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Simulation-aided Homologation of ESP Systems for NAFTA Vans by Software-in-the-Loop Simulation
Klaus Wüst, Daimler AG Albert Lutz, Robert Bosch GmbH
IPG Technology ConferenceEttlingen, 18.-19. September 2012
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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• ESP homologation by simulation –background of legislation
• Simulation environment -SiL exchange platform OEM/supplier
• Proof of functionality for vehicle variantson the basis of a validated “MasterCar”
• Results of the survey, robustness
• Banked curves robustness check
• Conclusion
Agenda
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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ESP homologation by simulation – background
• In Europe:Mandatory introduction of ESP systems for passenger cars and for trucks or buses via ECE-R13 and ECE-R13H
• ECE-R13 and –R13H allow homologation by simulation –either by HiL test stands or by SiL simulation
• Type approval by simulation at Daimler Trucks since 2011 –Simulation tool EBSim (Simpack models with SiL codes)
• Various driving maneuvers without precise criteria for trucks, maneuver “sine with dwell” for passenger cars, includingpass/fail criteria
• For NAFTA region:Mandatory introduction of ESP systems for passenger carsvia FMVSS 126, maneuver “sine with dwell”, self-certification (no type approval by authorities)
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Overview of Simulation EnvironmentSystem & Function Level
Component Level SW
ComponentDesign
Implementation
Release
System &FunctionDesign
ComponentRequirements
System Req.
ComponentVerification
ComponentValidation
SystemVerification
SystemValidation
Calibration
SiLSiL
SiL_genericSiL_generic
HiLHiL
SiL_genericSiL_generic
SiLSiL
RapidPrototypingRapidPrototyping
MiLMiL
SiLSiL
OOLOOL
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Set-up simulation environment
Actuation & ESP signals
Vehicle, Driver,
Environment, OEM-control inputs
Parameter modification
BOSCH
Vehicle dynamics simulation tools Vehicle, road, driver model OEM control systems OEM test automation
ESP-Simulation tool Control, sensor, brake model New braking system models Driver assistance
ESP internalsignal trace*.d97Animation
CM-Signal trace*.erg, *.info
Combined trace fileDaimler
CSSim
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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MasterCar - Approach
physical
Veh
icle
Var
iant
s B
,C, .
.=V
irtua
l Car
s
virtual
virtual
virtual
virtual
virtual
Simulation-Workshop
RPM - Robustness & Performance Monitoring
Veh
icle
Var
iant
A
= M
aste
r Car
Application-Process
In-Vehicle Tests
DFP - Digital FingerPrint
Measurementdriven
simulation
Real Test Drive
Virtual Test Drive
Virtual Test Drive - with parametervariations
Correlation
Correlation
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Validation of van vehicle dynamics using the “MasterCar”
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
• Step 1:Proof of tire characteristics (MFTYRE)
• Step 2:Measurement of 4 vehicle variants
• Step 3:Validation of steady state driving behavior
• Step 3:Validation of transient driving behavior
• Step 4:Validation of sine with dwell with ESC interventionsComparison Measurement with ESC / Simulationwith ESC / Simulation without ESC,Vehicle yaw velocity as a response to 200°steering wheel amplitude
-50
-40
-30
-20
-10
0
10
20
30
40
14 16 18 20 22 24
ZeitG
ierg
esch
win
digk
eit
Yaw Velocity vs. Time
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The simulation covers a wide range of vehicle variants• Examples for the vehicle variety (Sprinter for NAFTA market):
• 2 GVW variants, 2 wheelbases, 2 heights, 2 versions of rear overhang, bus or goods transport, 4 suspension variants, 3 tire variants approx. 120 possible variations
• Additional: variation of loading conditions (laden/unladen, c.o.g position)
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Results of the survey, robustness
• All simulated vehicle variants have fulfilled the evaluation criteria
• Step-by-step identification of worst case vehicle variants
• Example result:Comparison between ESP8 and ESP9 code for one vehicle variant
Vergl ESP8 ESP9Nafta KAWA 3.88t R2 LH2 CF2 C39
0
0.5
1
1.5
2
2.5
3
3.5
4
0 50 100 150 200 250 300
LW- Amplitude
Seite
nver
satz
1.0
71s
nach
Len
kbeg
inn
ESP8
ESP9
Vergl ESp8 ESP9Nafta KAWA 3.88t R2 LH2 CF2 C39
-100
-80
-60
-40
-20
0
20
40
60
80
100
0 50 100 150 200 250 300
LW-Amplitude
Nor
m. G
ierg
esch
w 1
s na
ch M
anöv
eren
de
ESP8
ESP9
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Additional ESP-Robustness Check: Banked Curves
Initial radius
Final radius
Elevation
Trajectory
Curvature
Tracks:
• Synthetic (S-Curve)
• Test-center (PBx)
• Public Road (cross-country up to Great Ocean Road)
Track X-Coordinate [m] Track Length [m]
Ele
vatio
n [ra
d]
Trac
k Y
-Coo
rdin
ate
[m]
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Track Analysis:Elevation ≥ x°
Banked Curve Detection:Counter-Values
Counter 1
Counter 2
Yaw Rate
Covering Criteria
Curve Entering
Counter 1 Counter 2
Covering
Additional ESP-Robustness Check: Banked Curves
Time [s]
MeasurementSimulation
Yaw
Rat
e [ra
d/s]
Lat.
Acc
eler
atio
n [m
/s2 ]
Time [s]
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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• Daimler and Bosch have successfully estab-lished an exchange platform for the simulation of van vehicle dynamics with active systems.
• The SiL platform is used for type approval investigations of ESP system as well as for investigations of a large amount of vehiclevariants and for robustness investigations.
• In future, this SiL process will also be used for other driver assistance systems, furthermoreimplementing additionally the tools IPG Test-Manager and QTronic TestWeaver.
Conclusion
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.