dr. mihai nica dvp&r...dr. mihai nica florian klück m.sc. avl list gmbh (headquarters)...

Dr. Mihai Nica

Florian Klück M.Sc.

AVL List GmbH (Headquarters)

Confidential

DVP&R

DVP&R Methodology @ AVL

Validation of Electrified Powertrain Systems

Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 2Confidential

DVP&R

The AVL-PTE Design Verification Plan & Reporting (DVP&R)unifies in one Workproduct (Master-Document) the Validationand Verification (V&V) test procedures that are to beperformed in the context of development projects ofmechatronic systems or its subsystems.

Additionally it enables progress monitoring anddocumentation of the execution of the V&V activities withinthe project development.

In this context the DVP&R combines the validation andverification principles of

mechanics,

electric & electronics,

and software development (including calibration)

to generate a simpler, more economical and reliable validationand verification process.

DVP&R: Unified test program for all skill areas


• DVP challenge and AVL solution

• AVL DVP methodology

• TARGETS and LOAD PROFILING

• Test Program

• Evaluation & Optimization

• Summary & Conclusion

AGENDA


DVP CHALLENGE & AVL SOLUTION


“Are the responsibilities

aligned?”

Traditional development process & test programs

New Worksplitbetween

departments

Modified responsibilities

New WorksplitSupplier &

OEM

Economic boundaries

Timeline

Budget

Capacity

DVP CHALLENGES

“Are we testing the right things?”“Do we have the right targets?”

“Are we testing at the right

time?”

New markets/ applications

Workflow Responsibilities Test targets Testing approaches

Specification & Requirements & Milestones

New/ modified systems

Verification tasks?

Failure modes?


Evaluation

FP - Analysis

Load Analysis

Mission Profile

Results, failures, measurement, data, new procedures

Test program

functional

development

Functional

development

and

reliability

&

durability

testing

• Basic DVP

• FMEA

• FP -Database

• Technical

specifications

• Others

Function

Reliability

&

Durability

Functional

issues

Design Verification & Validation Plan (DVP)Design Verification & Validation Plan (DVP)

Durability

&

reliability

test program

Reliability

and

durability

issues

LOAD MATRIX TM

Testing

requirementsTesting

Optimization

FP- Analysis

Load Analysis

Targets

Results, failures, measurement, data, new procedures

Test program

functional

development

Functional

development

and

reliability

&

durability

testing

• Basic DVP

• FMEA

• FP -Database

• Technical

specifications

• Others

Function

Reliability

&

Durability

Functional

issues

Design Verification and Validation Plan & Reporting (DVP&R)

Initial DVP durability

test program

Reliability

and

durability

issues

LOAD MATRIX

Testing

requirementsTesting

AVL DVP&R PROCESS & LOAD MATRIX INTERACTION

Verification

Validation


AVL DVP METHODOLOGY


DVP&R LIFE CYCLE

② DVP&R Planning

③ DVP&R Monitoring

① DVP&R Target

Definition

System Analysis

Application & Targets

Test Program

Evaluation andOptimization

System Analysis


Test Program


System Analysis


Test Program


System Analysis


Test Program



DVP&R PROCESS FLOW

For each project, the DVP&R Work product (i.e. Deliverable) will be planned and monitor on a level - based approach

(similar to the requirement engineering process)

……

EHW

…

SWSHW

PartsS+A …


IDENTIFY VERIFICATION TASKS FROM VEHICLE LEVEL DOWN TO COMPONENT LEVEL

System analysis

Generate a common understanding of the covered technical elements and their interfaces

DIFF

Electric Powertrain Example Topology Motor, Inverter

(+ HV Harness)

Shafts• Cardan shaft• Drive shaft• Rigid axle

• Transmission

Reduction Gear Unit

Electric Powertrain System:

- Motor

- Inverter

- HV Harness

(Inverter -> Motor)

- Transmissions

- Cardan and Drive Shafts

- Axle/Differential Gear Unit

- (Rigid) Axle

Axle/Differential Gear Unit

(Rigid) Axle


VISUALIZE VERIFICATION TASKS & FAILURE MODESEXAMPLE

Differential Gear Unit

Cardan & drive shafts

(Rigid) Axle

Transmission

HV-Harness

Motor

Inverter

Component failure mode combinations Verification tasks

Tasks to be executed

Tasks with unknown impact

Failure modes with unknown impact

Failure modes relevant

for verification

Failure modes relevant

for verification & validation

System analysis

Generate an overview what needs to be covered by the DVPDefine countermeasures to clarify unknown impacts


AVL DVP METHODOLOGY

TARGETS and LOAD PROFILING


LOAD PROFILING – USAGE SPACE ANALYSIS

Load

Dynam

ics

ExtraUrban

Highway

Offroad

Urban

Load

Dynam

ics

Field driving cycles

Analyze customer driving

and vehicle usage

patterns

Develop representative

customer vehicle usage

cycles

Profiles which include

velocity and gradient

Analyze target market

Analysis regarding:

Geography

Driving behavior

Road characteristics

Market segments

Population

Time

Velo

city

Example: Reference Highway

Analyze ambient

conditions

Analysis regarding:

Different regions

Different seasons /

months

Representative

distributions

Example: Ambient temperature distributions in

different areas

Example: Population of China


LOAD PROFILING – USAGE SPACE ANALYSIS

Lifetime distribution

matrix

No pre-existing data

Market researches

Varying boundaries

(vehicle loading, vehicle

gradients, ambient

conditions, vehicle modes)

Reduction step

Set up weighting tables

Calculate lifetime mileage

proportion

Consider variations which

fulfill target

Example: Lifetime distribution matrix

Generate larger data

base

Design of experiments

Variations included

Full variation of cycles &

parameters would lead to a

high number of cycles Example: Reduction step

TOTAL Urban Rural Highway Offroad

100.0% 20.0% 60.0% 18.0% 2.0%

10.0% 50.0% 11.0% 1.0%

10.0% 10.0% 7.0% 1.0%

15.0% 55.0% 15.0% 0.0%

5.0% 5.0% 3.0% 2.0%

4.0% 5.0% 4.0% 0.0%

14.0% 50.0% 12.0% 2.0%

2.0% 5.0% 2.0% 0.0%

100.0%

100.0%

100.00%

Vehicle loading: full

Ambient Temperatur (very low)

Ambient Temperatur (standard)

Ambient Temperatur (very hot)

%(lifetime km / lifetime hours)

Overall

Vehicle Gradient: flat

Vehicle Gradient: hilly

Vehicle loading: empty

TOTAL Auto Power Pure 4WD Save

100% 60% 5% 10% 20% 5%

(% of time)

Vehicle Modes

Flat

Hilly

Example:

profile slope weight

urban flat 15.0%

urban hilly 5.0%

rural flat 55.0%

rural hilly 5.0%

highway flat 15.0%

highway hilly 3.0%

offroad flat 0.0%

offroad hilly 2.0%ambient weight

very low 13.0%

standard 78.0%

very hot 9.0%

profile slope loading ambient mode weight

urban flat empty very low auto 0.585%

rural flat empty very low auto 3.575%

highway flat empty very low auto 0.715%

offroad flat empty very low auto 0.000%

urban hilly empty very low auto 0.195%

rural hilly empty very low auto 0.325%


DEFINITION OF COMPONENT LOAD PROFILES DERIVED FROM REAL WORLD VEHICLE DATA

Results:

• Reference cycles based on actual end customer usage

• Market related analysis report

Results

• Time based component load data• Parameter variation covering different

ambient conditions or control strategies

Results

• Lifetime load profiles • Lifetime load collectives for

components

Simulation model

Failure parameter

sheet

Damage modeling & statistical analysis

Usage space analysis

Reference cycle(s)

Targets & responsibilities

Utilize customer fleet data efficiently to generate load profiles for new systems and components

Fleet data


AVL DVP METHODOLOGY

TEST PROGRAM


DVP&R: GENERATION OF V&V PLANS

Software

…Design

Desig

n

Cha

nge

s

System

Qu

alit

y G

ate

s

Mile

sto

ne

s,

Te

sts

RCL

DVP&R

FP-Sheet

FMEA

Boundary

Diagrams

Requirements

Interface Analysis

Quality History

Customer Wants


DVP&RMAIN TEST CATEGORIES

10 Functional System Development and Integration

20 Geometrical Integration

• Performance and range• Core Functions (e.g. external Charging)• Emission and Consumption System• On-Board Diagnostics

• Geometrical Targets (Digital Mock-Up)• Weight monitoring• Center of gravity and inertia• Assembly (e.g. accessibility)• Serviceability



30 Mechanical System Development and Integration

• Durability• Mechanical Functional Testing (e.g. Efficiency)• NVH Functional Testing (e.g. NVH Analysis of

e-Machine)• Robustness and Misuse• Vibration, Stiffness, Strength• Shock, Crash, Crush

• Condensation and pressure handling• Cooling system performance• Tightness and vacuum test• Filling and Degassing of cooling circuit• Wind Tunnel Testing• Street testing (e.g. uphill towing)

40 Thermal System Development and Integration



50 Electrical System Development and Integration

60 System Safety

• HV Safety (ISO 26262)• Functional Safety• Vehicle Safety (active and

functional passive safety)• Safety of components

• HV Architecture• Energy Management• Load Balance• EMC (e.g. Immunity, Emission, ESD)


ADAS test and validation tools

ADAS V&V

ADAS validation (MIL cloud, MIL office, HIL,VIL, proving ground, public street)

Develop ADAS functions, control units and vehicle integration

ADAS Center


AVL DVP METHODOLOGY

EVALUATION & OPTIMIZATION


VISUALIZE STATUS AND RISKS OF ACTUAL DVP

Differential Gear Unit

Cardan & drive shafts

(Rigid) Axle

Transmission

HV-Harness

Motor

Inverter

Required tasks from system analysis Correlation with planned test program

Tasks to be executed

Tasks with unknown impact

Test programConnect verification tasks and failure mode with the planned program

Visualize risks and guide team to close gaps


DEFINITION AND VISUALIZATION OF DVP IMPROVEMENTS

Applied improvements

Targets & timeline Specify targets Improve timing of testingResponsibilities Align responsibilities

“Achievebest possibletask coverage”

Test program Modify procedures Define new proceduresRisk based task coverage Decide risk based on tasks in development

team

Status DVP-Result Main request

First analysis results

“Clarify responsibilities

Andtargets”

1st update of analysis

Final update of analysis

“Visualize effects of changes”

Management and project team Agree on changes Highlight & agree on remaining risks


SUMMARY & CONCLUSION


AVL DVPBENEFITS

AVL DVP

Increased technical and economical efficiency of verification and validation test program

Minimized risk of verification & validation gaps

Consideration of individual program targets, boundaries and customer processes. Evaluation and

optimization

Collection of all required testing activities in one document

Correlation of verification tasks and failure modes with planned testing program

Clear definition of project specific verification & validation targets

Alignment of responsibilities for complete test program Highlight needed missing information

Systemanalysis

Targetsand

Responsibilities

Test Program

Clear visibility of the verification & validation risks for all relevant components

Structured approach to make progress & improvements visible

Identification of verification tasks from vehicle level down to component level

Identification of components and failure modes to be covered by testing in one document

www.avl.com

Contact: [email protected]

THANK YOU

http://www.avl.com/

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