use Case (UC)Review Test Case (TC)OEM
AVL
Step 1
Step 2
Test PlanTest Analysis & Evaluation
Test Execution
APPLICATION OFTEST METHOD
Step 1 Analysis of function and usage to define relevant test cases Step 2 Optimization of test plan to perform efficient and effective testing
F. Illmeier / Engineering and Technology Powertrain Systems 12
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
3 – PROJECT EXAMPLE: Series Production Support
• Representative PT function testing including stresses, failures and interfaces to other vehicle systems
• Extensive maneuver catalog optimized to run 24-hours in 3-shift operation (1000 function tests per week)
• Definition, planning, execution and reporting of tests based on clearly defined step-by-step process (MBSE)
• Reproducible test conditions to avoid uncertainty caused by environment or usage
• Successfully executed to support hybrid vehicle series production launch of Japanese vehicle manufacturer
• Direct linkage with hybrid calibration to achieve drivability, performance, FE while maintaining reliability and safety
F. Illmeier / Engineering and Technology Powertrain Systems 13
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
4 – SUMMARY & OUTLOOK
What are the Benefits for AVL Customers
• AVL has extensive experience in hybrid PT development & testing as well as test systems & test methodology
• AVL is currently the only company with SOP project experience to offer such testing
• AVL synergies and experience with maneuver base testing, failure insertion, battery system conditioning, driver interface (HMI), functional safetyto be performed in different test environments
• On-going AVL customer project to extend methodology into PHEV diagnostics and optimization of operation strategy
AVL EngineeringServices inPT Development
AVL Test Bedsand Test Systems
F. Illmeier / Engineering and Technology Powertrain Systems 14
FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS
4 – SUMMARY & OUTLOOK
14
TEAADS – Test Environment for ADAS and Automated Driving Systems
General motivation of TEAADS:
Increasing extension of driver assistance systems for (semi-) automated driving
raises the need of automated test tools and tool chains in order to ensure
functional safety, robustness, and reliability.
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