maneuver based validation of bmw xdrive variants by using
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MANEUVER BASED VALIDATION OF BMW xDRIVE VARIANTS BY USING VIRTUAL - PowerPoint PPT Presentation

19.09.2012 Matthias Prebeck, Dr. Peter Rissling; BMW Group Michael Folie; IPG Automotive MANEUVER BASED VALIDATION OF BMW xDRIVE VARIANTS BY USING VIRTUAL VEHICLE INTEGRATION AND HIL TEST METHODS. IPG TECHNOLOGY CONFERENCE, SEPTEMBER 18 -19,


  1. 19.09.2012 Matthias Prebeck, Dr. Peter Rissling; BMW Group Michael Folie; IPG Automotive MANEUVER BASED VALIDATION OF BMW xDRIVE VARIANTS BY USING VIRTUAL VEHICLE INTEGRATION AND HIL TEST METHODS. IPG TECHNOLOGY CONFERENCE, SEPTEMBER 18 -19, KARLSRUHE. Freude am Fahren

  2. AGENDA. • Basics xDrive. • Testsystem. • Integration engine-model. • Maneuver based tests. • Testautomation. • Benefits and Outlook. MANEUVER BASED VALIDATION, 19.09.2012 Page 2

  3. BASICS xDRIVE. ACTIVE 4X4-SYSTEM. DSC (Master): ECU: DSC Computation target torque with respect to the driving sit. Send-out target torque on communication bus. Com. Bus LMV (Actuator): ECU: LMV Receive target torque and actuate clutch. Securing torque accuracy over temperature and lifetime. Requirements xDrive:  Maximum traction.  BMW-typical driving characteristics.  Reduced fuel consumption deficite. All advantages of a 4x4 car without the typical disadvantages. MANEUVER BASED VALIDATION, 19.09.2012 Page 3

  4. BASICS xDRIVE. 4X4 FUNCTIONS IN LMV-ECU. Signal conditioning Bussignals: Bussignals: Actual torque, Target torque, Computation Guardmodel … of internal Wheel speeds , … Abrasion- variables Degradation Torque model (thermal impact) and fail-safe controller (oil, coating) logics Diagnostics Sensors, Terminals (Current, U bat , GND) Control: current + mechanics MANEUVER BASED VALIDATION, 19.09.2012 Page 4

  5. BASICS xDRIVE. LATEST MODELS WITH xDRIVE. 09/2010 09/2009 07/2012 06/2010 5-Series 3-Series 7-Series 5-Series GT 2009 2010 2011 2012 2013 09/2009 09/2011 09/2010 11/2012 X1 6-Series 1-Series X3 MANEUVER BASED VALIDATION, 19.09.2012 Page 5

  6. TESTSYSTEM. HIL-PLATTFORM. Main Switch Power Supply 1 (Engine Start) Power Supply 2 Realtime Computer Patch Panel Plug-In TestBox 1 DSC FlexRay Plug-In TestBox 2 LMV CAN LMV-ECU + Actuator MANEUVER BASED VALIDATION, 19.09.2012 Page 6

  7. TESTSYSTEM. INTEGRATED TOOLS AND MODELS. CarMaker TestManager Engine-model XCP on FlexRay FlexConfig Diagnostic INCA Flash Tool MANEUVER BASED VALIDATION, 19.09.2012 Page 7

  8. TESTSYSTEM. COMBINATION OF ECUS AND MODELS. Flexray Gateway CarMaker-model (vehicle-dynamics-model) BMW engine-environment-model + engine control Residual-bus-simulation Transfer case DSC-ECU Behaviour model (LMV/DSC) (mounted LMV-ECU) 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. MANEUVER BASED VALIDATION, 19.09.2012 Page 8

  9. INTEGRATION ENGINE-MODEL. BMW ENGINE-MODEL. Compiled Simulink- model for CarMaker: Soft- ECU Layer: Communication via physical signals. Physical environment- model oft the engine. MANEUVER BASED VALIDATION, 19.09.2012 Page 9

  10. INTEGRATION ENGINE-MODEL. GENERATION ECU-MODEL. … C-Code Matlab/ Simulink Code-Generator *.c Generated C- *.h Code Compiler for ECU GCC-Compiler Sources for ECU Soft-ECU: simulation- model for Simulink (based on Simulink S- functions and CarMaker specific librarys) MANEUVER BASED VALIDATION, 19.09.2012 Page 10

  11. MANEUVER BASED TESTS. CATALOG. Typical maneuvers:  Different levels of grip.  Understeering.  High axle load. MANEUVER BASED VALIDATION, 19.09.2012 Page 11

  12. MANEUVER BASED TESTS. DEVELOPING A MANEUVER. Global settings: Setting global start values. Script-Control call for interaction with 3 rd party tools. Global maneuver commands. Maneuver step settings: Teststeps (mini-maneuver). Realtime expressions (state observer, end condition, operation functions). MANEUVER BASED VALIDATION, 19.09.2012 Page 12

  13. MANEUVER BASED TESTS. DEVELOPING A TRACK. 2D view: 3D view: Creating a track step by step. Import track data. Import GPS data. MANEUVER BASED VALIDATION, 19.09.2012 Page 13

  14. MANEUVER BASED TESTS. TEST-EXECUTION. IPGMovie: Starting on a hill with different levels of grip. MANEUVER BASED VALIDATION, 19.09.2012 Page 14

  15. MANEUVER BASED TESTS. ANALYSIS. Instruments IPGControl IPGMovie MANEUVER BASED VALIDATION, 19.09.2012 Page 15

  16. TESTAUTOMATION. TESTMANAGER. Test-results: passed failed Test-report: XLS 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. MANEUVER BASED VALIDATION, 19.09.2012 Page 16

  17. BENEFITS. • Frontloading. • Functional and system-tests. • Regression tests for new software. • Testautomation. • Fewer resources needed (cars, test-track). • Documentation of test results. OUTLOOK. • 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). MANEUVER BASED VALIDATION, 19.09.2012 Page 17

  18. THANK YOU FOR YOUR ATTENTION. QUESTIONS? MANEUVER BASED VALIDATION, 19.09.2012 Page 18

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