CAE-based Homologation of ESC-Systems using IPG CarM aker Karl - - PowerPoint PPT Presentation

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CAE-based Homologation of ESC-Systems using IPG CarM aker Karl - - PowerPoint PPT Presentation

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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

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SLIDE 1

www.opel.com

CAE-based Homologation

  • f ESC-Systems

using IPG CarM aker

Karl Michael Hahn

  • Dr. Henning Holzmann, Dr. Michael Kochem

Adam Opel AG

apply & innovate 2012 Karlsruhe, September 19th, 2012

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SLIDE 2

2 September 19th, 2012 K.M. Hahn

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
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SLIDE 3

3 September 19th, 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

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SLIDE 4

4 September 19th, 2012 K.M. Hahn

ECE13H Homologation through Simulation

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.

Background

Use of CAE in Homologation Process ECE-R 13-H

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
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SLIDE 5

5 September 19th, 2012 K.M. Hahn

Test Procedure

  • Pre-Test: A is the steering wheel angle at ay = 0.3g
  • Vehicle coasting in high gear at 80 ± 2 km/h
  • Steering amplitude for the initial run is 1.5 A
  • In each series of test runs the steering amplitude is

increased from run to run by 0.5 A

  • Max. steering amplitude ~ 270 deg

Background

Test Definition According to ECE-R 13-H (Sine-with-Dwell Test)

Sine-with-Dwell

Steering Wheel Angle Yaw Rate time time

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SLIDE 6

6 September 19th, 2012 K.M. Hahn

ECE13H-S7 Homologation

  • Effectiveness of ESC is determined by Performance Criteria
  • Vehicle must comply with all 3 performance criteria to achieve Homologation

at T0+1 35% at T0+1.75 20%

Background

E valuation Criteria ECE-R 13-H

Steering Wheel Angle Yaw Rate time time

T0 T0+1 T0+1.75

Stability (yaw rate ratios) Responsiveness (lateral deviation)

w/ ESC w/o ESC

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SLIDE 7

7 September 19th, 2012 K.M. Hahn

Background

Regulation designed for Simulation

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SLIDE 8

8 September 19th, 2012 K.M. Hahn

Background

Difference to FMVSS126

FM VSS 126: OEM Government

Self certification Verification

ECE R13-H: OEM Government

Witness testing

Certifier

Confirmation

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SLIDE 9

10 September 19th, 2012 K.M. Hahn

Motivation

Project Complexity Corsa (2005 - )

  • ABS / ESC

~70 Variants

Insignia (2008 - )

  • ABS / ESC
  • Damping
  • AWD

~150 Variants

Astra (2009 - )

  • ABS / ESC
  • Damping
  • Radar

~400 Variants

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SLIDE 10

11 September 19th, 2012 K.M. Hahn

Motivation

Increasing Test Requirements

Vehicle only Vehicle + Simulation

Cost comparison

Travel Equipment Manpower

  • Homologation test requires steering robot

At least one day test time per vehicle (setup & test execution)

  • Weather dependency
  • Cost for tracks and travel
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SLIDE 11

12 September 19th, 2012 K.M. Hahn

Architecture Development S ystem Integration Parameter Optimization SiL - Simulation (Math) Controller Application Random Testing Validation Driving Test (Road)

Motivation

Road-Lab-Math (RLM) S trategy applied to Chassis Controls

Performance Validation Diagnosis / Failsafe HiL - Simulation (Lab)

Certification

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SLIDE 12

13 September 19th, 2012 K.M. Hahn

Virtual Development Time Effort

Virtual ride & handling

  • ptimization

Virtual suspension and brake development Control systems validation

Simulation Environment at GM Europe

Virtual Vehicle Development (Timing)

SORP

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SLIDE 13

14 September 19th, 2012 K.M. Hahn CarMaker S imulink Pro

SiL-/HiL Simulation

Compiler Linker Component Models Maneuver Definitions ANSI-C

Suspension Simulation

Kinematic Analysis Compliance Analysis Virtual Vehicle Chart Characteristic Plots Data Processing

Body Topology Suspension Topology Tire Data Body Geometry Road Data Suspension Geometry ASCII Equations

  • f motion

Builder ADAMS Mesaverde

Vehicle Simulation

Handling Analysis Ride Analysis Virtual Vehicle Chart Characteristic Plots Data Processing Roll-over Analysis Ground Clearance Compliance Analysis HyperWorks MotionView

Simulation Environment at GM Europe

Vehicle Dynamics Simulation

Process for data generation and transformation defined Interfaces between tools established and verified Reliable data for certification

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SLIDE 14

15 September 19th, 2012 K.M. Hahn

Simulation Environment at GM Europe

Chassis Controls Simulation

Vehicle Dynamics Model Software-in-the-Loop Simulation (SiL) Test- automation

Aero PT Chassis Sensors Tires CAD

Hardware-in-the-Loop Simulation (HiL)

ESC Parkbrake

ECU- & Actuator Models

ESC Parkbrake

Actuator Models Simulation Results

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SLIDE 15

16 September 19th, 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

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SLIDE 16

18 September 19th, 2012 K.M. Hahn

Project Scope

Cooperation project Opel <-> Applus IDIADA

Opel Simulation IDIADA Simulation Opel Homologation IDIADA Homologation

  • Project was defined in close

cooperation between departments

  • Many steps were conducted

together (e.g. measurement setup, validation)

  • Joint approach improves

transparency

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SLIDE 17

19 September 19th, 2012 K.M. Hahn

Project Scope

Execution

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SLIDE 18

20 September 19th, 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

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SLIDE 19

21 September 19th, 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 Reps Setup Total runs Number of repetitions for each manoeuvre See Channel List Executions 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 Manoeuvres Number of manoeuvres to execute the test ESC configs Sides ESC ON, ESC OFF Left, Right Weight configs GVM
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SLIDE 20

22 September 19th, 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
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SLIDE 21

24 September 19th, 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

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SLIDE 22

25 September 19th, 2012 K.M. Hahn

Sine-with-Dwell Test Results

Vehicle Response for an exemplary Sine-with-Dwell Maneuver

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SLIDE 23

26 September 19th, 2012 K.M. Hahn

Sine-with-Dwell Test Results

ESC pressure response for an exemplary Sine-with-Dwell Maneuver

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SLIDE 24

28 September 19th, 2012 K.M. Hahn

Sine-with-Dwell Test Results

Summary Report of a Sine-with-Dwell Test

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SLIDE 25

29 September 19th, 2012 K.M. Hahn

Conclusions

  • Pilot project between Opel and IDIADA to achieve CAE-based

homologation of an ESC-system according to E CE-R 13-H

  • Setup of a high-quality simulation environment (HiL) is possible,

but requires advanced integration solutions and expertise

  • Validation of the simulation environment by extensive static and

dynamic measurements proves good correlation

  • Simulation results of Sine-with-Dwell

maneuver are very close to real measurements

  • Quality of simulation allows the

homologation of ES C systems

  • Process from testing to simulation

to homologation is well understood and documented

  • Approach allows OEMs to significantly reduce the number of

real tests during the ES C certification process