Efficient and Faster PLC Software Development Process for Automotive industry. Demetrio Cortese IVECO Embedded Software Design

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1 Efficient and Faster PLC Software Development Process for Automotive industry Demetrio Cortese IVECO Embedded Software Design

2 Automotive OEM Mandatory Requirement Delivery the new vehicle in short time and with high quality level. How will we satisfy it? How wil the product lifecycle accomplish the OEM objectives over time? 2

3 Introduction 3

4 Introduction Automotive Virtual Conference Demetrio Cortese 4

5 Introduction 5

Introduction ECU Architecture ISO IEC 12207 for Current

Life-Cycle Truck ECUs Model-Based Network IVECO Toolbox

6 Introduction ECU Architecture ISO IEC for Current Production Application Software Software Development Life-Cycle Truck ECUs Model-Based Network IVECO Toolbox Basic Software ECU Hardware ISO IEC and ISO for New Production 6

7 Automotive OEM Mandatory Requirement Delivery the new vehicle in short time and with high quality level. How will we satisfy it? How wil the product lifecycle accomplish the OEM objectives over time? 7

8 Market Opportunity In 2010 there was a market need to have a Shift range inhibitor system for Heavy vehicles with 9- and 16-speed transmission The above request was closed to the Start of Production of the vehicle. The Global Vehicle Development Process provided a new requirement: the features in terms of Hw and Sw must be delivered in six weeks 8

closed to the Start of Production of the vehicle.

9 Requirements Evaluation First answer: No Hw issue. A pre-existing programmable logic controller (PLC) hardware shall be used (optional for the reference market) Sw Features Development No chance to develop the functionality with the traditional approach: The System Engineer Team, that developed the preexisting PLC Sw, using a specific and dedicated toolchain provide the PLC supplier declared high risk to fail. Embedded Software Design Involvement for evaluation 9

Features Development No chance to develop the functionality with the traditional approach: The System Engineer Team,

10 Embedded Software Design Challenge Develop and deliver a specific functionality for PLC in six weeks No ESD Team experience in writing structured text for PLCs No Functional Specification Document available Two System Engineers knew the probable functional behavior The Supplier Tool-chain must be used for the final integration and downloading in the target PLC Usual System Testing and Validation must be done 10

Two System Engineers knew the probable functional behavior The Supplier Tool-chain must be used for the

11 Embedded Software Design Team Solution Rational The aggressive deadline required a compressed Software Development schedule that left no room for specification or implementation errors Paradigms change Model based approach Application: Simulink + Simulink PLC Coder Collaborative work between System Engineers and Software engineers Usage of the existing Integration and downloading environment, provided by the PLC provider. 11

based approach Application: Simulink + Simulink PLC Coder Collaborative work between System Engineers and

12 Requ. & Spec. Operational Phases Requirements Specification Actors Customer System Engineers System Engineers Software Engineers Steps Reqs. Definition Reqs. Analysis System Test Plan Specification Model Design & Simulation No Requirement Documents No Specification Documents NO System Test Plan Well-Designed Model Outputs Preliminary Test Patterns 12

Engineers Software Engineers Steps Reqs. Definition Reqs.

13 Implementation Operational Phase Model Design Coding Actors Software Engineers Software Engineers Steps Model Design Model Testing Code Generation using Simulink PLC Coder Outputs Customized Model SW Docs Defined Model Test Patterns Structured test code (standard ) 13

Generation using Simulink PLC Coder Outputs Customized Model SW Docs

14 Integration and System Testing phases Integration & Integration Testing System Testing Actors Software Engineers System Engineers System Engineers Software Engineers Steps Integration System Testing using test bench System Vehicle Testing on road Outputs PLC Target Deployement of the verified system to the vehicle for onroad tests Continue fine-tune using Simulink and Simulink PLC Coder to quickly update and redeploy the software between tests 14

Vehicle Testing on road Outputs PLC Target Deployement of the verified system to the vehicle for onroad tests

15 Results Development time cut by 40% We delivered the software in less than 35 days and used the remaining time for road testing Specification and Implementation errors eliminated With Simulink we create an executable specification and the collaborative work between the system engineers and the Software engineers reduced specification errors Using Simulink PLC Coder,we have also eliminate implementation errors. Functionality Reusability The Functionality Model has already been reused, using Embedded Coder, in the Vehicle Master ECU and now we plan to reuse the same functionality in a different vehicle. 15

Software engineers reduced specification errors Using Simulink PLC Coder,we have also eliminate implementation errors.

TÜ V Rheinland Industrie Service

TÜ V Rheinland Industrie Service Business Area: Automation / Functional Safety Contact Minsung Lee +82-2-860-9969 mailto : minsung.lee@kor.tuv.com Sales Account Manager for Functional Safety Fax +82-2-860-9862