Dr. Ulrich Lauff, Dr. Kai Pinnow, and Dipl.-Ing. Florian Schmid. New Tools and Methods for Validation and Calibration

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1 Special Reprint from HANSER automotive 10/2015 Dr. Ulrich Lauff, Dr. Kai Pinnow, and Dipl.-Ing. Florian Schmid New Tools and Methods for Validation and Calibration Mastering complex vehicle systems reliably Oktober 2015 Jahrgang 14 15, Infineon Technologies Sichere ICs für autonomes Fahren Softing Automotive Standardisierte Diagnose für ODX und OTX ETAS Validierung und Applikation leicht gemacht AM_2015_10_AM_Titel [Print]_${ }.indd :21 ETAS GmbH Borsigstraße Stuttgart Germany Phone: sales.de@etas.com Special Reprint Carl Hanser Verlag, Munich All rights reserved, including reprinting, photographic or electronic reproduction, as well as translation.

2 New Tools and Methods for Validation and Calibration The validation and calibration of networked systems demand new tools and methods: Isolated test series at the test bench and in the vehicle are no longer sufficient to optimize and assure the behavior of complex systems during all kinds of operating conditions. To meaningfully supplement them and to fully utilize their possibilities, ETAS has developed new solutions for the integration of several tests within one test bench or during one road test. Figures: ETAS; scandinaviastock Fotolia.com 2 HANSER automotive 10 / 2015 Carl Carl Hanser Verlag, München Munich

3 Figure 1: A test vehicle equipped with the ES800 measurement system during the final configuration stage. The system time-synchronously records signals of ECUs, vehicle buses, networks, and measurement devices in the vehicle. The complete measurement is recorded by a data logger. Engineers can use the wireless capability of the system to remotely configure the measurement. At the end of the test drive, the recorded data can be retrieved from the storage medium for analysis. Figures: ETAS Measurements for validation and calibration of vehicle systems are performed at the test bench and in the vehicle. The number of diverse measurements and the data volume of single measurements depend on the number and the range of system functions, the dependencies between the functions, the number of diverse operating conditions and driving situations, as well as specific characteristics of sensors and actuators. The measuring expenditure differs across projects with the number of applied vehicle and system variations. Measure all In the past, isolated measurements were often performed to answer a single question. For predicting and mastering the behavior of complex systems such as modern high-tech combustion engines, hybrid gears, or advanced brake and driver assistance systems, this approach would not be enough: It would be an immense advantage to combine as many measurement tasks as possible. This means to measure all in one run at the test bench or in the vehicle. With this approach, diverse measurement parameters can be correlated, depending functions can be optimized, and complex defect characteristics can be understood. At the same time, measuring results, e.g., for OBD approval, can be documented seamlessly. Economically, it also makes sense to use test benches and test vehicles most efficiently by integrating as many measurement tasks as possible into one test. This leads to the requirement of complete and time-synchronous recording of measurement signals from diverse sources for measurements in vehicles. In advanced driver assistance systems these sources are for example sensors such as stereo cameras and radars generating huge amounts of raw data during the drive, which have to be processed by the ECUs in real-time. Synchronous recording of measurement data with a high rate For the recording of measurement data in a vehicle, ETAS offers a solution on the basis of INCA, the new product family ES800, and the new, real-time capable FETK-Trace ECU interface [1]. With this solution, signals of electronic controls can be recorded at high rates synchronously to signals of vehicle buses and networks (Figure 1), requiring minimal ECU resources. Big Data goes Automotive With this substantial amount of high quality data recorded by the described solution, valuable information on the behavior of complex electronic vehicle systems can be gained. In order to easily reuse the measurement data, immense amounts of measurement data must be sorted by relevant characteristics, e.g., object of investigation, experimental vehicle, environment, and projects. For this purpose, Big Data technologies, which were developed for the internet, can be applied effectively. The efficient user interface accesses powerful computer clusters, data bases, navigation and selection mechanisms, search algorithms, as well as visualizations and enables engineers to use and re-use measurement data for their purposes. For the development and the operation of Big Data systems for vehicle-related data, ETAS closely cooperates with diverse Bosch departments to bundle existing com-» HANSER automotive 10 /

4 Figure 2: EHANDBOOK provides a new format for interactive, graphical documentation of electronic controls. petences for core issues such as test planning, performance and transport of measurement data, data management, data analysis, and reporting. Modeling of complex systems on the basis of measurement data On the basis of measurement data, the behavior of complex systems can be precisely modeled, analyzed, and optimized at the PC by means of ETAS ASCMO [2]. The tool can predict and optimize for example fuel consumption and pollutant emissions of complex combustion engines in dependence of rotational speed (rpm), load, as well as all engine-driven variables. For the calibration of engine ECUs for instance, characteristic maps for injection and ignition can be calculated, which account for the best compromise between minimum pollutant emissions and minimum fuel consumption. ETAS ASCMO supports a multitude of use cases and offers a wide range of functions including visualizations and tools for model evaluation as well as powerful optimization algorithms. In addition, the tool simplifies the demanding task to identify the measuring points, which are necessary to characterize the system behavior. Deep knowledge of the system and special mathematical know-how is not required to build ETAS ASCMO models: The models, which precisely display the behavior of complex systems, are generated automatically by means of modern statistic learning processes. Standardized, automated, and documented calibrations Through the use of numeric optimization and simulations, the efficiency of calibrating vehicle systems can be significantly increased. However, some tasks, such as assessing calibration quality and fine tuning, can only be done during a road test. Calibration engineers need suitable instruments to process these calibration tasks in the vehicle in a systematic manner. The knowledge of calibration experts can be documented in a structured way by means of ETAS INCA-FLOW models and can be passed to other users: With this tool, calibration engineers can autonomously model graphically complex calibration processes in the form of flow process charts. In addition, recurring cycles can easily be automated. In this way, other users can be led through complex steps of specific calibrations. Automotive manufacturers and ECU suppliers HANSER automotive 10 /

5 worldwide are using INCA-FLOW successfully to standardize the calibration process in their companies [3]. Interactive ECU documentation For the calibration of vehicle systems, engineers rely on the proper documentation of ECU functions. Typical ECU documentations contain between 10,000 and 20,000 pages, which are traditionally delivered in PDF-format. EHAND- BOOK provides a new format for the documentation of electronic controls, which enables an interactive, graphical display of functions and signal flows (Figure 2). The graphical representation makes it much easier to understand certain interactions. When needed, relevant details of a function can be merged into one view with one click. Navigation to relevant contents and contextual display of additional information of variables are achieved through powerful search functionality and an integrated database. From various source data, a flexible, adaptable process generates an EHANDBOOK container with ECU documentation. For that purpose, models from ETAS ASCET or Simulink are transformed into new, interactive graphics. Also C code can be displayed in form of the graphical EHANDBOOK models! To reference the generated ECU documentation, calibration engineers use EHANDBOOK-NAVIGATOR. The tool supports the user with an intelligent search and zoom functionality, which offers a quick overview of the system but also enables deep diving into the details. EHANDBOOK-NAVIGATOR can be combined easily with the INCA measurement and calibration tool. In this case, users can import relevant measurement and calibration variables automatically from the EHANDBOOK documentation into their experiments and conversely dynamically display the values of measurement variables, which are used in the experiment, in EHAND- BOOK-NAVIGATOR. ETAS is expanding the solution for interactive ECU documentation in close alignment with Robert Bosch GmbH as a pilot customer. For Bosch customers, EHANDBOOK documentation of their ECUs is already available on request. Independently, some automotive manufacturers are already using this new solution for the documentation of their content. tool solutions are supported all complementing each other. With ETAS ASCMO, the behavior of complex systems can be modeled and optimized on the basis of measurement data with high quality. With INCA-FLOW, complex processes can be standardized and automated as well as the knowledge of calibration experts can be documented. EHAND- BOOK is an extremely efficient tool for the interactive documentation of complex systems, which enables calibration engineers during their work in the vehicle to quickly view both the functionality of ECU functions and the signal flows through several functions. With the ES800 solution and the FETK ECU plug-on device, ECU data and system environment data can be recorded synchronously with high rates. In conjunction with Big Data methods for the processing of vehicle-related data, the new measurement technology as well as the presented advanced calibration solutions aim at the improvement of quality and the increase of efficiency during the validation of vehicles, systems, and ECUs. W (oe) Translated by ETAS GmbH Bibliography [1] F. Kaiser, U. Lauff und C. Müller, Leistungsfähige Werkzeuge für fortschrittliche Fahrzeugelektronik, Hanser automotive OEM Supplier, [2] S. Hoffmann, M. Schrott, T. Huber und T. Kruse, Modellbasierte Methoden zur Applikation moderner Verbrennungsmotoren, MTZ - Motortechnische Zeitschrift, Vol. 76, No 4, pp , April [3] S. Meyer und R. Reddy, Fünf Jahre erfolgreiche Kooperation zwischen ETAS und IAV mit INCA-FLOW, automotion, No. 2, pp , Dr. Ulrich Lauff is Senior Expert Marketing Communication at ETAS GmbH. Dr. Kai Pinnow is Chief Systems Engineer at ETAS GmbH. Summary Several new methods for the calibration and validation of complex vehicle systems with a wide range of innovative Dipl.-Ing. Florian Schmid is Product Manager ES891 at ETAS GmbH. 5 HANSER automotive 10 / 2015 Carl Hanser Verlag, Munich

6 Open to Anything Except Compromise How can you integrate electronic systems into cars efficiently without compromising on functionality, safety, or quality? ETAS open and scalable solutions are the right choice, especially if you are open to efficient development. Our competent experts support you throughout the entire process starting with consulting and design, then testing and validation, right up through integrating the software on PCs, in the lab, and in the car. See for yourself at