simulation for development of chassis mechatronic systems

Simulation for Development of

Chassis Mechatronic Systems

May 3, 2016 VECTOR TESTING SYMPOSIUM, STUTTGART, DR. MATTHIJS KLOMP, VOLVO CARS 1

Dr. Matthijs Klomp, Technical Specialist – Vehicle Dynamics CAE

• Vehicle Dynamics CAE @ Volvo Cars – Who are we and what do we do?• The software and electronics revolution in cars – what does it mean and how do

we meet these new challenges? (Spoiler #1: Simulation!)• Simulation – Implementation examples• Conclusions – (Spoiler #2: Simulation is necessary!)

agenda

May 3, 2016 2VECTOR TESTING SYMPOSIUM, STUTTGART, DR. MATTHIJS KLOMP, VOLVO CARS

product development


Obj. Vehicle Requirements

Sub-system Requirements

Component Requirements

Component Testing

Sub-system Testing

Objective Vehicle Testing

Subjective Vehicle Testing

Voice of Customer Market Acceptance

Component Design

Subj. Vehicle Requirements

Vehicle Level

System Level

Component Level

• Trends: Safe, Green & Convenient

• Common statement: ”More than 80 percent of automotive innovations are driven by electronics, and amongst them, 90 percent are supported by means of software.”

• What we see clearly is:• More vehicle variants in shorter time• Functional growth (exponential?) – e.g. autonomous drive

• How do we meet these challenges?

Our reality: Transformation in progress


Functions

Software

Electronics

Complexity – network topology

May 3, 2016 VECTOR TESTING SYMPOSIUM, STUTTGART, DR. MATTHIJS KLOMP, VOLVO CARS 5

• Enables testing of solutions before hardware is built• Enables fully automatic repeatable testing of real driving situations• Supports continuous integration of SW functional increments• Leverages computing power (n*24/7 versus 1*8/5)• Measure the immeasurable – all signals are available

Simulation as an enabler


Pinpoint Decisions, Inc.

• Vision “Fully virtual vehicle dynamics development”

• Predict handling, steering & ride comfort

• Virtual tuning of tires

• Virtual tuning of suspension (springs, dampers, stabilizer bars, bushings, hard-points and structural stiffness of chassis & body)

• Virtual tuning of steering control (boost, damping, active return, path control, etc.)• Virtual tuning of brake control (yaw, side-slip and roll control)

• Focus on event based testing (1:1 equivalence to physical testing)

Vehicle Dynamics @ Volvo Cars


System Analysis: suspension K&C


Vehicle manuever: Parking Sweep 100°/s 10 km/h


ISO 19634: Steady-State Constant Radius


• Virtual Vehicle Architecture• Platform and infrastructure to virtually develop networked mechatronic system functions• Purpose driven fidelity of simulation models (plant and controller)• Purpose driven integration of simulation models (configuration)

• Unified models• Tool vendor independent models• Functional Mock-up Interface

• Purpose driven fidelity• Real-time online• Error controlled offline• Configuration in PLM system

Virtual vehicle architecture


Gimbergsson & Törmänen, 2013

Integral process for functions, performance, functional safety and quality testing

Consistent Use of Simulation Models

May 3, 2016 12VECTOR TESTING SYMPOSIUM, STUTTGART, DR. MATTHIJS KLOMP, VOLVO CARS Courtesy: 91015/Edo Drenth

• Structured (questions pre-defined)• Standard load-cases• Highly automated• Pre-defined variations

• Semi-structured (variations of questions)• Monte Carlo / DOE simulations• Stress test (automatically find error states)• Sensitivity studies

• Unstructured (ad-hoc questions)• Explorative testing (driving simulator, 24/7 off-line driving)• Random variations / fault injection• Visual inspection of data• Data mining (new questions on existing data)

Methods – test strategy


Find & report issues

Propose solution

New/updated requirements and/or test methods

• Chassis Nodes• VDDM/BCM: Vehicle Dynamics Domain Master / Brake Control Module• PSCM: Power Steering Control Module• SUM: Suspension Control Module• SAS: Steering Angle Sensor

Vehicle dynamics domain


Steering System Suspension SystemBrake System

Propulsion CAN HS

• In XC90 development:• Fault injection to test correct error handling and diagnostics• Test that functions are available and possible to activate• Test of software download and other production related features• Test of communication with other nodes in the car• System safety testing including end-to-end protected signaling

• Today and onwards:• Dynamic testing of vehicle dynamics functions• Dynamic long-time testing• Integration with driving simulator• Integration with steering system test-rig

Vehicle dynamics domain testing


Steering System Rig

Moving Base Driving Simulator

Off-line steering system optimisation

16VECTOR TESTING SYMPOSIUM, STUTTGART, DR. MATTHIJS KLOMP, VOLVO CARS

Electric Power Assist Steering System

Parameterization and Optimisation Employing

Computer-Aided Engineering

Marcus Ljungberg (VCG), Mikael Nybacka (KTH), Gaspar Gil Gómez (VCG) and Diomidis Katzourakis (VCG)SAE 2015 World Congress & Exhibition. 2015-01-1500, Steering and Suspension Technology Symposium

May 3, 2016

On-line steering system optimisation


Calibration (INCA / CANape)

DoE / Optimization (ModeFrontier)

Vehicle & Rest-bus Simulation (CarMaker on DS1006)

Post-processing (Sympathy for Data)

Remote GUI Control via TCP/IP

StWhlAgStWhlTrq

Result file

Performance metricsProcess automation via COM

VehSpdTieRodFrc

XCP via CANTieRodPos

Steering System Verification Using

Hardware-in-the-Loop

Linköping University, Vehicular Systems Bjelevac, SalkoKarlsson, PeterISRN: LiTH-ISY-EX--15/4831--SE

• ECE/TRANS/WP.29/GRRF/2014/12: “Where a vehicle has been physically tested in accordance with paragraph 8., the compliance of versions or variants of that same vehicle type may be demonstrated by a computer simulation, which respects the test conditions of paragraph 8. and the test procedure of paragraph 9.9. The use of the simulator is defined in Annex 1 to this Regulation.”

Virtual homologation of ESC systems


Source: www.cvel.clemson.edu

https://www.google.se/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjnmeCt6bfJAhUF6A4KHUD4CXAQjB0IBg&url=http://www.cvel.clemson.edu/auto/systems/stability_control.html&bvm=bv.108194040,d.ZWU&psig=AFQjCNGbD2h8sBXJ46GuY8XNiJ-pM31vJw&ust=1448961725321505

• S90 brake internal SW road release without physical prototypes

• Virtual homologation & steering in development

Virtual release of brake and steering systems


Diomidis Katzourakis, Stavros Angelis, Matthijs Klomp, Albin Johnsson, Robert HanssonVirtual Brake Software Release

24th International Symposium on Dynamics of Vehicles on Roads and Tracks, August 17-21, 2015, Graz / Austria

• ECE regulation: “The simulated vehicle behaviour and operation of he vehicle stability function is comparable with that seen in practical vehicle tests.”

• Objective metrics on the validation the simulation model has been missing so far• Proposed standards:

• ISO/DIS 19364: Passenger cars -- Vehicle dynamic simulation and validation -- Steady-state circular driving behavior

• “If all [physical] tests lie within the boundaries [specified in the standard], then the simulation is considered valid for determining steady-state behaviour up to the limits in lateral acceleration covered in the testing.

• ISO/DIS 19365: Passenger cars -- Vehicle dynamic simulation and validation -- Sine with dwell stability control testing

• “If the number of the first test in each series in which ESC intervention occurs for physical testing matches the corresponding number for the first test in the simulated series ±1 as specified in 9.2.2, and the conditions specified in 9.3.3 are met for the three tests used for comparison (see 9.2.3), the simulation tool is considered valid for representing vehicle behaviour in the sine with dwell test.”

Validation of simulation models


• Albert Einstein: “As simple as possible, but not simpler”• George Box: ”All models are wrong; the practical question is how wrong do they

have to be to not be useful” • Claude Rouelle: ”Make it useful before you make it complicated”

Model validity – accuracy vs usefulness


Robert G. Sargent – “Verification and validation of simulation models” Proceedings of the 2011 Winter Simulation Conference

• Boundaries are based on Adams/Car data from ISO/DIS 19364

Example for steady-state circular driving


22

• 0.3 – 30 Hz motion frequency• Motion envelope

• X: ± 0.8 m• Y: ± 0.75 m• Z: ± 0.15 m• Rotations: ± 20°

Vehicle dynamics driving simulator


Example 1: Suspension control & Driving Simulator


Rest-bus & I/O Simulation (CANoe on VT System)

Measurement & Calibration (CANape)

Vehicle Simulation(Concurrent Linux64)

Suspension Control Module

FMI Coupling (FDX via Ethernet)

Driving Simulator

Chassis CAN 4xWhlPos [V]3xVertAcc [V] 4xDmprCrnt (A)

XCP via Measurement CAN

Cockpit & Motion Platform Variables (EtherCat)

May 3, 2016 25

Example 2: Brake control & Driving Simulator

VECTOR TESTING SYMPOSIUM, STUTTGART, DR. MATTHIJS KLOMP, VOLVO CARS

Concurrent

VT SystemRest Bus & I/O

CarRealTime

Vehicle Model

CAN(Chassis & Propuslion)

ethernet(UD

P)

SWA, VehSpd,brkpedpos

VDDM/BCM

Vacuum pump

Servo StWhlAg

StWhlTqcontroller BrkPedPosBrkpedpos (analog)

4x WhlSpd

FlexRay(Backbone)

Booster

Master

cylinder

Brakeclampingforce (4x)

J1962

Diagnostic Connector

Diagnostics

EthernetVCM

MCAL (INCA, CANape)

XCP on Ethernet

• Current focus for release testing is vehicle simulation and ECU-in-the-loop (HIL)• Future focus is on increased SIL testing (virtual ”ECU”)• Why:

• Scalable: theoretically only limited to the number of computer nodes• Component black/grey-box testing possible

• How:• Component (SWC:s) source code (as for target) built for Windows (desktop) and Linux (HPC cluster).• Composition models with emulation and/or stubs of microcontroller abstraction layer (MCAL)• Components and compositions as FMU’s according to the FMI standard• Support for calibration using same variables/signals as for target ECU via XCP on Ethernet.• SIL models (component and compositions) are automatically built at each CI loop.

• Challenges• Tool chain (standardised?) for creating SIL models as described above• Tool chain for integration and simulation of (100+) SIL models (CANoe?)

Outlook – Move from HIL to SIL Testing


•Virtual development methods are required to meet the challenges of the future

•Unified / scalable simulation architecture in all phases of development (MIL, SIL, HIL)

•Leverage strengths of virtual development

conclusions


simulation for development of chassis mechatronic systems

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