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!