FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS

Transcription

1 FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS Tech Day AVL Nordiska, November 19 th, 2014 Thomas R. Weck AVL Powertrain and Hybrid System

2 OVERVIEW 1 WHAT IS THE PROBLEM? 2 FUNCTIONAL TESTING 3 PROJECT EXAMPLE 4 SUMMARY & OUTLOOK F. Illmeier / Engineering and Technology Powertrain Systems 2

3 1 WHAT IS THE PROBLEM? Driver Interface HCU Gasoline ENG DC/AC 1 DC/AC 2 EM2 MOT Starter 12V DC/AC 3 HV Battery Starter 12V AMT EM1 EM3 GEN Diesel ENG IL4 2,0 HSDI Vehicle Hybrid CL Cooling DC/DC EM1: BSG Driver Interface HCU DC/AC TFSI Vehicle Hybrid Cooling IL4; 1,4L; EU V Driver Interface HV Battery ECU / HCU EM2 DC/DC CL EM2 Vehicle DC/AC DCT7 el. Oil Pump VW Jetta Hybrid Hybrid Cooling HV Battery DC/DC Increasing Complexity Rising number of vehicle variants High number of topologies & architectures New vehicle functionalities (e.g. E-Drive) Divergent Vehicle Targets Performance vs. Fuel Efficiency Emissions vs. Drivability Diversity of Market Demands Heterogeneous Development Environment Cross Domain Collaboration Development Quality & Risk Product Lifecycle & Product Development Reduced product lifecycle & product usage Reduced development time & effort for single variant F. Illmeier / Engineering and Technology Powertrain Systems 3

4 1 WHAT IS THE PROBLEM? WORST CASE... HOW DID THAT HAPPEN? 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? Recall actions in US market ( ) increase from 15.5 to 20.5 Mio. CAM DO (Center TRADITIONAL of Automotive Management), USAGE March 2014 PROFILES / TEST CYCLES COVER ALL OPERATION CONDITIONS? General Motor s recalled 29 Mio. Vehicles in the first half of 2014 FORTUNE Magazine, August 15, 2014 WHAT IS THE TEST COVERAGE AND IS IT REPRESENTATIVE? HOW ARE AUTOMOTIVE STANDARD CONSIDERED (ISO 26262)? F. Illmeier / Engineering and Technology Powertrain Systems 4

5 1 WHAT IS THE PROBLEM? Test Mileage: 2007: 24 Million km 2009: 36 Million km März : 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: HEISE March 1 st, 2014 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 F. Illmeier / Engineering and Technology Powertrain Systems 5

6 1 WHAT IS THE PROBLEM? Traditional Mechanical View Mechanical Focus (Durability) Focus (Durability) NEW: Functional Focus (Coverage Causal Dependence) Customer Load Profile Component Component Load/Stress Load/Stress Variation of driver profiles depending on customer usage Activates, operates and stress the PT system Interacts with other vehicle systems Mix of representative drive cycles (city, motorway, mountain) Customer Load Profile Reacts to changes in environmental conditions Changes the load profiles for components Consideration of environmental condition (humidity, temperature, altitude) Prevents/reduces component damage Provides additional limp home capabilities BALANCED = components designed to meet customer needs Unforeseen interactions? -> undefined conditions Definition of mechanical load profiles (e.g. speed, torque, vibration) and affection of components Limited operational interaction (consider breakdown to component level) Powertrain & Vehicle System Operation Evaluation of damage relevant conditions F. Illmeier / Engineering and Technology Powertrain Systems 6

7 2 FUNCTIONAL TESTING System (Vehicle) Targets & Boundaries SoP (Vehicle Launch) Synergies Product Definition, Test Methodology Integration, Validation 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 Methodology to improve Integration and Testing 7

8 VIRTUAL FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 2 FUNCTIONAL TESTING Test Requirements Quality History Environment & Drive Cycles Hybrid System Product Definition Definition of Routes Data Conversion Data Export Analyze of physical Structure, Components and Functions Find operating States/Transitions Define Test Cases Test Plan Test Bed Finalize Test Plan & Confirm in Simulation F. Illmeier / Engineering and Technology Powertrain Systems 8

9 2 FUNCTIONAL TESTING Information Vehicle Targets Usage Requirements System States Control Factors Component -Parameters -Functions Test Cases System Model WHERE is the Information Generated & Managed? & HOW is the Information Used? Test View in Definition in Preparation in Execution *Model Based Systems Engineering for PT Testing F. Illmeier / Engineering and Technology Powertrain Systems 9

10 In Out FUNCTIONAL TESTING OF COMPLEX VEHICLE SYSTEMS 2 FUNCTIONAL TESTING Test Environment Cameras Sensors Failure Insertion Unit Failure Insertion Unit Actuators xcu Diagnostic System New FIU CAN CAN + - Automation... Test Initialization, Test Execution, Data Recording, Test Confirmation, Re-Initialization On the Test Bed Test Bed Automation and Test Management Limit Observation CAN Battery Emulator Additional actuators & cameras to observe and input into the driver interface Electrical Load Unit 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 F. Illmeier / Engineering and Technology Powertrain Systems 10

11 3 PROJECT EXAMPLE: Series Production Support OEM Review AVL Use Case (UC) Test Case (TC) Step 1 Step 2 APPLICATION OF TEST METHOD Test Analysis & Evaluation Test Execution Test Plan Step 1 Analysis of function and usage to define relevant test cases Step 2 Optimization of test plan to perform efficient and effective testing F. Illmeier / Engineering and Technology Powertrain Systems 11

12 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 F. Illmeier / Engineering and Technology Powertrain Systems 12

13 4 SUMMARY & OUTLOOK 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 safety to be performed in different test environments On-going AVL customer project to extend methodology into PHEV diagnostics and optimization of operation strategy AVL Engineering Services in PT Development AVL Test Beds and Test Systems F. Illmeier / Engineering and Technology Powertrain Systems 13

14 4 SUMMARY & OUTLOOK 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. F. Illmeier / Engineering and Technology Powertrain Systems 14 14

15 AVL CONTACT INFORMATION Thomas R. Weck Hybrid Powertrain Integration AVL POWERTRAIN WORLD APP 15