Symposium on Automotive Embedded Systems Development Yokohama, Oct 9th, 2015

Virtualization as key for efficient development of embedded automotive systems Chances and challenges of XiL Dr. Tobias Kreuzinger, Senior Manager Test & Validation, ETAS K.K. 1

Public | ETAS/ETS-Yh | Oct 2015 | © ETAS GmbH 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Efficient development of embedded automotive systems Agenda

Agenda

2

1

Challenges in test and validation of ECU software

2

Today’s development style

3

Virtualization as enabler for efficient validation

4

Chances and Challenges of XiL

5

Summary

Public | ETAS/ETS-Yh | Oct 2015 | © ETAS GmbH 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Efficient development of embedded automotive systems Agenda

Agenda

3

1

Challenges in test and validation of ECU software

2

Today’s development style

3

Virtualization as enabler for efficient validation

4

Chances and Challenges of XiL

5

Summary

Public | ETAS/ETS-Yh | Oct 2015 | © ETAS GmbH 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Efficient development of embedded automotive systems Rapid increase of system complexity − Automotive trends drive complexity − Rapidly increasing costs for internal development and external resources Engine Management

Vehicle Motion

Management

Transmission Management

Battery Management

Shorter innovation cycles Brake Management

Consumption and emission requirements

Number of labels Degree of freedom Calibration effort

12 10

Increased interdomain connectivity

9 SWComponent 2

SWComponent 3

AUTOSAR Interface

AUTOSAR Interface …

AUTOSAR Interface

Basic Software Module (BSM)

8 5

ECU Hardware

4

1997

9.000

4.00 0

New layered standard architecture

12.000

Microcontroller Abstraction

2002 2004

16.000

AUTOSAR-RTE

25.000

SWComponent 1

2007

2010

Engine control complexity

New functions and variants

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Efficient development of embedded automotive systems Challenges in validation

How to ensure comprehensive validation under a large variety of possible driving scenarios?

5

Traffic

City

Extreme conditions

Country road

Highway

Mountain road

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Efficient development of embedded automotive systems Statements from European OEM

of development time no real prototypes are available

of engineers get evaluation experience in the global vehicle 6

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Efficient development of embedded automotive systems Distributed development requires validation alternatives

Geographically distributed co-development between OEM and suppliers further limits hardware-based software validation due to …

TIER2

TIER1

OEM

Software Lorem Models2

Hardware

Integration of Components

System Integration

… time-intensive and costly ECU prototype transportation

7

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Efficient development of embedded automotive systems Agenda

Agenda

8

1

Challenges in test and validation of ECU software

2

Today’s development style

3

Virtualization as enabler for efficient validation

4

Chances and Challenges of XiL

5

Summary

Public | ETAS/ETS-Yh | Oct 2015 | © ETAS GmbH 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Efficient development of embedded automotive systems Today: Hardware-based validation only in late development stages

Feedback loops in the standard V-model … Specification, design & implementation

System & ECU network

Design Integration, validation and calibration

Correct

Integrate

Validate

Extreme lead time

Sub-system & ECU network

Very long lead time

Long reaction time

ECU

60% of development time no prototypes available

Function / Composition

Unit / Component

Only … require often costly hardware prototypes for validation purposes … result in long lead times through late validation 9

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10%

of engineers get access to real car

Efficient development of embedded automotive systems Development and maintenance cycles in OEM and Tiers

Long and costly feedback loops in the standard V-model Plant modeling based on real engine data

Mass production

Correct

Integrate

Validate

OEM

Development cycles to improve control model

Design

Trouble at the market

Tier 1

Maintenance cycles for after market

10

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Efficient development of embedded automotive systems Test and validation as major software development cost driver

Test and validation significantly impact ECU software development costs „Empirical rule of 10” – The costs of rectifying a fault, increase by a factor of 10 with every passed phase before it is detected.

of software engineering costs are attributed to test and validation

Rectification Cost Factor

40%

10,000

Ref: GM

8,000 6,000 4,000 2,000 -

Requirement Design Implementation Validation

Production

Product Engineering Phase Target: Early error identification and elimination through frontloading 11

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Efficient development of embedded automotive systems Agenda

Agenda

12

1

Challenges in test and validation of ECU software

2

Today’s development style

3

Virtualization as enabler for efficient validation

4

Chances and Challenges of XiL

5

Summary

Public | ETAS/ETS-Yh | Oct 2015 | © ETAS GmbH 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Efficient development of embedded automotive systems Virtualization as enabler for efficient validation

Solution approach “Virtualization” − Frontloading through early execution of debugging, validation, verification and calibration without complete target hardware being available. − Object under test and its environment can be simulated through different phases of the V-cycle. − Target is to increase development efficiency by • reducing development and reaction time • reducing development costs • increasing quality

13

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Efficient development of embedded automotive systems From HiL (Hardware-in-the-Loop) to XiL (X-in-the-Loop)

OR

EMS

MCU

Engine

BMS

E-motor

(Configuration example) Real ECU 14

TCU

Battery pack

Transmission

(Real-time) Real-time simulation Soft ECU for rest-bus simulation or full Virtual ECU

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Efficient development of embedded automotive systems Customer reference

Full Vehicle Simulator, Asian OEM, Passenger Cars, 15 ECUs Customer need: − Integration of ECUs from different Tier1s to verify distributed functions, communication, and diagnostics − Scalable solution to maximize utilization along all vehicle families, also to be used for component test Solution: − Switching between Soft-ECUs for rest-bus simulation and real ECUs − Integration of plant-models of different simulation tools (SimulationX, AVL-Cruise, ETAS/Simulink) − Error-safe and convenient variant handling

− Test process consulting 15

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Efficient development of embedded automotive systems MiL / SiL / HiL system integration platform architecture MiL: Closed-loop simulation of control and plant models on Windows PC SiL: Virtual ECUs can be integrated replacing control models HiL: Real ECUs can be integrated replacing virtual ECUs

FMU = Functional Mockup Unit

Plant/ Control

FiL/HiL

FMU connector Communication layer Integration & simulation platform with visualization & automation

MiL

SiL

HiL Virtual ECU

16

COSYM Real ECU

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Efficient development of embedded automotive systems The XiL-mapping in the V-model

17

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Efficient development of embedded automotive systems Agenda

Agenda

18

1

Challenges in test and validation of ECU software

2

Today’s development style

3

Virtualization as enabler for efficient validation

4

Chances and Challenges of XiL

5

Summary

Public | ETAS/ETS-Yh | Oct 2015 | © ETAS GmbH 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Efficient development of embedded automotive systems Virtualization as enabler for efficient validation

Enable earlier feedback loops on all integration levels … Specification, design & implementation

Virtual integration, validation and calibration

Design

Integration, validation and calibration

Correct

System & ECU network

Validate

Benefits

Sub-system & ECU network

− Detect defects as early as possible

ECU

Software

Module

… through model-based design as well as virtual validation and pre-calibration 19

Integrate

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− Reduce overall test, validation, and calibration costs − Reach better testcoverage − Simplify exchange of development artefacts btw. OEMs and Tiers

Efficient development of embedded automotive systems So what’s the problem?

Lack of compatibility between tools and development artifacts Coding (Interfaces/Structure)

Plant-Models

Programming Tools & Compilers

Test Automation

Test Systems

… cause huge manual overhead for migration, refactoring, and assuring consistency 20

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Efficient development of embedded automotive systems Standardization

ETAS bets on three important standards to enable systems virtualization:

AUTOSAR enables virtualization of the ECU and easy exchange of Software artefacts

Standard for model exchange and co-simulation of simulation models via FMI*

Re-use of test cases by decoupling test automation software from the test system. (ASAM XiL)

FMI: functional mockup interface

21

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Efficient development of embedded automotive systems Virtualization as enabler for efficient validation

With standards, truly seamless virtual validation is possible, Specification, design & implementation System & ECU network

Test-case Virtual integration, validation and database calibration

Design

Integration, validation and calibration

Test Automation Tool

Correct

Sub-system & ECU network

ECU

Software

Module

i.e. reuse of tools, models, and test-cases of each stage without manual efforts

23

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Integrate

Validate

Efficient development of embedded automotive systems Other challenges ahead

Availability of the right data and the right models remains a challenge Availability of data for parameterization of models − prototypes are only available in late development phases − accessibility of crucial quantities − accuracy of data – right measurement equipment

Selection of the right plant model: MiL through HiL − variable step solver vs. fixed step solver (real-time capability) − physical vs. mathematical/data-based

− required computation power − use-case for the model and required complexity, accuracy, and validity

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Efficient development of embedded automotive systems Levels of plant-model complexity

4 – Performance 3 - Functional 2 - Standard 1 - Basic

25

• Ultra high fidelity models for calibration, also for complex sub-systems (e.g. exhaust, combustion)

• High end performance testing • Quantitatively correct model behavior • Test-bench data for parameterization of models

• Extended Vehicle Functionality • Qualitatively correct model over wide operation range • Parameterization based on physics and vehicle key data

• Basic Vehicle Functionality • Basic Closed-Loop setup (main control loops) • Adequate vehicle acceleration behavior (steady state)

• Hardware Emulation for I/O Test • Open-Loop stimuli from basic vehicle driving behavior

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Model Accuracy = Costs / Effort

5 – Calibration

• Function Calibration Environment

Efficient development of embedded automotive systems Challenges of virtualization

The Break-Even for Virtualization How to increase the ratio of virtualization?

Cost/ Effort

Plant Model

Prototype

Break-Even

− Modularity and re-use of component or sub-system models over several development cycles − Verified and validated models for a wide operating range

85% of tests 1 Basic

26

2 Standard

3 Functional

4 System Readiness

5 Calibration

Complexity

− Consistent data − New ways of user-friendly and semi-automatized model generation, e.g. ASCMO

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Efficient development of embedded automotive systems Virtualization use-case example: Model-based calibration (DoE) ASCMO @ Hyundai*

LABCAR (HiL) as a Virtual Vehicle for Calibration

Facts and Figures

Advantages by using ETAS ASCMO

 >2.5% global fuel/CO2-reduction  ASCMO modeling algorithm shows much higher accuracy then the compared to an existing mature conventional physical models for system simulation calibration for one of their latest  Optimal ratio of data-No./model quality  high efficiency increase engines  Easy tool handling / good usability also for inexperienced users  Less than 700 measurements on a test bed (~2 days) were necessary to achieve this * Results published in MTZ Worldwide April 2015, Volume 76, Issue 4 pp 24-29

27

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Efficient development of embedded automotive systems Agenda

Agenda

28

1

Challenges in test and validation of ECU software

2

Today’s development style

3

Virtualization as enabler for efficient validation

4

Chances and Challenges of XiL

5

Summary

Public | ETAS/ETS-Yh | Oct 2015 | © ETAS GmbH 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Efficient development of embedded automotive systems Summary

Virtualization is the key for frontloading development tasks: − Virtual and HW-based ECUs are validated seamlessly in same tool chain

− Standards and compatible tools are THE prerequisite for efficient virtualization − Support efficient cooperation between OEM and suppliers − Larger number of engineers can get their hands on the “virtual vehicle” − More driving scenarios can be validated in early development phases  Increased quality at reduced effort / development costs

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Symposium on Automotive Embedded Systems Development Yokohama, Oct 9th, 2015

THANK YOU FOR YOUR ATTENTION

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