virtual ESC protection Design and implementation of new tool chain - - PowerPoint PPT Presentation

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virtual ESC protection Design and implementation of new tool chain - - PowerPoint PPT Presentation

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Design and implementation of new tool chain for virtual ESC protection Design and implementation of new tool chain for virtual ESC protection 01 Elektronische Fahrwerksysteme | EFS-34 chassis simulation 02 Tool chain requirement 03 Tool

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Design and implementation of new tool chain for virtual ESC protection

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Design and implementation of new tool chain for virtual ESC protection

Elektronische Fahrwerksysteme | EFS-34 chassis simulation

01

Tool chain requirement

02

Tool migration project

03

Results and expertise

04

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 2

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Elektronische Fahrwerksysteme EFS-34 chassis simulation

01

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 3

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Company at a glance

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus

Founded 2009 Location Ingolstadt/Wolfsburg Interest GIGATRONIK Group (51%) Audi Electronics Venture (49%) Employees 315 (April 2016) Company management Wilhelm Schmitt, Audi AG

  • Dr. Edwin Tscheschlok,

GIGATRONIK Group

Fields of activity

System integration Divisional Director - Markus Brummer System software development Divisional Director - Stefan Sollmann Interdisciplinary functions Divisional Director - Raimund Hofmayer IN/VE – Innovation management and pre-development Divisional Director - Stefan Sollmann

Company

4

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Audi Electronics Venture GmbH cooperation network

e.solutions

Das Joint Venture von Elektrobit und Audi

Prof. Gustafsson AEV cooperation platform

To increase the speed of automotive electronics innovations and developments, AEV enters into collaboration with technology companies.

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 5

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EFS-34 chassis simulation

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus

Real test drive Multibody systems Real-time capable vehicle dynamics Virtual test drive Environment simulation

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Tool chain requirement

02

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MLBevo crosslinking 1 MLBevo crosslinking 2 MLB 3

Scope [%]

50 100 150 200 250 300

Required test scopes in virtual test drive

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus

2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Topics transfer EFS

  • 2. Supplier

FlexRay B channel crosslinking of control units Assistance systems pACC crosslinking of chassis control unit Collective functions Movement manager

Today

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Scope [%]

50 100 150 200 250 300

Personnel and resources planning

2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Starting point Topics transfer EFS

Planning from 2011

Employees [%]

100 200 300

Personnel development

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ESC test field structure and standardisation

Standardisation of ESC cubes Universal simulator Structuring

  • f test area

Occupational Health and Safety Combination of dry/wet ESC cubes Connection to Audi IT Universal vehicle dynamics models variant reduction Implementation

  • f night run

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Scope [%]

50 100 150 200 250 300

Personnel and resources planning

2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Starting point Topics transfer EFS

Planning from 2011

Employees [%]

100 200 300 Option 1 planning without change to tool chain Option 2 planning with tool chain change

Personnel development

Adaptation required

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Tool chain requirements

Connection to Group standards (e.g. EXAM) Potential for certification Flexible & intuitive

  • peration

State of the art & standardised interfaces Professional tool environment

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Tool chain for business process outsourcing

Model management Project management Test- development Test- evaluation Test- execution

Internally developed Matlab environment for ESC simulation

  • No standardised interfaces
  • veDYNA as vehicle dynamics model
  • Error-prone, low stability

 30% night run abort rate

  • Over 400 functionally dependent scripts

 Time-consuming training and maintenance  Certification not possible

  • No connection to ODIS & EXAM

Tool chain requirements not met

HAP HIL workstation

Test automation

Simulation tool

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Test task Results management

Interface Control unit

Test automation

Target tool chain

Simulation tool

EXAM (Test control)

Framework

Vehicle dynamics model Manoeuvre development Manoeuvre control Model management

Requirements- based

Doors Interface simulator/ hardware ControlDesk Versioning Sub version MM6 Datalyzer ODIS

During development

Report creation Database result Test evaluation

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Catalogue specifications comparison

Simulationstool

Requirement Provider 1 Provider 2 Provider 3 Standard components models    Own models integration    dSPACE hardware platform    Signal manipulation    Measurement simulation    Adaptive driver    Animation    Manoeuvre creation (graphical)    Roads definition (graphical)    Process automation    FMI/FMU   

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Evaluation to prototypical implementation

Criterion Provider 1 Provider 2 Provider 3 Test creation effort (test catalogue #2) 100 % 50 % 25 % Test execution duration #2 100 % n.r. 15 % Test migration effort 100 % n.r. 35 % Development phase testing

  • n.r.

+

  • Tech. Support
  • +

+ Familiarisation time

  • +

Operability, usability

  • +

Model changes effort

  • n.r.

+ Debugging

  • n.r.
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n.r. = not rateable

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Financial expenditure for simulation tool migration

Provider 1 Provider 2 Provider 3 Licences 2 1 3 Migration expenditure 3 1 1

Ranking: 1 = best in comparison, descending order

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Internal migration costs 1 2 2 Maintenance per year 3 1 2

Total costs 2 1 3

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Scope [%]

50 100 150 200 250 300

Personnel and resources planning

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2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Starting point Topics transfer EFS

Planning from 2011

Employees [%]

100 200 300

Cost benefits

Option 1 no change Option 2 planning with tool chain change

Personnel development

Adaptation required

Migration start

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Tool migration project

03

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Test case migration for test catalogue #2 example

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6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 Migrated Evaluations Before = after Total

100% Test cases [%]

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EFS-34 chassis simulation tool migration status (27/04/2016)

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#01 #02 #03 #04 #05 #06 #07 #08 #09 #10 #11 #12 #13 #14 #15

6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4

100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

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Number of vehicle variants

Platform # Drivetrain Transmission Body Axles Steering Wheel sys Brake Engine Transmission Sensors Restbus A1 Conventional Four-wheel drive Automatic A2 conv. Four-wheel drive Manual gearbox B2 conv. Front Manual gearbox B3 PHEV Four-wheel drive Automatic B4 conv. Four-wheel drive Automatic D1 EV Four-wheel drive E1 conv. Four-wheel drive Automatic E2 PHEV M1a Four-wheel drive Automatic E3 conv. Four-wheel drive Automatic F1 MHEV Four-wheel drive Automatic J1 PHEV Four-wheel drive Automatic J2 conv. Four-wheel drive Automatic J3 MHEV Four-wheel drive Automatic J4 conv. Four-wheel drive Automatic J5 MHEV Four-wheel drive Automatic J6 conv. Four-wheel drive Automatic

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Results and expertise

04

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0 % 50 % 100 %

2016

3 4 5 6 7 8 9 10 11 12 13 14 15 16 CW 100 % 0 % 50 %

available resources

ESC simulators utilisation

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus

Productive test bench operation Total Resource coverage [%]

Migration: 30 % reduction in active simulators

2015

14 15 16 17 18 19 20 21 22 23 24 25 26 27 CW

Documented downtime not including setup time

effective utilisation approx. 40 % effective utilisation approx. 75 % average utilisation

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Figures, data, facts about ESC testing tool migration

EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus

Starting point As of 06/2016 Degree of automation low EXAM -> test control Test cases migrated 100 % 98.4 % Test bench operating time for catalogue #2 | #4 | #5 Veh.1 -- 71.9 23:28 h | 22:12 h | 15:59 h Veh.1 -- 75.5 12:04 h | 10:17 h | 08:23 h Processing time #2 | #4 | #5 40 h | 35 h | 40 h 40 h | 25 h | open Test creation duration with evaluation 100 % 50 %

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Today Scope [%]

50 100 150 200 250 300

Personnel and resources planning

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2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Starting point Topics transfer EFS

Planning from 2011

Employees [%]

100 200 300 Option 2 planning with tool chain change

Personnel development

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Central tool chain successes in ESC testing

Automation

  • Coding (vehicle installation state)
  • Writing of data records (vehicle parameters – tyre data)
  • Setting of adjustment channels (field data acquisition)

=> full coverage possible over weekend

  • Next step: Sequences of multiple successive catalogues
  • Objective: Time to full protection of an entire baseline

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Migration difficulties and challenges

  • Evaluation adjustment: phase-based to manoeuvre-based evaluation
  • Common manoeuvre description understanding
  • Creation of shared team knowledge
  • Continuous test operation (5 test executions during migration)
  • New software and interface adaptation during operation: Decision as to

whether required adjustment with fixed deadlines should be implemented in new or old tool chain

  • Spirit of transformation and active risk management

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Success factors

  • Test automation responsibility by experienced employees
  • Stringent migration specifications and mandatory use of new standards
  • Migration speed tracking
  • Adaptive support for decreasing migration speed
  • Free radicals: targeted direct/indirect support and kappa shifts
  • Tried and tested training programme: Tool chain immediately mandatory for all testers
  • Professional support for all participating software manufacturers (purchasing tools)
  • Great use of teams

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Thank you!

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