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
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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
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Integrated functionalities between PT, ESP, Steering, Lighting, Suspension, Infotainment
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Autonomous Driving & Parking
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Car2Car (C2C) & Car2Infrastructure (C2I) for warning systems, early detection of traffic condition
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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
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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
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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
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Representative PT function testing including stresses, failures and interfaces to other vehicle systems
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Extensive maneuver catalog optimized to run 24-hours in 3-shift operation (1000 function tests per week)
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Definition, planning, execution and reporting of tests based on clearly defined step-by-step process (MBSE)
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Reproducible test conditions to avoid uncertainty caused by environment or usage
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Successfully executed to support hybrid vehicle series production launch of Japanese vehicle manufacturer
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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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