Vehicle in the Loop

An integrated approach for Chassis Systems development

November, 4th 2014

E. Raffone, C. Rei, M. Ieluzzi, P.P. Paravizzini, P. Turco

CHASSIS & Vehicle Dynamics

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Agenda

2

� System set-up for ABS/ESC application

o Software Architecture (RapidPro ECU sw)

o Open loop testing functionality

o Basic 3D environment

� Model Based Development Process: Main Design & Validation step

o Vehicle Dynamics Modelling

o Software in the Loop - Example of “fault injection”

o Vehicle Experimental Development & Performances Validation

� Vehicle in the Loop concept idea

� VIL - System Architecture & Preliminary Realization

� CRF’s V.I.L. Laboratory

� Conclusion & Next Steps

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Model-Based Development Process

Integration of different experiences & skills

3

System ValidationSystem DesignReq. & Constrains

System Control Design

CIL (Component In the Loop)

HIL (Hardware In the Loop)

Safety assessment

(eg. Fault injection)

System Calibration &

Perform. Assessment

On Vehicle System

Validation & Develop.

Safety

Requirements

(PHA,FMEA,..)

Performance Requirements

(eg.Target Setting)

Constraints

(Cost, Power,...)

Functional Requirements

Design Flow

“Rapid Prototyping” Code generation

Target ECU

Code Generation

(fixed point, ..

(Software In

the Loop)

IO-62-DV

IO-63-DV

Bench Test

Validation & Develop.

2008-10B-IO-001

2008-10B-IO-001

Architecture & System Design

Modeling & Identification

IO-60-DV

IO-61-DV

Diagnosis DesignRevision phase

SIL

Recovery Design

Vehicle Dynamics

Virtual Analysis

Chassis Systems

V.D. Performances

Development & Evaluation

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Model Based Development

Main Design & Validation step

4

Hardware in the Loop • Real Hardware;

• Real-time Vehicle Model

Vehicle Development & ValidationObjective & Subjective “on Track” Assessment

Revision phase

Revision phase

Vehicle model

Active systems model

Systems ValidationSystems Design

Revision phase Vehicle simulator

COMPONENTE DA TESTARE

Attuatore

Emulazione Sensori

Output simulatore

Seganli di misura Comandi

Input simulatore

Software Real-Time

SensoriHDW to SFW

AttuazioneHARDWARE

SOFTWARE DI

SIMULAZIONE

Software in the Loop• System Hardware Model;

• Vehicle Model.

H2IL

BBW_System Simulink Model

Vehicle Simulink Model

Libreria CAE diSistemi Controllo Autotelaio

From WorkSpace:

• Simulazione manovre;

• Simulazioni Fault;

To WorkSpace:

• Risultati;

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Model Based Development

Vehicle Dynamics Modelling

-40 -30 -20 -10 0 10 20 30 400

100

200

300

400

500

600

Angolo ruote (δruote) [deg]

Angolo

vola

nte

( δ

vol)

[deg]

Tau = 13

sx

dx

-40 -30 -20 -10 0 10 20 30 400

100

200

300

400

500

600

Angolo ruote (δruote) [deg]

Angolo

vola

nte

( δ

vol)

[deg]

Tau = 13

sx

dx

-100 -50 0 50 100-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

-360

-90-4504590

360

Scuotimento ∆x [mm]

∆ ε

= f

( ∆x, δ

ruote

) [d

eg]

TAMPONAMENTO RIMBALZO

-100 -50 0 50 100-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

-360

-90-4504590

360

Scuotimento ∆x [mm]

∆ ε

= f

( ∆x, δ

ruote

) [d

eg]

TAMPONAMENTO RIMBALZO

Suspension & Steer elastic & kinematics

characteristics

Vehicle Inertial & geometric properties

Vehicle Models

0 10 20 300

2000

4000

6000

scorrimento [%]

Fx [

N]

Fz = 1 KN

Pneumatici Posteriori = Mich_ENXH1_185_65_15

Fz = 2 KN

Fz = 3 KN

Fz = 4 KN

Fz = 5 KN

0 5 10 150

2000

4000

6000

deriva [deg]

Fy [

N]

Fz = 1 KN

Fz = 2 KN

Fz = 3 KN

Fz = 4 KN

Fz = 5 KN

0 5 10 15-100

-50

0

50

deriva [deg]

Mz [

Nm

]

Fz = 1 KNFz = 2 KN

Fz = 3 KN

Fz = 4 KN

Fz = 5 KN0 50 100

0

50

100

mux [%]

mu

y [

%]

alfa = 2°

Fz = 4 KN

alfa = 4°

Fz = 4 KN

alfa = 6°

Fz = 4 KNalfa = 8°

Fz = 4 KN

0 10 20 300

2000

4000

6000

scorrimento [%]

Fx [

N]

Fz = 1 KN

Pneumatici Posteriori = Mich_ENXH1_185_65_15

Fz = 2 KN

Fz = 3 KN

Fz = 4 KN

Fz = 5 KN

0 5 10 150

2000

4000

6000

deriva [deg]

Fy [

N]

Fz = 1 KN

Fz = 2 KN

Fz = 3 KN

Fz = 4 KN

Fz = 5 KN

0 5 10 15-100

-50

0

50

deriva [deg]

Mz [

Nm

]

Fz = 1 KNFz = 2 KN

Fz = 3 KN

Fz = 4 KN

Fz = 5 KN0 50 100

0

50

100

mux [%]

mu

y [

%]

alfa = 2°

Fz = 4 KN

alfa = 4°

Fz = 4 KN

alfa = 6°

Fz = 4 KNalfa = 8°

Fz = 4 KN

Tyre characteristics

From detailed data (multi-body model) . . .

. . . to functional “real time” model

5

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Model Based Development

Software in the Loop - Example of “fault injection”

45 degree Step steer input @ 100 kph

No faultNO Diagnosis

Diagnostic

Isolation

Fault: primary Steer sensor � 0°

Effect = Yaw Disturbances

Fault

Steering Wheel angle fault

Steer by WireECU Model &

Control Strategy

Actuator Model Sensors modelVehicle Model

6

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Model Based Development

Vehicle Experimental Development & Performances Validation

Vehicle “tuning”

Test plan definition

& vehicle setup

1 2 3 4 5 6 7 8 9 10Hz

Vehicle A

Vehicle B

Vehicle C

Experimental data analysis

Objective & Subjective Assessment

Revision phase

Output for the

7

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Model Based Development

Main Design & Validation step

8

Hardware in the Loop • Real Hardware;

• Real-time Vehicle Model

Vehicle Development & ValidationObjective & Subjective “on Track” Assessment

Revision phase

Revision phase

Vehicle model

Active systems model

Systems ValidationSystems Design

Revision phase Vehicle simulator

COMPONENTE DA TESTARE

Attuatore

Emulazione Sensori

Output simulatore

Seganli di misura Comandi

Input simulatore

Software Real-Time

SensoriHDW to SFW

AttuazioneHARDWARE

SOFTWARE DI

SIMULAZIONE

Software in the Loop• System Hardware Model;

• Vehicle Model.

H2IL

Vehicle in the Loop

BBW_System Simulink Model

Vehicle Simulink Model

Libreria CAE diSistemi Controllo Autotelaio

From WorkSpace:

• Simulazione manovre;

• Simulazioni Fault;

To WorkSpace:

• Risultati;

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Vehicle in the Loop concept idea

RT model & Bench control

BenchElectronics

Visualization & Data acq.

Workshop car lifter

Pc projector

• Simple and robust HIL for in workshop usage

• Complete active system HW & E/E architecture

• Standard interface for Human interaction

• Realistic “Real Time” Vehicle Dynamics Model

Why “Vehicle in the Loop” ?

� It’s based on the same commercial tools normally used by car engineer

� We built cars & ViL approach is the development tool closer to the real cars

� It’s a simple way to apply HIL techniques in day-by-day workshop usage

� It’s a portable system. Simple to be used close to the test track

9

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Vehicle in the Loop

System Architecture & Preliminary Realization

Real-Time

Vehicle

Model

Visualization

&

Data Acq.

Chassis

Systems

& HMI

Analog & Digital SignalsEmulated Measurements

& Expected CAN Signals

Auxiliary

CAN Network

1st Preliminary Realization

Steering

Sensor

Master

Cylinder

Pressure

Gas Pedal

Position

Brake

Switch

Clutch

Switch

…e.g.

Gyro

Engine

Signals

Wheel

Sensors

…

Visualization

PC Gas Pedal

Brake Pedal

Real-Time

Vehicle Model

Steering

CAR Visualization

10

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Vehicle in the Loop

System set-up for ABS/ESC application

Sensors

ABS/ESC

PedalActuator

Wired Inputs

Wired O

utp

uts

CAN nodes

emulation CA

N

Inte

rface

Real Vehicle

Force Req

Wheel

Speeds

Wheel

Pressures

CAN

msgs

3D

Animation

Interface

RapidPro ECU

CAN

msgs

3D Visualization

Wheel PressureSensors

Brake Calipers

11

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Vehicle in the Loop

Software Architecture (RapidPro ECU sw)

V.i.L.

Manager

CAN bus

signal

overwriting

CAN bus

signals

freeze after

start up

Vehicle Model

& Open Loop

Maneuvers

From

Vehicle

C-CAN

To Vehicle C-CAN

&

3D Visualization

12

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Vehicle in the Loop

Open loop testing functionalities

M

e

r

g

e

Emulated input

Applied

input

0 2 4 6 8 100

20

40

60

80

100

120

140

160

180Steering-wheel angle

time [s]

[deg]

0 1 2 3 4 5 6 70

10

20

30

40

50

60

70

80

90Steering-wheel angle

time [s]

[deg]

0 5 10 15 20 25 30-40

-30

-20

-10

0

10

20

30

40Steering-wheel angle

time [s]

[deg

]

Open-loop commands profile

Maneuvers manager

Robot driver

13

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Vehicle in the Loop

Open loop testing results – emulated input

0 1 2 3 4 5 6 7-4

-2

0

2

4

6

8

10

Tempo [s]

[m/s

2],

[deg]

& [

km

/h]

Vel*Psip

Ay

Beta

Dfmedio

Vel/10

0 1 2 3 4 5 6 70

50

100

[deg]

Steering wheel angle

0 1 2 3 4 5 6 70

20

40

60Gas Pedal

time [s]

[%]

0 1 2 3 4 5 6 70

50

100

[deg]

Steering wheel angle

0 1 2 3 4 5 6 70

20

40

60Gas Pedal

time [s]

[%]

Steer step manoeuvre

14

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Vehicle in the Loop

Basic 3D environment based on MathWorks Toolboxes

Visualization

&

Data Acq.

From Vehicle

Model

Visualization

Sink

15

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Vehicle in the Loop

CRF’s V.I.L. Laboratory

16

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

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Vehicle in the Loop

ABS in action on Vehicle in low µ

0 5 10 15 20 250

50

100

150

200

Time [sec]

Pre

ssu

re [b

ar]

Master Cylinder Pressure

0 5 10 15 20 25-50

0

50

100

150

Fro

nt

Wh

ee

l P

res

su

re [

ba

r]

0 5 10 15 20 250

50

100

150

Re

ar

Wh

ee

l Pre

ss

ure

[b

ar]

Time [s]

sx

dx

0 5 10 15 20 25-50

0

50

100

150

Wh

ee

l Sp

ee

d [K

m/h

]

Time [s]

Front Left Wheel

VG

Wheel

0 5 10 15 20 25-50

0

50

100

150

Wh

ee

l Sp

ee

d [K

m/h

]

Time [s]

Front Right Wheel

VG

Wheel

0 5 10 15 20 25-50

0

50

100

150

Wh

ee

l Sp

ee

d [K

m/h

]

Time [s]

Rear Left Wheel

VG

Wheel

0 5 10 15 20 25-50

0

50

100

150

Wh

ee

l Sp

ee

d [K

m/h

]

Time [s]

Rear Right Wheel

VG

Wheel

Wheel Pressure Sensors

Brake Calipers

Brake action

Master Cylinder Pressure Sensors

Wheel Speed Signals

ABS/ESC

17

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Vehicle in the Loop

CRF’s V.I.L. Laboratory

18

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Conclusion & Next Steps

Next Steps

� VIL approach extension to all Chassis Systems

� Automation of “Robot driver” / Emulated input testing

� VIL system integration with CRF’s Virtual Reality Lab

Conclusion

� A new approach to support Chassis System development has been shown

� VIL approach is a flexible, cheap and close to the real cars

� VIL is portable and robust. Simple to be moved closer to vehicle testing area

� VIL is based on the same commercial tools normally used by car engineer

� MATLAB/Simulink toolboxes cover the main part of VIL approach needs

� 1st test case applied to ABS/ESC system has showed big potentiality

19

Vehicle in the Loop:

an integrated approach for Chassis Systems development

This document contains information which are proprietary of CRF. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CRF

4-11-2014

Public

Thanks for your kind attention

P. Turco - CHASSIS & Vehicle Dynamics

Tel.: +39 011 9083.826 E-mail: patrizio.turco@crf.it

Enrico RAFFONE

Michele IELUZZI Claudio REI

Pier Paolo PARAVIZZINI

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