FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS

FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS Tech Day AVL Nordiska, November 19th, 2014 Thomas R. Weck AVL Powertrain and Hybrid System FUNCTIONAL ...
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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS Tech Day AVL Nordiska, November 19th, 2014 Thomas R. Weck AVL Powertrain and Hybrid System

FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS OVERVIEW

1 – WHAT IS THE PROBLEM? 2 – FUNCTIONAL TESTING

3 – PROJECT EXAMPLE 4 – SUMMARY & OUTLOOK

F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 1 – WHAT IS THE PROBLEM?

HCU

DC/AC 1

DC/AC 2

DC/AC 3

EM2 MOT

Starter 12V

Gasoline ENG

HV Battery

HCU

DC/AC

Starter 12V EM1 GEN

HV Battery

AMT

ECU / HCU

HV Battery

EM3

Diesel ENG IL4 2,0 HSDI Driver Interface

DC/AC

 Increasing Complexity Rising number of vehicle variants High number of topologies & architectures New vehicle functionalities (e.g. E-Drive)

Vehicle

Hybrid CL Cooling

EM2

DC/DC

DCT7

EM1: BSG

Driver Interface

TFSI Hybrid Cooling Vehicle IL4; 1,4L; EU V

DC/DC

CL EM2

Driver Interface

el. Oil Pump VW Jetta Hybrid

Vehicle Hybrid Cooling

DC/DC

 Divergent Vehicle Targets Performance vs. Fuel Efficiency Emissions vs. Drivability Diversity of Market Demands  Heterogeneous Development Environment Cross Domain Collaboration Development Quality & Risk  Product Lifecycle & Product Development Reduced product lifecycle & product usage Reduced development time & effort for single variant

F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 1 – WHAT IS THE PROBLEM? WORST CASE ... HOW DID THAT HAPPEN ? HOW DOES CURRENT TESTING / VERIFICATION / VALIDATION COVER ALL POSSIBLE OPERATING AND USAGE CONDITIONS ? HAS THE COMPLEXITY OF THE VEHICLE SYSTEMS BEEN CONSIDERED (PHEV/HEV, Driver Assist, Chassis Controls)? IS THAT COMPLEXITY REFLECTED IN POWERTRAIN TESTING ?

Recall actions in US market (2012-2013) increase from 15.5 to 20.5 Mio.

DO TRADITIONAL USAGE PROFILES / TEST CYCLES COVER ALL OPERATION CONDITIONS ?

CAM (Center of Automotive Management), March 2014

General Motor’s recalled 29 Mio. Vehicles in

WHAT IS THE TEST COVERAGEthe AND IS IT REPRESENTATIVE ? first half of 2014 FORTUNE Magazine, August 15, 2014

HOW ARE AUTOMOTIVE STANDARD CONSIDERED (ISO 26262) ?

F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 1 – WHAT IS THE PROBLEM? Test Mileage: 2007: 24 Million km

2009: 36 Million km März 2009

2020: 250 Million km

The biggest hurdle is validation to confirm that the system does not cause failures. One has to execute 250 million test kilometers states the Bosch executive director.

???

Source: Mercedes Benz

Source: HEISE March 1st, 2014



Integrated functionalities between PT, ESP, Steering, Lighting, Suspension, Infotainment



Autonomous Driving & Parking



Car2Car (C2C) & Car2Infrastructure (C2I) for warning systems, early detection of traffic condition

F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 1 – WHAT IS THE PROBLEM?

TraditionalMechanical View – Mechanical Focus (Durability) Focus (Durability) NEW: Functional Focus (Coverage – Causal Dependence) 

Variation of driver profiles depending onthe customer  Activates, operates and stress PT systemusage

 Interactsdrive with other vehicle systems Mix of representative cycles (city, motorway, Customer mountain)  Reacts to changes in environmental conditions



Customer Load Profile

Load  Changes the load profiles for components  Consideration of environmental condition (humidity, Profile Prevents/reduces component damage temperature, altitude) 

Provides additional limp home capabilities

BALANCED = components designed to meet customer needs 

Component Component Load/Stress Load/Stress

Unforeseen interactions? -> undefined conditions



Definition of mechanical load profiles (e.g. speed, torque, vibration) and affection of components



Limited operational interaction (consider breakdown to Powertrain & Vehicle component level) System Operation



Evaluation of damage relevant conditions

F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 2 – FUNCTIONAL TESTING SoP (Vehicle Launch)

System (Vehicle) Targets & Boundaries

Synergies Product Definition, Test Methodology

 PT Design/Specification  Definition of Targets & Usage  Definition of Interactions (Vehicle, System, Environment)  Systematic Planning of Integration, Verification and Validation  Definition of Preventive Action

Integration, Validation

 PT Test Specification  Definition of Use and Test Cases  Definition of Test Systems and Test automation  Systematic Execution, Documentation and Proof  Support of Corrective Action

AVL Know-how in Hybrid Development, Tools and Methodology to improve Integration and Testing

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 2 – FUNCTIONAL TESTING Test Requirements

Quality History

Hybrid System

Environment & Drive Cycles

VIRTUAL

Product Definition  Analyze of physical Structure,  Definition of Routes Components and Functions  Data Conversion  Find operating States/Transitions  Data Export  Define Test Cases

Test Bed

Test Plan

F. Illmeier / Engineering and Technology Powertrain Systems

Finalize Test Plan & Confirm in Simulation 8

FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 2 – FUNCTIONAL TESTING Information … in Definition

Vehicle Targets Usage

System Model

Requirements

System States Control Factors

WHERE is the Information Generated & Managed ? & HOW is the Information Used ?

Component -Parameters -Functions

Test View

… in Preparation

… in Execution

Test Cases

*Model Based and Systems Engineering for PT F. Illmeier / Engineering Technology Powertrain Systems

Testing

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 2 – FUNCTIONAL TESTING Test Environment Cameras

Actuators

In

Failure Insertion Unit

Out

Sensors

Diagnostic System

Failure Insertion Unit

xCU

+-

CAN

FIU CAN

New Automation...  Test Initialization,  Test Execution,  Data Recording,  Test Confirmation,  Re-Initialization On the Test Bed

Limit Observation Test Bed Automation and Test Management

CAN

Battery Emulator

 Additional actuators & cameras to observe and input into the driver interface  Battery conditioning to speed up the test initialization (achieve SOC faster)

Electrical Load Unit

 Interaction with vehicle diagnostic system to analyze test results and re-initialize after failures  Stress- & failure insertion on test bed, to confirm system reaction with E/E failures F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 3 – PROJECT EXAMPLE: Series Production Support OEM

Review

Use Case (UC)

Test Case (TC)

AVL

Step 1

APPLICATION OF TEST METHOD Step 2

Test Analysis & Evaluation

Test Execution

Test Plan

Step 1 Analysis of function and usage to define relevant test cases Step 2 Optimization of test plan to perform efficient and effective testing

F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 3 – PROJECT EXAMPLE: Series Production Support

F. Illmeier / Engineering and Technology Powertrain Systems



Representative PT function testing including stresses, failures and interfaces to other vehicle systems



Extensive maneuver catalog optimized to run 24-hours in 3-shift operation (1000 function tests per week)



Definition, planning, execution and reporting of tests based on clearly defined step-by-step process (MBSE)



Reproducible test conditions to avoid uncertainty caused by environment or usage



Successfully executed to support hybrid vehicle series production launch of Japanese vehicle manufacturer



Direct linkage with hybrid calibration to achieve drivability, performance, FE while maintaining reliability and safety 12

FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 4 – SUMMARY & OUTLOOK What are the Benefits for AVL Customers • AVL has extensive experience in hybrid PT development & testing as well as test systems & test methodology • AVL is currently the only company with SOP project experience to offer such testing • AVL synergies and experience with maneuver base testing, failure insertion, battery system conditioning, driver interface (HMI), functional safety to be performed in different test environments

• On-going AVL customer project to extend methodology into PHEV diagnostics and optimization of operation strategy

AVL Engineering Services in PT Development F. Illmeier / Engineering and Technology Powertrain Systems

AVL Test Beds and Test Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 4 – SUMMARY & OUTLOOK TEAADS – Test Environment for ADAS and Automated Driving Systems General motivation of TEAADS: Increasing extension of driver assistance systems for (semi-) automated driving raises the need of automated test tools and tool chains in order to ensure functional safety, robustness, and reliability.

F. Illmeier / Engineering and Technology Powertrain Systems

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FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS AVL CONTACT INFORMATION Thomas R. Weck Hybrid Powertrain Integration [email protected]

AVL POWERTRAIN WORLD APP www.avl.com

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