FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS

FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS

Tech Day AVL Nordiska, November 19th, 2014

Thomas R. WeckAVL Powertrain and Hybrid System

F. Illmeier / Engineering and Technology Powertrain Systems 2


OVERVIEW

1 – WHAT IS THE PROBLEM?

2 – FUNCTIONAL TESTING

3 – PROJECT EXAMPLE

4 – SUMMARY & OUTLOOK




Increasing ComplexityRising number of vehicle variantsHigh number of topologies & architecturesNew vehicle functionalities (e.g. E-Drive)

Divergent Vehicle TargetsPerformance vs. Fuel EfficiencyEmissions vs. DrivabilityDiversity of Market Demands

Heterogeneous Development EnvironmentCross Domain CollaborationDevelopment Quality & Risk

Product Lifecycle & Product DevelopmentReduced product lifecycle & product usageReduced development time & effort for single variant

VehicleDriver Interface

HV BatteryDC/AC 1

DC/DCHybrid Cooling

DC/AC 2HCU

Gasoline ENGEM1

GEN

EM2

MOT

DC/AC 3

EM3


HV BatteryDC/AC

DC/DCHybrid Cooling

HCU

Diesel ENG

IL4 2,0 HSDI

AMT

Starter 12V

CL EM2

EM1:

BSG

TFSI

IL4; 1,4L; EU V

EM2

DCT7

VW Jetta

HybridCL

Starter 12V

el. Oil

Pump


HV BatteryDC/AC

DC/DCHybrid Cooling

ECU /

HCU

http://www.nies.ch/switzerland/air/2003-05-31/index.de.php/1

http://www.nies.ch/switzerland/air/2003-05-31/index.de.php/1


WORST CASE ... HOW DID THAT HAPPEN ?

Recall actions in US market (2012-2013)

increase from 15.5 to 20.5 Mio.CAM (Center of Automotive Management), March 2014

General Motor’s recalled 29 Mio. Vehicles in

the first half of 2014FORTUNE Magazine, August 15, 2014

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 ?

DO TRADITIONAL USAGE PROFILES / TEST CYCLES COVER ALL

OPERATION CONDITIONS ?

WHAT IS THE TEST COVERAGE AND IS IT REPRESENTATIVE ?

HOW ARE AUTOMOTIVE STANDARD CONSIDERED (ISO 26262) ?




März 2009

???

Test Mileage:

2007: 24 Million km

2009: 36 Million km

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

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

• Autonomous Driving & Parking

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

Source: HEISE March 1st, 2014



http://www.spiegel.de/fotostrecke/fotostrecke-18056-6.html

http://www.spiegel.de/fotostrecke/fotostrecke-18056-6.html


Traditional View – Mechanical Focus (Durability)

Variation of driver profiles depending on customer usage

Mix of representative drive cycles (city, motorway,

mountain)

Consideration of environmental condition (humidity,

temperature, altitude)

BALANCED = components designed to meet customer needs

Definition of mechanical load profiles (e.g. speed, torque,

vibration) and affection of components

Limited operational interaction (consider breakdown to

component level)

Evaluation of damage relevant conditions

ComponentLoad/Stress

CustomerLoadProfile

Activates, operates and stress the PT system

Interacts with other vehicle systems

Reacts to changes in environmental conditions

Changes the load profiles for components

Prevents/reduces component damage

Provides additional limp home capabilities

Unforeseen interactions? -> undefined conditions

ComponentLoad/Stress

CustomerLoadProfile

Powertrain & VehicleSystem Operation

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



7



Product Definition,Test Methodology

Integration,Validation

SoP(Vehicle Launch)

System (Vehicle)Targets & Boundaries

Synergies

PT Design/Specification

Definition of Targets & Usage

Definition of Interactions

(Vehicle, System, Environment)

Systematic Planning of Integration,

Verification and Validation

Definition of Preventive Action

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 Methodologyto improve Integration and Testing




Product Definition

Test Bed

VIR

TU

AL

Quality

History

Hybrid

SystemEnvironment &

Drive Cycles

Definition of Routes

Data Conversion

Data Export

Analyze of physical Structure,

Components and Functions

Find operating States/Transitions

Define Test Cases

Finalize Test Plan

& Confirm

in Simulation

Test

Requirements

Test Plan




WHERE is the Information

Generated & Managed ?

&

HOW is the Information

Used ?

Information

Usage

Component

-Parameters

-Functions

System States

Control

Factors

Vehicle

Targets

Test Cases

RequirementsSystem Model

Test View

… in Definition

… in Preparation

… in Execution

*Model Based Systems Engineering for PT Testing




Battery

Emulator

+ -

CAN

xCU

CAN

Diagnostic System

InO

ut

Failure

Insertion

Unit

Sensors

Actuators

FIU CAN

Test Bed

Automation

and Test

Management

Limit Observation

Additional actuators & cameras to observe and input into the driver interface

Battery conditioning to speed up the test initialization (achieve SOC faster)

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

New

Automation...

Test Initialization,

Test Execution,

Data Recording,

Test Confirmation,

Re-Initialization

On the Test Bed

Failure Insertion Unit

Electrical Load Unit

Cameras

Test Environment



3 – PROJECT EXAMPLE: Series Production Support

Use Case (UC)Review Test Case (TC)OEM

AVL

Step 1

Step 2

Test PlanTest Analysis & Evaluation

Test Execution

APPLICATION OFTEST METHOD

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



3 – PROJECT EXAMPLE: Series Production Support

• 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




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 safetyto be performed in different test environments

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

AVL EngineeringServices inPT Development

AVL Test Bedsand Test Systems




14

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.

15


AVL CONTACT INFORMATION

Thomas R. WeckHybrid Powertrain Integration

[email protected]

AVL POWERTRAIN WORLD APP

www.avl.com

FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS

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