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Taking you to the next level apply & Innovate 2012 , IPG Technology Conference, Karlsruhe, 21 and 22 June 2012 iTPMS-in-the-Loop Solution for Comprehensive Validation Tasks for indirect Tire Pressure Monitoring Systems According to the

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Taking you to the next level

IPG Automotive GmbH 19.09.2012 1

iTPMS-in-the-Loop Solution for Comprehensive Validation Tasks for indirect Tire Pressure Monitoring Systems According to the New ECE-R 64 Regulation

Oliver Blanco-Hague, Coralie Dandre, MICHELIN Manufacture Française des Pneumatiques Charles Miquet, Bernhard Schick, IPG Automotive GmbH

„apply & Innovate 2012“, IPG Technology Conference, Karlsruhe, 21 and 22 June 2012

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IPG Automotive GmbH 19.09.2012 2

  • Introduction
  • Direct and indirect TPMS systems
  • TPMS Test procedure according to ECE R-64
  • Requirements for indirect TPMS HIL application
  • iTPMS-in-the-Loop solution for comprehensive Validation Tasks
  • Conclusion

TPMS-in-the-Loop Solution

Agenda

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IPG Automotive GmbH 19.09.2012 3

Initial Situation

  • Today ~ 15% of new vehicles are equipped with Tire Pressure Monitoring Systems

(TMPS)

  • TPMS will be mandatory by the new regulation ECE-R 64 from 11/2012 for vehicle in

categories M1 (<3.5 T) and N1 equipped with single tyres

  • Direct and indirect TPMS are existing and could be used
  • OEMs are motivated to push to the indirect TPMS systems in order to saving money

TPMS Will Be Mandatory by ECE-R 64 from 11/2012

Introduction

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IPG Automotive GmbH 19.09.2012 4

Challenges

  • Indirect TPMS are cheaper but lead to extreme testing effort
  • Huge numbers of vehicle variants, loads, driving conditions, road conditions, tire

variants etc. must be approved to guarantee a robust system

  • Sophisticated simulation tools for virtual test drive can support to reduce time and

money within the whole validation process.

  • A powerful simulation platform, a comprehensive test concept as well as reliable

models – especially a reliable tire model – are needed

TPMS Will Be Mandatory by ECE-R 64 from 11/2012

Introduction

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IPG Automotive GmbH 19.09.2012 5

Technology

  • Tire pressure sensor mounted either on the inside
  • f the rim or on the end of the valve stem inside the

tire or outside.

  • Information transmitted wirelessly to the receiver

module using radio frequency communication

Direct TPMS Systems

Direct and Indirect TPMS Systems

Characteristics

  • Higher costs
  • Absolute pressure values, sometimes also the tire

temperature

  • Battery of the sensor has to be changed for such

systems

Source : Continental Source : VDO Source : Dunn Tire

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IPG Automotive GmbH 19.09.2012 6

Technology

  • Indirect TPMS are embedded as ESC function
  • TPMS function uses the wheel speed sensor

signals to detect a possible under-inflated tire

Indirect TPMS System

Direct and Indirect TPMS Systems Wheel speed sensor (*4)

ESP

Characteristics

  • Cheaper
  • No absolute pressure values, only relative
  • have to be reset by the driver once the tires are checked and all

pressures adjusted correctly

  • sensitive to the influences of different tires and external influences

like road surfaces and driving speed or style

ESP ABS ASR VDC VAFs

TPMS

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IPG Automotive GmbH 19.09.2012 7

Detection Methods of the Indirect TPMS

Direct and Indirect TPMS Systems Wheel speed sensor (*4)

ESP

Circumference Effect

  • Pressure loss only in one tire detectable
  • Position of un-inflated tire couldn’t be

exactly detected

  • Tire slip influences the detection quality

Un-inflated tire detection by wheel circumference comparison Different tire pressure Lead to different roll radius Which lead to different wheel speeds

Source : Michelin

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IPG Automotive GmbH 19.09.2012 8

Detection Methods of the Indirect TPMS

Direct and Indirect TPMS Systems

Un-inflated tire detection using spectrum analysis Different tire pressure Frequency Effect

  • Eigen-frequency is tire individual 35-50Hz
  • Shift of eigen-frequency could be detected
  • Position of inflated tire could be detected
  • Pressure loss of more tire are detectable

Tyre mode shapes f

A

Frequency

P

Eigen-frequency oscillation due to Inflation pressure variation

Source : Michelin

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IPG Automotive GmbH 19.09.2012 9

Ambient and road condition

  • Ambient temperature between 0 C and 40 C
  • Road test surface with good grip and dry during the test

Vehicle conditions

  • Usual load condition
  • Vehicle speed
  • Speed range from 40 km/h and 120 km/h for puncture test
  • Speed range from 40 km/h and 100 km/h for the diffusion test and the malfunction

test

  • The whole speed range shall be covered during the test.

TPMS Test Procedure According to ECE R-64

Regulation ECE 64

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IPG Automotive GmbH 19.09.2012 10

  • Drive the vehicle for a minimum of 20 minutes within

the speed range and with an average speed of 80 km/h (+/-10 km/h)

TPMS Test Procedure According ECE R-64

Regulation ECE 64

  • At the discretion of the Technical Service, where the

driving test is undertaken on a track (circle/oval) with only turns in a single direction, then the driving test should be equally split (+/-2 minutes) in both directions

  • Within the 5 minutes of completing the learning phase,

measure the warm pressure of the tyre(s) to be deflated. The warm pressure shall be taken as the value Pwarm. This value will be used for subsequent operations. Warm-up Procedure and learning phase

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IPG Automotive GmbH 19.09.2012 11

TPMS Test Procedure According ECE R-64

Regulation ECE 64

  • Low tyre pressure detection phase
  • TPMS shall illuminate the warning signal

< 60 minutes after reducing the pressure

  • Low tyre pressure detection phase
  • TPMS shall illuminate the warning signal

< 10 minutes after reducing the pressure Puncture test

  • Deflation phase
  • Deflate one of the vehicle's tyres within 5

min until Pwarm -20% (Ptest) or min. of 150 kPa

  • Stabilization period 2-5 minutes

Diffusion test

  • Deflation phase
  • Deflate all four tyres within 5 minutes until

Pwarm - 20% - 7 kPa (Ptest)

  • Stabilization period 2-5 minutes
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IPG Automotive GmbH 19.09.2012 12

TPMS Test Procedure According ECE R-64

Regulation ECE 64

  • Failure detection
  • TPMS shall Illuminate the warning signal

< 10 minutes after generating the failure Malfunction test

  • Test procedure
  • Simulate a TPMS malfunction, for example, by

disconnecting the power source to any TPMS component, or disconnecting any electrical connection between TPMS components, or installing a tyre or wheel on the vehicle that is incompatible with the TPMS.

  • Drive the vehicle for up to 10 minutes
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IPG Automotive GmbH 19.09.2012 13

A huge validation effort is needed due to the large number of variants

  • Tire / wheel combination
  • Load conditions
  • Vehicle variants
  • Chassis variants
  • Speed
  • Ambient conditions (temperature)

Context : a Huge Variety of Configurations

Requirements for Indirect TPMS HIL Application

  • Roads
  • Uneven
  • Even
  • Cross-country winding roads
  • Autobahn
  • …
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IPG Automotive GmbH 19.09.2012 14

Software & Model Environment

  • Vehicle
  • Driver and maneuver
  • Road
  • Analysis tools
  • Test automation

Requirements : a Powerful HIL Simulation Platform

Requirements for Indirect TPMS HIL Application

HIL Tool Environment

  • FailSafeTester tool
  • Diagnostic tool support
  • CCP/XCP and flash tool
  • CAN/FlexRay/LIN tools
  • HIL instruments
  • …

HIL Testbench for ESP

  • Simulation of all I/O signals
  • CAN Communication
  • Hydraulic signal acquisition
  • Accurate wheel speed sensor

module

  • …
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IPG Automotive GmbH 19.09.2012 15

  • Tire Pressure modeling
  • Physical pressure effect
  • Tire pressure, which is function of tire temperature
  • as input quantity of the tire model (not only parameter)

Requirements : a Reliable Tire Model

Requirements for Indirect TPMS HIL Application

Time Wheel speed [rpm]

f

A

Frequency

P

A reliable tire model is required

  • High accurate physical tire model with realistic behavior.
  • Temperature signal of inflation medium
  • Tire eigen-frequency modelling, which is pressure dependent
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IPG Automotive GmbH 19.09.2012 16

TameTire model structure

TameTire for iTPMS-in-the-Loop

iTPMS-in-the-Loop

TameTire Data Base

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IPG Automotive GmbH 19.09.2012 17

Wheel Speed Sensor Signal Monitoring

iTPMS-in-the-Loop

Wheel speed Pulse IPG M400 Wheel Speed sensor signal

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IPG Automotive GmbH 19.09.2012 18

iTPMS-in-the-Loop Solution

iTPMS-in-the-Loop

Thermo-mechanical tire model

  • Temperature effect
  • Pressure effect

TameTire Data Base

f

A

Frequency

P

Tire eigen-frequency module Software modules User GUI

IPG M400

Hardware component

t I (A)

Pulse Shift Wheel Speed signal

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IPG Automotive GmbH 19.09.2012 19

  • TPMS system are mandatory for passenger cars from 11/2012 according to

the ECE R-64

  • Indirect TPMS are cheaper but lead to extreme testing and validation effort
  • A powerful simulation platform, a comprehensive test concept as well as

reliable models – especially a reliable tire model – are needed

  • iTPMS-in-the-Loop module fulfills this sophisticated validation task for indirect

TPMS

iTPMS-in-the-Loop : the Solution for Indirect TPMS Validation

Conclusion