A View on Tool Interoperability Solutions at Ford Motor Company
Dr. Ahsan Qamar Vehicle Controls & Systems Engineering
Research & Advanced Engineering Ford Motor Company [email protected]
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Research and
Advanced Engineering
Contributors
• Kurt Osborne (Electrical & Electronics Systems Engineering)
• Eileen Davidson (Powertrain Engineering)
• Bill Bailey (Vehicle System Analysis)
• George Walley (Vehicle Controls & Systems Engineering)
• Chris Davey (Vehicle Controls & Systems Engineering)
Slide Title
Research and
Advanced Engineering 3
Distributed Development
cost
profit
mass
reliability
active safety robustness
maneuverability regulatory compliance
Fuel consumption
Passive safety production rate
geometry
Systems
Engineering
Production
Project
Management
Software
Engineering
Powertrain Controls
CAD/CAE
• Vehicle Controls
Slide Title
Research and
Advanced Engineering 4
Old Landscape
Functional Concepts Stakeholder/Attribute Requirements
Detailed Design & Analysis
FMEA
Supply Chain Quality Production Plan Calibration Support & Maintenance
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Research and
Advanced Engineering 5
Old Landscape
Functional Concepts Stakeholder/Attribute Requirements
Detailed Design & Analysis
FMEA
Supply Chain Quality Production Plan Calibration Support & Maintenance
Some Partial Integration Mostly Information Silos
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6
Current Landscape VSEM Supported Integration
Software Release Software Update SW System
Development
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7
Global Features reference hierarchical
decomposition of derived Functions
• The VSEM Feature- Function Architectural
Framework supports: • Software System Feature development lifecycles
that are decoupled from traditional hardware
component based engineering.
• Engineering Work Products to be immediately
accessible and re-usable based on Feature
mapping.
VSEM – Global Feature Dictionary
Slide Title
Research and
Advanced Engineering 8
VSEM Supported Software Delivery
Powertrain Controls
Climate Controls
Chassis Controls
EESE
Infotainment
Active Safety
Production Software
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Research and
Advanced Engineering 10
Goal 1: Inform About Dependencies
Systems
Engineering
Production
Project
Management
Software
Engineering
Powertrain Controls
• Vehicle Controls
CAD/CAE
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Research and
Advanced Engineering 11
Goal 2: Manage Change Across Disparate & Heterogeneous Models
Systems
Engineering
Production
Project
Management
Software
Engineering
Powertrain Controls
CAD/CAE
• Vehicle Controls
D D
D
D D
D
D D
D
D D
D D
D
D
D D
D
D
D D
D
D D
D
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Research and
Advanced Engineering 12
Goal3: Make Decisions Based on Information from Multiple Data Sources
System Engineering Analysis CAD/CAM
Decision Maker
Software Development
Changing an ECU
Requirements coverage Solution to overlapping concerns
Overall fuel Efficiency
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Research and
Advanced Engineering 13
Goal 4: Facilitate Data Exchange About Managed Artifacts Between Different Enterprise Systems
Calibration Requirements
Test
Slide Title
Research and
Advanced Engineering 14
Current State of Data Exchange Standards
• Limited to exchange of geometric and configuration data
– STEP AP203 (Mechanical), AP 209 (Structural), AP 210 (Electro-Mechanical), AP 239 (PLCS), JT – visualization
– STEP AP 233 – systems engineering –> slow uptake
• Product data exchanged in native file formats, informal communication or document-based
• Standards mostly focus on how to move data from one place to the other
• Not (always) necessary to migrate data
– OSLC – web of engineering data -> lightweight
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Research and
Advanced Engineering 16
Powertrain Controls
• Most of the code done in-house – A mix of model-based code generation and hand code
• Gas powertrain – Driver software (which is hardware dependent) is supplier-developed
– Interface specifications provided to the supplier (document-based)
• Diesel powertrain – Supplier-built software (COTS)
– Mostly model-based, but also hand code
• Gasoline Models are not shared with suppliers, but Diesel’s are
• Migrating towards AUTOSAR in the near future
Gas Engine Powertrain Controls
Diesel Powertrain Controls
Supplier
Supplier
Interface Spec
Code
Interface Spec
COTS software
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Research and
Advanced Engineering 18
Advantages with AUTOSAR
• Integration of new features on existing ECU’s
• Tier-1 application software and OEM owned SW will co-exit on an ECU
• Transferring SW components between ECUs, supporting flexible architectures
• A HW independent RTE, based on SW components, with standardized data exchange
Runtime Environment (RTE)
Basic SW
Application Software
SW-C 1 SW-C 2
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Research and
Advanced Engineering 19
Electrical & Electronic Systems Engineering (EESE)
• Climate Control
– Model-based design -> can leverage AUTOSAR components
• Infotainment
– UML/SysML modeling is employed with Rational Rhapsody
– UML model shared with the supplier -> code generated from UML to C
• Supplier is provided both models and documents providing interface specifications
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Research and
Advanced Engineering 21
Comparison of Integration Approaches
point-to-point single shared meta-model
Hybrid
Domain Vocabulary Common Vocabulary
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Research and
Advanced Engineering 22
Example 1: Failure Mode Avoidance (FMA)
• FMA work is time consuming with specifications duplicated to FMA tools
• FMA tools disconnected from core design tools
• Mandatory FMA Rubric is needed
• Interoperability with FMA tools
– Automatic import, export, and document generation
Slide Title
Research and
Advanced Engineering 23
Solution
Reliability & Robustness Checklist (RCL) Failure Modes Effects Analysis (FMEA)
MBSE System Modeling Tool (SysML)
Process Diagram (P-Diag) Lean Failure Mode Avoidance (LFMA)
Failure Mode Avoidance Work
Contributors: Walley, G., Meinhart, M., Corral, M., Nefcy, B., Davison, M., Stanek, J.
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Research and
Advanced Engineering 24
Interoperability Supported Through SysML
P-Diagrams
FMEAs
RCLs
Boundary Diagram
SysML Models LFMA
VSEM - Teamcenter
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Research and
Advanced Engineering 25
Example 2: Integrated Vehicle Analysis
• Vehicle Model composed of various HW and Controller domain models
– Modelica for HW models
– Simulink for controller models
Integrated Vehicle Function & Attribute
Analysis (IVA) Capability
Integrated Vehicle Function & Attribute
Analysis (IVA) Capability
Electrical
Supply Loads Dist
H-ware Control
HMI
Thermal - Aero
Cool Front End Underhood
H-ware Control
Thermal - Aero
Cool Front End Underhood
H-ware Control
Climate
A/C Heat Cabin
H-ware Control
Climate
A/C Heat Cabin
H-ware Control
Powertrain
Eng Trn Dln
H-ware Control
Exh Fuel
Powertrain
Eng Trn Dln
H-ware Control
Exh FuelVeh Sys Control
Control
Arch Alg
Veh Sys Control
Control
Arch Alg
Chassis
Veh Ste Brk
H-ware Control
WhlSusp
Chassis
Veh Ste Brk
H-ware Control
WhlSusp
Coupled data &
analysis interface
Addresses
top of ‘Vee’
Dynamics NVH Performance
Comfort
Drivability
Energy
Safety
Emissions
Cross-Domain Cross-Attribute /
Cross-Function
Domain Sub-domain Model architectures,
models, data
Contributor: Bailey, W.
Slide Title
Research and
Advanced Engineering 26
Integrated Vehicle Analysis - Process
Start from a common Vehicle Reference Architecture in SysML
Add analysis-specific I/O and model content to create a Specialized Analysis Architecture
From this architecture, use custom model transformations to generate model templates with predefined interfaces in Simulink and Modelica.
Domain model developers then add content to the model templates
If I/O changes are required, they must come from the shared SysML model
Finally, models are integrated into a vehicle model and used to perform a system-level analysis
Slide Title
Research and
Advanced Engineering
Example 3 : Hybrid Approach - Models as Graphs
Requirements CAD Geometry
Model
Physical
Architecture
x y
u v
Pattern
Cross-Model Relations
Variable Bindings Implict
(inferable)
Herzig, S., Qamar, A., Paredis, C. , Inconsistency Management in MBSE, GPDIS 2014
Slide Title
Research and
Advanced Engineering
Mediation Between Multiple Vocabularies
Base
Vocabulary
Domain Voc. #1
Domain Voc. #2
Domain Voc. #n
Domain
Voc. #3
Language Voc. #4
Language Voc. #3
Language
Voc. #2
Language Voc. #1
Language Voc. #m
e.g., Requirements
e.g., DOORS
e.g., SysML
Inference Paths
e.g., Rule 1
e.g., Rule 2
Herzig, S., Qamar, A., Paredis, C. , Inconsistency Management in MBSE, GPDIS 2014
Slide Title
Research and
Advanced Engineering 29
Key Takeaways
• Data exchange standards have limited uptake
• Moving data Vs creating information traces
• Tool interoperability supporting product life-cycle and system engineering work is vital
• Reasoning over distributed sources with traceability
• Scalability of point-to-point vs single shared meta-model vs hybrid integration approaches
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