CAE-based Homologation of ESC-Systems using IPG CarM aker Karl Michael Hahn Dr. Henning Holzmann, Dr. Michael Kochem Adam Opel AG apply & innovate 2012 Karlsruhe, September 19 th , 2012 www.opel.com
Agenda � Background E CE-R 13-H � Motivation � Simulation Environment at GM Europe � Vehicle Dynamics Simulation � Chassis Controls Simulation � Project Scope � Validation of the Simulation Environment � Static Measurements � Dynamic Measurements � Validation Results � Sine-with-Dwell Test Results � Conclusions 2 September 19 th , 2012 K.M. Hahn
Background Test Procedure ECE-R 13-H � Electronic Stability Control (ESC) systems have proven to be very effective in reducing accidents and fatalities � European Commission decided that all new vehicles have to be equipped with a functional ESC � ECE-R 13-H specifies the basic requirements of an ESC and how this can be tested and certified � ECE-R 13-H currently does not evaluate the control quality of the ES C 3 September 19 th , 2012 K.M. Hahn
ECE13H Homologation through Simulation Background Use of CAE in Homologation Process ECE-R 13-H When one physical vehicle has been tested according to ECE-R 13-H, other vehicle variants or versions based on the same vehicle type may be subsequently homologated through simulation. Process to be applied: Test a Target Vehicle according to ECE-R 13-H Sine-with-Dwell test � Generate a vehicle simulation model of the target vehicle and correlate it � to an acceptable level of accuracy requested by Type Approval Agency Simulate critical variants and versions to identify worst case examples � Present results to obtain homologation for all configurations � 4 September 19 th , 2012 K.M. Hahn
Background Test Definition According to ECE-R 13-H (Sine-with-Dwell Test) Test Procedure � Steering Wheel Angle Pre-Test: A is the steering wheel angle at a y = 0.3g � Vehicle coasting in high gear at 80 ± 2 km/h Steering amplitude � for the initial run is 1.5 A � time � In each series of test runs the steering amplitude is increased from run to run by 0.5 A � Max. steering amplitude ~ 270 deg Yaw Rate time Sine-with-Dwell 5 September 19 th , 2012 K.M. Hahn
ECE13H-S7 Homologation Background E valuation Criteria ECE-R 13-H Effectiveness of ESC is determined by Performance Criteria � Vehicle must comply with all 3 performance criteria to achieve Homologation � Stability (yaw rate ratios) Responsiveness (lateral deviation) Wheel Angle Steering time w/o ESC Yaw Rate w/ ESC time T 0 T 0+1 T 0+1.75 at T 0+1 � 35% at T 0+1.75 � 20% 6 September 19 th , 2012 K.M. Hahn
Background Regulation designed for Simulation 7 September 19 th , 2012 K.M. Hahn
Background Difference to FMVSS126 FM VSS 126: Self certification OEM Government Verification ECE R13-H: Witness testing Confirmation OEM Certifier Government 8 September 19 th , 2012 K.M. Hahn
Motivation Project Complexity Astra (2009 - ) Insignia (2008 - ) Corsa (2005 - ) � ABS / ESC � Damping � � ABS / ESC ABS / ESC � Radar � Damping ~400 Variants � AWD ~150 Variants ~70 Variants 10 September 19 th , 2012 K.M. Hahn
Motivation Increasing Test Requirements � Homologation test requires steering robot � At least one day test time per vehicle (setup & test execution) � Weather dependency � Cost for tracks and travel Cost comparison Travel Equipment Manpower Vehicle only Vehicle + Simulation 11 September 19 th , 2012 K.M. Hahn
Motivation Road-Lab-Math (RLM) S trategy applied to Chassis Controls SiL - Simulation HiL - Simulation Driving Test (Math) (Lab) (Road) Architecture Development Performance Validation Controller Application S ystem Integration Diagnosis / Failsafe Random Testing Parameter Optimization Validation Certification 12 September 19 th , 2012 K.M. Hahn
Simulation Environment at GM Europe Virtual Vehicle Development (Timing) SORP Effort Virtual Control Virtual suspension systems ride & handling and brake validation optimization development Virtual Development Time 13 September 19 th , 2012 K.M. Hahn
Simulation Environment at GM Europe Vehicle Dynamics Simulation Suspension � Process for data generation and transformation defined Simulation Data Virtual Vehicle Kinematic � Interfaces between tools established and verified Suspension Chart Processing Analysis Geometry Characteristic Compliance Compliance Maneuver Plots Analysis Analysis Definitions Suspension � Reliable data for certification Topology Compiler Equations Builder Linker of motion Vehicle Virtual Vehicle Body Handling Simulation Chart Topology Analysis Component Ride Characteristic Models Analysis Plots Data Body Roll-over Processing Geometry Analysis Ground HyperWorks Clearance MotionView Tire Data SiL-/HiL Road Data Simulation ASCII ADAMS ANSI-C CarMaker Mesaverde S imulink Pro 14 September 19 th , 2012 K.M. Hahn
Simulation Environment at GM Europe Chassis Controls Simulation ECU- & Actuator Models ESC Test- Parkbrake automation Vehicle Dynamics Model Software-in-the-Loop Simulation (SiL) Aero PT Chassis Sensors Tires CAD Actuator Models Simulation Results ESC Parkbrake Hardware-in-the-Loop Simulation (HiL) 15 September 19 th , 2012 K.M. Hahn
Simulation Environment at GM Europe Hardware-in-the-Loop Pump Motor Emulator ESC E CU ESC Hydraulic Current Measure- ment Card 16 September 19 th , 2012 K.M. Hahn
Project Scope Cooperation project Opel <-> Applus IDIADA � Project was defined in close IDIADA IDIADA cooperation between Homologation Simulation departments � Many steps were conducted together (e.g. measurement setup, validation) Opel Opel � Homologation Simulation Joint approach improves transparency 18 September 19 th , 2012 K.M. Hahn
� Project Scope Execution 19 September 19 th , 2012 K.M. Hahn
Validation of the Simulation Environment IDIADA provided Testing and Simulation S upport in the Process Comprehensive testing of reference vehicle � Static Measurements � Dynamics Measurements Construction of passive model � Focus on suspension & steering � Tires Validation of passive model � According to IDIADA criteria � Extended validation program 20 September 19 th , 2012 K.M. Hahn
Validation of the Simulation Environment Comprehensive Testing of Reference Vehicle Static Measurements � K&C test of front and rear axles � Additional sensors for suspension parameters � Extended test matrix to generate complex suspension maps based on multiple inputs � Center of Gravity � Static geometry and corner weights Dynamics Measurements � Handling tests to characterize handling response � Brake tests to characterize braking system � ABS & ESC tests Test Manoeuvres Reps Weight configs ESC configs Sides Setup Total runs Number of manoeuvres to execute Number of GVM ESC ON, ESC OFF Left, Right See Channel Executions the test repetitions for List each manoeuvre Steady-State Cornering Const. Speed 1 AY = 0-lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 12 Frequency Response Linear Range 1 AY = ± 3 3 1 GVM 1 OFF 1 -- Setup 1 3 Step steer + Free control release 6 AY = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 72 On-centre feeling weave 1 3 1 GVM 1 OFF 1 -- Setup 1 3 Power-off reaction 6 AY = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 72 Braking in a turn 6 AX = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 3 ON, OFF, No YRS 2 Left, Right Setup 1 108 Double lane change 7 V = 80-85-90-95-100-105-lim 3 1 GVM 2 ON, OFF 1 -- Setup 1 42 Dwell sine test 20 �� 20 steps of SWA) 2 1 GVM 2 ON, OFF 2 Left, Right Setup 1 160 472 21 September 19 th , 2012 K.M. Hahn
Validation of the Simulation Environment Construction of a Vehicle Passive Model � Complex suspension maps generated by an in-house tool for conversion of K&C tables to IPG CarMaker model � Supplemented with vehicle data supplied from Opel (powertrain, body, aerodynamics) � Accurate representation of load & instrumentation � Validated against K&C tests 22 September 19 th , 2012 K.M. Hahn
Validation of the Simulation Environment Final Validation Results � S teady S tate parameters � Frequency Response parameters � S ine with Dwell parameters Ready for Active Model validation 24 September 19 th , 2012 K.M. Hahn
Sine-with-Dwell Test Results Vehicle Response for an exemplary Sine-with-Dwell Maneuver 25 September 19 th , 2012 K.M. Hahn
Sine-with-Dwell Test Results ESC pressure response for an exemplary Sine-with-Dwell Maneuver 26 September 19 th , 2012 K.M. Hahn
Sine-with-Dwell Test Results Summary Report of a Sine-with-Dwell Test � � � � 28 September 19 th , 2012 K.M. Hahn
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