Engelbert Loibner AVL List GmbH

Gothenburg

October 24th, 2013

MULTI-DISCIPLINARY

SYSTEM SIMULATION –

HIGH QUALITY MODEL

REUSE IN POWERTRAIN

DEVELOPMENT

2

CO2 / Fuel Consumption

Real Driving Emissions

Broad Vehicle Portfolio

Shifting calibration tasks to an earlier development stage

Reduction of development costs €

Reduction of development time

Keep quality standards 1

Increased system complexity (EAS, OBD, Hybridization)

CHALLENGES IN THE POWERTRAIN DEVELOPMENT

New role of

simulation

KEY TRENDS ON OEM SIMULATION AND TESTING

3

1 With increased frontloading, office simulation takes over more functional

development tasks

Strength

Virtualization of

test beds

Delineation between office simulation, HiL and test bed is blurring as the

share of simulation increases 2

Model quality as

enabler

Model quality is in focus to be further enhanced – producing a high quality of

simulation results with quality processes likely known from HW prototyping 3

Cross-domain

perspectives

The future of simulation is driven by cross-domain perspectives, pushed for

by the vehicle domain, as key even for traditional domains like powertrain 4

Organizational /

cultural barriers

While the importance of all-encompassing data and model management is

well received, organization and culture become the huge barrier hard to take 5

Preference of

open solutions

The OEMs’ future requirements are to be met by new business models of

tool vendors for of open tools and envirenments 6

Source: Market interviews, Berylls Strategy Advisors analysis = In realization with most OEMs, high impact = Vision only

Based on ~40 market interviews conducted, 6 key-topics have been identified

Systems

Com-

ponents

OEM STRATEGIES – INTEGRATION DIRECTIONS

4

Within one organization, we discern four integration directions

B Horizontal integration

Across the process chain of design,

development, simulation, testing,

validation / calibration

C Cross-domain integration

Requiring collaboration of departments

E.g. for drive dynamics and energy

management

Source: Market interviews, Berylls Strategy Advisors analysis

CAD MiL/SiL/

HiL

Test

bed Road

Office

simula-

tion

Powertrain Chassis E/E

B

…

…

…

…

…

…

ADAS

Engine ECU

…

Driveline

Transmission

Engine

Mechanic

al syste

ms

Com

bustio

n / T

herm

od.

Flu

ids / A

ir flo

w

C

Vehicle

D Cross-expertise integration

Requiring collaboration of experts

E.g., for interactions of airflow /

thermodynamics / stability

Full

vehicle

Domains

D

A Vertical integration

From part / component to system or

full vehicle, including scalability of

models (e.g., 3D 1D)

Within one discipline, e.g. mechanical

or airflow or thermodynamics

A

THE NEW ROLE OF SIMULATION

Mastering speed and complexity with vehicle development processes centered around simulation.

This is leading to

model-based development, in which simulation and testing

are highly integrated.

6

AVL INTEGRATIVE AND OPEN DEVELOPMENT PLATFORM Power Train Engineering

Development Process & Process Tool Environment

Consistent, comparable results

Models

Evaluation

Data

Methods

Process

Design, Configuration, Performance Prediction

TestBed Testing

System Configuration

Detailed

Component

Design &

Analysis

Road Testing

HIL

Testing

MiL/SIL

Testing

Integration, Calibration, Performance Validation

Sub-System Layout

& Optimization

Re

al W

orl

d

Vir

tua

l W

orl

d

CONSISTENT, OPEN AND SCALABLE MODELS

7

CONSISTENT MODELS –

From Office to Lab to Road

Test Simulation

Knowledge

CONSISTENCY – Re-use models in various phases of the development process

8

Sub-system integration,

Hil function test,

Real-world test,

Calibration

0 10 20 30 40 50 60 70 80 90 100

CO

2 P

ote

nti

al (%

)

Concept potential,

Veh. Benchmark

Vehicle Concepts

Component testing:

engine, e-motor, battery,

…

Parameter study,

Comp. Matching,

System analysis

VEHICLE SIMULATION TODAY: APPLICATIONS ALONG THE DEVELOPMENT CYCLE

Components development,

Control functions implementation,

Shift pattern, Pre-calibration

SINGLE SYSTEM

PLANT MODEL

Realization / Implementation

Comp. Test Comp. Design

Sys. Test

In-Vehicle Test

Fleet Test

Sys. Design

Concept

Target

9

SYSTEM SIMULATION INTEGRATION – Engine Test Bed

AVL PUMA Engine Testbed

PUMA Open EMCON400

ISAC400

Adv. Sim. Interface, Signal Prep.,

Test Run Synch.

Load Control

RG/a, RG/v

Engine Dyno

Vortrag Wiesbaden 2013

Manheller

Consistent application of simulation models in hybrid powertrain development – From simulation to optimization to testbed

Wiesbaden – 22.10.2013

5th International Symposium on Development Methodology

Vortrag Wiesbaden 2013 Manheller

Controller

I1

I2

…

O1

O2

…

O1

Vehicle

O2

…

I1

I2

…

Consistent simulation environment - Approach

5th International Symposium on Development Methodology

Co-Simulation of vehicle-

and detailled HCU-model

Co-Simulation is used for

offline optimization of

operating-strategy

parameters

Simulation modells of

vehicle and HCU are

implemented in testbed-

environment

Rta-file serves as signal-

interface to testbed

Generic signal-linking on

testbed environment

Offline-Simulation (Office) Online-Simulation (Testbed)

Testbed environment

Vehicle

I1

…

C1 … C2 C7 C8 … …. … …

Controller

C3

C4

…

C1

C2

…

Vehicle.rta

Controller.rt

a C5

C6

…

C7

C8

…

C1

… …

C3

… … …

O2

O1

I2

I1

… …

O2

O1

I2

…

Optimization

I1

…

Vortrag Wiesbaden 2013 Manheller

Process chain - Modelling

5th International Symposium on Development Methodology

Vehicle

System

SubsystemVehicle

Drivetrain

Engine

Cockpit including driver

Analysis

Signal Interface Matlab

Signal Interface Testbed

Flange

Drivetrain

Engine

Cockpit including driver

Analysis

Signal Interface Matlab

Signal Interface Testbed

Flange

Offline-Simulation Testbed

Vortrag Wiesbaden 2013 Manheller

Engine-in-the-Loop at Weissach

5th International Symposium on Development Methodology

Vortrag Wiesbaden 2013 Manheller

Results of implementation on different plattforms

5th International Symposium on Development Methodology

0 100 200 300 400 500 600 700 800 900 1000 1100 1200Zeit [s]

velo

cit

y [

km

/h]

0

60

120

sta

te o

f ch

arg

e [

%]

40

50

60

en

gin

e s

peed

[rp

m]

[-]

0

2000

en

gin

e t

orq

ue [

Nm

] [-

]

0

200

400

sp

eed

el.

mach

ine [

rpm

] [1

/min

]

0

3000

torq

ue e

l. m

ach

ine [

Nm

] [-

]

-300

0

300

Offline-Simulation

Testbed-Simulator

Testbed

16

FRONTLOADED TEST METHODS –

From Road to Lab to Office

CONSISTENT MODELS –

From Office to Lab to Road

Test Simulation

Knowledge

CONSISTENCY – Bringing test and calibration to earlier development phases

17

Use Case Requirements

Specification,

Concept Analysis

Turbo Lag Analysis

Transmission

Durability

Prediction

Shift Quality

Optimization

Tip-in Calibration on

Engine Testbed

Engineering

Target

• Fuel economy

• performance

• emissions

• Engine

performance

• turbo charger

selection

Torque fluctuations,

accumulated damage

for component life

prediction

Virtual shift quality

calibration

Calibration of

dynamic vehicle

response to a tip-in

torque disturbance

Requ

. m

od

el

de

tail

leve

l Engine

Driveline

Vehicle

Control

Use

d S

olu

tion

Engine CRUISE

Maps

BOOST RT

Physical engine

CRUISE, BOOST RT

Maps, dyn. response

CRUISE, BOOST RT

Maps, dyn. response

PUMA ETB

Real engine

Driveline CRUISE

Kinematic / dynamic

CRUISE

Rotational dynamics

CRUISE

Detailed transmission

CRUISE

Detailed transmission

CRUISE

Detailed driveline

Vehicle CRUISE

Longitudinal

CRUISE

Longitudinal, tire slip

CarSim

Vehicle dynamics

CarSim

Vehicle dynamis

AVL VSM

Driveability vehicle

Control CRUISE and Matlab

Basic functions, maps

Matlab/Simulink

Basic ECU functions

Matlab/Simulink

Basic TCU functions

Matlab/Simulink

Extended TCU func.

Matlab/Simulink

Basic functions

SYSTEM SIMULATION RE-USE: USE CASES performed with an OEM

Sub-System Layout

& Optimization

System Configuration

Detailed Component

Design & Analysis

MiL / SiL / HiL TestBed Testing

ECU

FRONTLOADING ECU TIP-CALIBRATION AT OEM – ROAD APPLICATION PERFORMED ON ENGINE TESTBED

18

Vehicle dynamic

responses passed to

AVL Drive to score

drive quality

AVL-DRIVE

AVL-VSM simulates

vehicle dynamics

relevant for

driveability

AVL CRUISE simulates

the driveline from engine

output to wheel hubs.

AVL-VSM Speed /

Torque

connection

AVL PUMA

AVL CAMEO changes

the relevant ECU

parameters

AVL CAMEO

specifies the initial

speed and pedal

position and starts

Tip-In Event

AVL CAMEO gets the

measurement performed by

AVL Drive and stores the

results/scores.

AVL CAMEO

19

FRONTLOADED TEST METHODS –

From Road to Lab to Office

CONSISTENT MODELS –

From Office to Lab to Road

OPEN SYSTEM

Test Simulation

Knowledge

CONSISTENCY – Open for other environment

20 E.Loibner, AVL List GmbH, 2012

CRUISE INTEGRATION WITH OTHER TOOLS AND ENVIRONMENTS

Direct links have been established with major 3rd party codes, and other

software can be interfaced via MATLAB and C interfaces.

FMI (Dymola, …)

21

Systems Simulation Environment

Controller Development Environment

Controller

CONTROL FUNCTION DEVELOPMENT USING CRUISE AND MATLAB/SIMULINK

Controller Development Environment

Systems Simulation Environment

Plant Model

So

ftw

are

in

th

e L

oo

p

Mo

de

l in

th

e L

oo

p

22

CRUISE v2013 HIGHLIGHTS CRUISE FMI – Functional Mockup Interface

Example: MATLAB/Simulink Engine

FMI extends open model integration

capabilities among tools

FMI supports model exchange and co-

simulation as independent OPEN standard

developed as an Modelica Association Project

Example: Dymola HVAC Example: C-Code Based Battery

USER INTERFACE

SOLVER

FMI

External

Model

FMI Internal

Model

23

AVL InMotion

Host PC

Realtime PC

Co-Simulation

Test Catalogue, Automation,

Visualization

Powertrain

Vehicle, Driver, Env.

Controls

SYSTEM SIMULATION INTEGRATION – Co-simulation for Vehicle Energy Management

IPG CarMaker

24

OpEneR project: Optimal Energy Management & Recovery

Aim: Development of predictive driving control strategies & driver assistance

systems, that increase vehicle efficiency to reduce CO2 emissions, increasing

driving range & safety of electric vehicles, by using data from radar, video, GPS

navigation, car-to-infrastructure & car-to-car systems, …

Partners:

25

Vehicle Energy Management Simulation 3008 FEV E-4WD Concept

Baseline Vehicle is 3008 Hybrid4 transformed into Fully Electric 4WD vehicle. Front conventional internal combustion engine replaced with 2nd e-Machine. New larger battery package fitted. Bosch ESP®hev w/ vacuum booster is replaced by Advanced Regenerative Braking

System ESP®hev + iBooster. Accessories adapted (Heating, Cooling, Charging device, Cockpit HMI).

3008 Hybrid4 3008 OpEneR

26

Vehicle Energy Management Simulation Energy Management Development Process

Software Development Process – Technology Levels

Level 0 Level 1 Level 2 Level 3

Integration of Complex Subsystems

Powertrain, Subsystems … Car2x … … ESP®hev, iBooster

… Satellite Navigation

… Radar, Video

…

Sensing Traffic & Environment Conditions

Weather Cond.

Traffic Jams

Road Works

3D Road … Op

En

eR

Ve

hic

le D

eve

lop

me

nt

Simulation toolchain development for simultaneous engineering

27

Vehicle Energy Management Simulation Model & Sub-system Interface Definition

Vehicle

Testtrack

Sub-systems

HEVC_M1b/CALCULATION/EMM_PMU/VEH_ON

Printed 20-Dec- 2006 18:04:34

VEH_ON

en: Entry_VEH_ON();

du: During_VEH_ON()

du: F_Traction_Driver();

en = Entry_VEH_ON function

du = During_VEH_ON function

du = F_Traction_Driver function

ENG_OFF

ENG_STOPENG_START

ENG_RUN

OffC = ENG_StopC function

OffC = ENG_OffC function

runC = ENG_RunC function

startC = ENG_StartC function

Parameters for the HEV System are optimised, for each cycle; the parameters and maps

are inputvalues depending on the Course signal. The internal structure of the Statemachine

is not changed / varied.

[ ENG_OffC() ]

[ ENG_StartC() ]

2

[ ENG_RunC() ]

1

[ ENG_StopC() ]

[ ENG_RunC() ]Controller

Environment

Driver model

Sensors

Powertrain

Navigation

HMI Simulink model with CRUISE & SystemC model interfaces:

Info. exchange between various subsystems.

Incorporation of temporal behavior.

Signal exchange between sim. tools.

Consistency of signal features

Interface definition.

28

Vehicle Energy Management Simulation Energy Management

Optimum Torque Split E-Machines have temperature & voltage dependent efficiencies. Optimum torque split → efficient traction & regeneration. Potential torque distribution control algorithm determined offline. Usage of 1x e-Machine on low inclinations more efficient. Efficiency improvement with optimal torque distribution of up to 8%.

29 © 2013 AVL List GmbH AVL Advanced Simulation Technologies, Graz, Austria

IMPLEMENTING MODEL-BASED DEVELOPMENT BRINGS ITS OWN COMPLEXITIES AND PROBLEMS…

Simulation skills?

Model scalability?

Model availability?

Diversity & compatibility of tools?

…?

WE NEED AN

EFFICIENT APPROACH

30 © 2013 AVL List GmbH AVL Advanced Simulation Technologies, Graz, Austria

OUR TARGET: Support development with an integrative, open and consistent simulation approach,

enabling reuse

of high-quality models throughout development...

31 © 2013 AVL List GmbH AVL Advanced Simulation Technologies, Graz, Austria

… for powertrain system concept analysis, design and development:

IN THE OFFICE

ON THE ROAD

ON THE TEST BED

IN THE HIL ENVIRONMENT

P000000-7002-03 32 Confidential

APPLICATION EXAMPLE: VEHICLE ENERGY MANAGEMENT – THE ENGINE

Global Vehicle Model for Analysis of Transient Load/Driving Cycles

Cooling system

Vehicle

Speed

Engine Speed, Torque

Brake Request

Heat

Engine

Speed

Load Signal

Velocity

Temperature

Consumer Power (Pumps, Fan, etc.)

Torque

Speed

Control Strategy

Temperature

Cooling Request

Calibration

Parameters

map_1

…

map_2

Driving Cycle

60

0

30

Vehicle Model Engine Model

33 Real-time factor

0.1 0.01 1 10 100

Mo

del

dep

th

1D gas dynamics in crank angle resolution

Neural Network

Mean value gas path & representative cylinder in crank

angle resolution Mean value gas path &

surrogate cylinder

Map-based engine model

Predestined for MiL

& HiL application

(e.g. calibration)

Multi-physics models

Empirical models

0D gas dynamics & representative cylinder in crank

angle resolution

0D gas dynamics & cylinders in crank angle resolution

REALTIME ENGINE

ENGINE SIMULATION TODAY: SCALABLE ENGINE MODEL DEPTH FOR DESIGN AND CALIBRATION

34

PERFORMED BOOST RT ENGINE PLANT MODELS FOR MODEL-IN-THE-LOOP & HARDWARE-IN-THE-LOOP

1.4 L NA gasoline engine with VVT:

Driving cycle simulations and powertrain optimization

13 L Diesel engine with VTG turbocharger for commercial vehicle:

Driving cycle simulations and VTMS investigations

1.4 L gasoline engine with mechanical supercharging & VVT:

System simulation: engine – vehicle – ECS – VTMS)

Large engine 6 & 12 cylinder (> 80 L/cyl.) for ship propulsion:

MiL, development of ECS

Large dual fuel engine 6 cylinder (> 80 L/cyl.) for ship propulsion:

HiL on dSPACE platform

Large duel fuel engine (bore > 380 mm) for ship propulsion:

HiL on ETAS platform

1.6 L HSDI EU5 & EU6 engine with HP & LP EGR for passenger car:

HiL on dSPACE platform

10 L Diesel engine with 2 stage charging system & HP EGR (commercial vehicle & construction machine):

HiL on ETAS platform

2.8 L GDI engine with 2-stage sequential turbocharging & EGR

MiL & HiL on dSPACE platform

Engine for locomotive application with 2-stage turbocharging and EGR (asymmetric configuration)

HiL on ETAS platform

P000000-7002-03 35 Confidential

APPLICATION EXAMPLE: VEHICLE ENERGY MANAGEMENT – THE WHOLE SYSTEM

Global Vehicle Model for Analysis of Transient Load/Driving Cycles

Cooling system

Vehicle

Speed

Engine Speed, Torque

Brake Request

Heat

Engine

Speed

Load Signal

Velocity

Temperature

Consumer Power (Pumps, Fan, etc.)

Torque

Speed

Vehicle Model Engine Model

Control Strategy

Temperature

Cooling Request

Calibration

Parameters

map_1

…

map_2

Driving Cycle

60

0

30

VEHICLE ENERGY MANAGEMENT SYSTEM CONCEPT STUDY

Control Engine

Drivetrain + Chassis Cooling

Coolant / Oil temperatures Structure temperatures

Engine speed, friction Wall heat losses

Se

nso

rs

(T,

P,

etc

.)

Actu

ato

rs

(th

rott

le, S

C)

Ve

hic

le v

elo

city

Am

bie

nt te

mp

. G

ea

rbo

x f

rictio

n

Pu

mp

,

Fa

n p

ow

er

Accelerator pedal Brake, Clutch, Gear

SIMUALTION MODEL VALIDATION WITH MEASUREMENTS

NEDC:

Start with cold system conditions

38 © 2013 AVL List GmbH AVL Advanced Simulation Technologies, Graz, Austria

OUR NEXT STEP:

AVL CRUISE M Multi-disciplinary system simulation

Our vision:

Support development with an integrative, open and

consistent simulation approach enabling reuse of high-quality

models throughout development.

For powertrain system design, analysis and development

- in the office

- In a HiL environment

- On the test bed

- On the road

39 © 2013 AVL List GmbH AVL Advanced Simulation Technologies, Graz, Austria

CRUISE M MULTI-DISCIPLINARY SYSTEM SIMULATION

Realtime Engine

After-

treatment

Scalable physical modeling depth

and speed

Consistent plant modeling from

concept to calibration and testing

Single platform for all AVL

powertrain realtime models

Open interfaces to 3rd party tools

supporting standards (FMI)

Flexible model customization

VEHICLE ENERGY MANAGEMENT SYSTEMS: From multiple tools …

Aftertreatment Engine

Drivetrain + Chassis Cooling / Lubrication

Coolant / Oil temperatures Structure temperatures

Engine speed, friction Wall heat losses

Hea

t flo

w,

em

issio

ns

Te

mp

era

ture

Ve

hic

le v

elo

city

Am

bie

nt te

mp

. G

ea

rbo

x f

rictio

n

Pu

mp

,

Fa

n p

ow

er

Ambient temperature

Time [s]

Spee

d [

km

/h]

80

0Time [s]

Spee

d [

km

/h]

80

0

… to a modular package, …

Aftertreatment Engine

Drivetrain + Chassis Cooling / Lubrication

Coolant / Oil temperatures Structure temperatures

Engine speed, friction Wall heat losses

Hea

t flo

w,

em

issio

ns

Te

mp

era

ture

Ve

hic

le v

elo

city

Am

bie

nt te

mp

. G

ea

rbo

x f

rictio

n

Pu

mp

,

Fa

n p

ow

er

Ambient temperature

… to highly convenient system simulation in a single environment, …

… open for other tools, …

Flowmaster

Cameo Model

AmeSim

Matlab/Simulink

Kuli

Functional Mock-up

AVL DRIVE

CarMaker

CarSim

Custom C-Code

Time [s]

Spee

d [

km

/h]

80

0Time [s]

Spee

d [

km

/h]

80

0

44

Test System

PUMA Open

• Component Test

• Calibration

• Integration Test

• Validation

Vir

tua

l W

orl

d

Re

al W

orl

d

System Analysis

• System concepts & specification

• Control functions concept/design

• Virtual function test & pre-

calibration

... reusable anywhere in a model based development process.

HiL System

• Function test

• Model based

calibration

InMotion

CarMaker

CONSISTENT AND SCALABLE MODELS

CRUISE M APPLICATION AREAS

CRUISE M APPLICATION AREAS

CRUISE M APPLICATION AREAS

48

Use Case Requirements

Specification,

Concept Analysis

Turbo Lag Analysis

Transmission

Durability

Prediction

Shift Quality

Optimization

Tip-in Calibration on

Engine Testbed

Engineering

Target

• Fuel economy

• performance

• emissions

• Engine

performance

• turbo charger

selection

Torque fluctuations,

accumulated damage

for component life

prediction

Virtual shift quality

calibration

Calibration of

dynamic vehicle

response to a tip-in

torque disturbance

Requ

. m

od

el

de

tail

leve

l Engine

Driveline

Vehicle

Control

Use

d S

olu

tion

Engine CRUISE

Maps

BOOST RT

Physical engine

CRUISE, BOOST RT

Maps, dyn. response

CRUISE, BOOST RT

Maps, dyn. response

PUMA ETB

Real engine

Driveline CRUISE

Kinematic / dynamic

CRUISE

Rotational dynamics

CRUISE

Detailed transmission

CRUISE

Detailed transmission

CRUISE

Detailed driveline

Vehicle CRUISE

Longitudinal

CRUISE

Longitudinal, tire slip

CarSim

Vehicle dynamics

CarSim

Vehicle dynamis

AVL VSM

Driveability vehicle

Control CRUISE and Matlab

Basic functions, maps

Matlab/Simulink

Basic ECU functions

Matlab/Simulink

Basic TCU functions

Matlab/Simulink

Extended TCU func.

Matlab/Simulink

Basic functions

SYSTEM SIMULATION RE-USE: USE CASES performed with an OEM

Sub-System Layout

& Optimization

System Configuration

Detailed Component

Design & Analysis

MiL / SiL / HiL TestBed Testing

49

SYSTEM SIMULATION RE-USE: USE CASES performed with an OEM New Situation introducing CRUISE M

Sub-System Layout

& Optimization

System Configuration

Detailed Component

Design & Analysis

MiL / SiL / HiL TestBed Testing

Use Case Requirements

Specification,

Concept Analysis

Turbo Lag Analysis

Transmission

Durability

Prediction

Shift Quality

Optimization

Tip-in Calibration on

Engine Testbed

Engineering

Target

• Fuel economy

• performance

• emissions

• Engine

performance

• turbo charger

selection

Torque fluctuations,

accumulated damage

for component life

prediction

Virtual shift quality

calibration

Calibration of

dynamic vehicle

response to a tip-in

torque disturbance

Requ

. m

od

el

de

tail

leve

l Engine

Driveline

Vehicle

Control

Fu

ture

So

lution

Engine CRUISE M Engine

Maps

CRUISE M Engine

Physical engine

CRUISE M Engine

Maps, dyn. response

CRUISE M Engine

Maps, dyn. response

PUMA ETB

Real engine

Driveline CRUISE M Driveline

Kinematic / dynamic

CRUISE M Driveline

Rotational dynamics

CRUISE M Driveline

Detailed transmission

CRUISE M Driveline

Detailed transmission

CRUISE M Driveline

Detailed driveline

Vehicle CRUISE M

Longitudinal

CRUISE M Driveline

Longitudinal, tire slip

CarSim

Vehicle dynamics

CarSim

Vehicle dynamis

AVL VSM

Driveability vehicle

Control CRUISE M Matlab

Basic functions, maps

Matlab/Simulink

Basic ECU functions

Matlab/Simulink

Basic TCU functions

Matlab/Simulink

Extended TCU func.

Matlab/Simulink

Basic functions

50 © 2013 AVL List GmbH AVL Advanced Simulation Technologies, Graz, Austria

Es muss nicht dieses

Bild sein, aber eine

Bergstrasse

Es muss nicht dieses

Bild sein, aber ein

Büro