MANEUVER BASED VALIDATION OF BMW xDRIVE VARIANTS BY USING VIRTUAL - - PowerPoint PPT Presentation

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MANEUVER BASED VALIDATION OF BMW xDRIVE VARIANTS BY USING VIRTUAL VEHICLE INTEGRATION AND HIL TEST METHODS.

IPG TECHNOLOGY CONFERENCE, SEPTEMBER 18 -19, KARLSRUHE.

19.09.2012 Matthias Prebeck, Dr. Peter Rissling; BMW Group Michael Folie; IPG Automotive

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• Basics xDrive.
• Testsystem.
• Integration engine-model.
• Maneuver based tests.
• Testautomation.
• Benefits and Outlook.

AGENDA.

MANEUVER BASED VALIDATION, 19.09.2012

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BASICS xDRIVE. ACTIVE 4X4-SYSTEM.

MANEUVER BASED VALIDATION, 19.09.2012

• Com. Bus

LMV (Actuator): Receive target torque and actuate clutch. Securing torque accuracy over temperature and lifetime. DSC (Master): Computation target torque with respect to the driving sit. Send-out target torque on communication bus. ECU: DSC ECU: LMV

All advantages of a 4x4 car without the typical disadvantages.

Requirements xDrive:  Maximum traction.  BMW-typical driving characteristics.  Reduced fuel consumption deficite.

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BASICS xDRIVE. 4X4 FUNCTIONS IN LMV-ECU.

MANEUVER BASED VALIDATION, 19.09.2012

Abrasion- model (oil, coating) Guardmodel (thermal impact) Degradation and fail-safe logics

Bussignals: Target torque, Wheel speeds, … Sensors, Terminals (Current, Ubat, GND) Bussignals: Actual torque, … Control: current + mechanics

Signal conditioning Computation

• f internal

variables Diagnostics Torque controller

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BASICS xDRIVE. LATEST MODELS WITH xDRIVE.

MANEUVER BASED VALIDATION, 19.09.2012

2009 2010 2011 2012 2013

09/2009 7-Series 09/2009 X1 06/2010 5-Series GT 09/2010 5-Series 09/2010 X3 09/2011 6-Series 07/2012 3-Series 11/2012 1-Series

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TESTSYSTEM. HIL-PLATTFORM.

MANEUVER BASED VALIDATION, 19.09.2012

Main Switch Power Supply 1 (Engine Start) Power Supply 2 Realtime Computer Patch Panel FlexRay CAN Plug-In TestBox 1 DSC Plug-In TestBox 2 LMV LMV-ECU + Actuator

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TESTSYSTEM. INTEGRATED TOOLS AND MODELS.

MANEUVER BASED VALIDATION, 19.09.2012

Engine-model CarMaker TestManager Diagnostic Flash Tool XCP on FlexRay FlexConfig INCA

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TESTSYSTEM. COMBINATION OF ECUS AND MODELS.

MANEUVER BASED VALIDATION, 19.09.2012

CarMaker-model

(vehicle-dynamics-model)

Transfer case (mounted LMV-ECU) DSC-ECU BMW engine-environment-model + engine control Residual-bus-simulation Flexray Gateway Behaviour model (LMV/DSC)

Gateway for signal-manipulation on flexray. Residual-bus-simulation to provide all necessary bus signals. Behaviour model (LMV/DSC): simplified model if one of the ECUs is not connected to the bus.

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INTEGRATION ENGINE-MODEL. BMW ENGINE-MODEL.

MANEUVER BASED VALIDATION, 19.09.2012

Compiled Simulink- model for CarMaker:

Layer: Communication via physical signals. Physical environment- model oft the engine. Soft- ECU

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INTEGRATION ENGINE-MODEL. GENERATION ECU-MODEL.

MANEUVER BASED VALIDATION, 19.09.2012

C-Code Matlab/ Simulink *.c …

Code-Generator

*.h

GCC-Compiler Generated C- Code

Sources for ECU

Compiler for ECU Soft-ECU: simulation- model for Simulink (based on Simulink S- functions and CarMaker specific librarys)

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MANEUVER BASED TESTS. CATALOG.

MANEUVER BASED VALIDATION, 19.09.2012

Typical maneuvers:

• Different levels of grip.
• Understeering.
• High axle load.

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MANEUVER BASED TESTS. DEVELOPING A MANEUVER.

MANEUVER BASED VALIDATION, 19.09.2012

Global settings: Setting global start values. Script-Control call for interaction with 3rd party tools. Global maneuver commands. Maneuver step settings: Teststeps (mini-maneuver). Realtime expressions (state

• bserver, end condition, operation

functions).

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MANEUVER BASED TESTS. DEVELOPING A TRACK.

MANEUVER BASED VALIDATION, 19.09.2012

2D view: 3D view: Creating a track step by step. Import track data. Import GPS data.

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MANEUVER BASED TESTS. TEST-EXECUTION.

MANEUVER BASED VALIDATION, 19.09.2012

IPGMovie: Starting on a hill with different levels of grip.

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MANEUVER BASED TESTS. ANALYSIS.

MANEUVER BASED VALIDATION, 19.09.2012

Instruments IPGMovie IPGControl

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TESTAUTOMATION. TESTMANAGER.

MANEUVER BASED VALIDATION, 19.09.2012

passed failed Test-report: XLS Test-results: Realtime-expression for signal evaluation criteria's . TestLog function to collect and display results (passed / failed). TestManager can be remote controlled and modified from ScriptControl or TCP/IP socket.

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BENEFITS.

MANEUVER BASED VALIDATION, 19.09.2012

OUTLOOK.

• Frontloading.
• Functional and system-tests.
• Regression tests for new software.
• Testautomation.
• Fewer resources needed (cars, test-track).
• Documentation of test results.
• Prepare test-system for the next generation of the xDrive-systems.
• Integration of the ECU model as AUTOSAR-component.
• Integration of DSC functions in CarMaker (no more ECU hardware is needed).

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THANK YOU FOR YOUR ATTENTION. QUESTIONS?

MANEUVER BASED VALIDATION, 19.09.2012