Test Drives Efficient testing processes at Suzuki, featuring component testing and virtual vehicle testing

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1 page Suzuki motor corporation Virtual Vehicle Test Drives fficient testing processes at Suzuki, featuring component testing and virtual vehicle testing dspac Magazine / dspac GmbH, Paderborn, Germany info@dspacecom wwwdspacecom

2 page Since, Suzuki Motor Corporation has been efficiently intensifying their use of dspac simulators for the safe development of electronic control units (CUs) So far, Suzuki uses several simulators for individual CUs, including body and airconditioning, as well as engine, transmission and allwheel drive CUs But for the models Kizashi and Swift, a dspac virtual vehicle simulator takes over the efficient verification of all vehicle control functions lectronic control technology is evolving with features such as adaptive cruise control (ACC), electronic stability programs (SP), and precrash safety systems At the same time, more functions are integrated into a single CU to reduce the overall number of CUs per vehicle Complex functions are distributed on several networked CUs Acrosstheboard validation of distributed functions is not possible with component simulators for individual CUs, and real test drives are not safe for testing such complex systems with all the connections and dependencies between functions A virtual vehicle simulator is required to test the whole CU network equirements for the Virtual Vehicle To efficiently validate all of a vehicle s distributed control functions the dspac virtual vehicle simulator has to meet the following preconditions: nformation on each CU and its functions has to be shared across the whole hardwareintheloop (HL) system Network tests must be possible, even if not all CUs are available yet dspac Magazine / dspac GmbH, Paderborn, Germany info@dspacecom wwwdspacecom

3 page Suzuki motor corporation Component Simulator vs Virtual Vehicle To test a single CU, eg for engine management, a component simulator is required t comes with a dedicated setup for the CU under test To test multiple CUs or a complete CU network including all communication aspects, a virtual vehicle simulator is required Several simulators are closely integrated to represent a complete vehicle A virtual vehicle can be configured for different vehicle variants eal loads must be includable and switching between load and model must be automated Test execution must be easy, so that Suzuki s engineers can focus on function design, not test creation Variant handling by switching between vehicle models or parameter sets must be easy to reduce HL system downtime Suzuki s inhouse tools, eg, for diagnostics and AM monitoring, have to be connected to the dspac virtual vehicle Virtual Vehicle Setup The simulator consists of five integrated racks that are each configured for certain vehicle components, like engine, body electronics, driver assistance systems, etc The controlled system models are all taken from dspac Automotive Simulation Models (ASM) Besides drivetrain and vehicle dynamics models, this setup also features models for the electrical system and the surrounding traffic to test ACC functionality Test automation is performed by dspac AutomationDesk together with the ealtime Testing (TT) extension This virtual vehicle simulator can be configured and parameterized for the different variants of Suzuki Kizashi and Swift Flexibility of the Virtual Vehicle The virtual vehicle simulator was designed to handle timeconsuming tasks such as changing the target vehicle or vehicle configuration efficiently For example, the test target engine can be switched from a gasoline engine CU to a diesel engine CU in just five minutes The only manual tasks are releasing and attaching the CU harnesses Changing the optional vehicle features such as ACC or aircondition dspac Magazine / dspac GmbH, Paderborn, Germany info@dspacecom wwwdspacecom

4 page Configuration of the virtual vehicle: The dspac processor and /O boards are installed in five racks ing, which vary according to the vehicle class, is simply a matter of changing settings in dspac Control Desk, the experiment software Test Process Any problem detected by the virtual vehicle can be verified thoroughly and in great detail on a component simulator For example, a closedloop problem detected by automatic tests overnight can be investigated and corrected the next day DS Gasoline/ DS x DS Diesel ngine DS Slave DS_ no ASM ngine Gasoline/Diesel DS DS DS DS DSS DS slave_c DS_ ack Simple Body Model ack Body, Window, emote Starter CAN LN LN LN Serial ASM lectrical Components DS DS DS DS x DS DS Master DS ack Transmission, AWD, Body CAN A CAN A GW CAN B CAN B GW ASM Drivetrain Simple Body Model DS DS DS DS DS DS DS DSS DS slave_b DS_ ack ACC, SP, Air Conditioner, Airbag, nstrument Panel, Body Serial Serial Serial CAN ASM Vehicle Dynamics + advanced BrakeHydraulics ASM Traffic Simple Body Model DS DS PS x DS DS DS slave_d no DS_ ASM lectrical Components ack Dynamic model part CU communications CU s of this rack dspac /O boards dspac processor + Gigalink Gigalink cable Gigalink cable, synchronized swinging buffer for some signals The biggest result of installing the dspac virtual vehicle simulator was that it enabled us to easily perform important tests that we couldn t even run before Katsuhiko Douhata, SUZUK MOTO COPOATON on the component simulator When the problem is solved the new, correct function can be restored to the virtual vehicle for further automatic testing Unlike the component simulator, the virtual vehicle contains many parameters that are dynamic, which increases the depth of testing As long as the tester uses the same test environment for the virtual vehicle simulator and the component simulator, it is possible to run common parameters, common environmental conditions, and common tests By adding test cases on a daily basis, testers can thoroughly verify control functions with large numbers of conditions The Advantages of estbus Simulation CU functions that will be available on future CUs and CUs that are not yet available can be implemented by using restbus simulation and CAN gateway functions estbus simulation is a method normally applied to CUs that are only available in virtual form and cannot participate in CAN communication The CAN gateway functions simulate abnormal states such as data corruption or wrong values on the bus to falsify and correct CU messages if the available CU was developed for a different vehicle platform Combining these methods allowed Suzuki to develop new functions even without a complete CU network f an CU was missing some functions, they were implemented using the two methods The whole implementation was optimized and the behavior of the other CUs was tested in this way Problems that might occur for new functions and CUs that could have an impact on the whole CU network were eliminated Use of dspac Products Suzuki had been using dspac products for some years, so it was possible to transfer existing test Yasuhiro Hayashi (on the left) Yasuhiro Hayashi is General Manager of the automobile electric design department at Suzuki in Shizuoka, Japan Katsuhiko Douhata (on the right) Katsuhiko Douhata is a technical expert for automobile electric design at Suzuki in Shizuoka, Japan dspac Magazine / dspac GmbH, Paderborn, Germany info@dspacecom wwwdspacecom

5 Knürr Miracel H mm H PX A Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot Slot H H H P A D S _ T P A D S _ T P A D S _ T P A D S _ PA A U X / A U X x U b a t P WM _ N D G _N (P WM _N ) D G _ N (P WM _ N ) P B D S _ PB D A C _ F x V B A T ± D A C ± D A C ± A D C ± A D C T T P A D S _ PA N J G N D G _ O U T D G _ O U T (D G _C A M + ) P B D S _ PB C A N + ± S WA V / C D G _ C A N X D /T X D P WM _ O U T T T P D S _ P S V B A T + D A C D S P D A C P WM _ o u t T T T P A D S _ PA A U X / A U X x U b a t P WM _ N D G _N (P WM _N ) D G _ N (P WM _ N ) P B D S _ PB D A C _ F x V B A T ± D A C ± D A C ± A D C ± A D C T T P A D S _ PA N J G N D G _ O U T D G _ O U T (D G _C A M + ) P B D S _ PB C A N + ± S WA V / C D G _ C A N X D /T X D P WM _ O U T T T P D S _ P S V B A T + D A C D S P D A C P WM _ o u t T T T H H L B /F U L B /F U L B /F U L B /F U L B / F U T L B/ F U V B A T / P S x x POW SWTCH V O U T / V O U T / V O U T / V O U T / F A A m A m A m A O F F S T F U L L S C A L L C F U S F U S G N P U P O S S T F U o n ly T F U o n ly T F U o n ly T F U o n ly T F U o n ly T F U o n ly T F U o n ly T F U o n ly T F U S F U S F U S F U S F U S F U S + V + V V F U S F U S F U S F U S F U S F U S + V + V V T MGNCY STOP AÊT D 'UGNC NO T AUS MG NZA F U o n ly T T H e a ts in k T T CAB Knürr Miracel H mm H PX A DS DS _ DS_ / DS_ / DS_ / DS _ DS _P_ DS _P_ DS _P_ DS _P_ DS _P_ DS _P_ DS _ P A D S _ T T H T P A D S _ PA A U X /A U X x U b a t P WM _ N D G _ N ( P WM _ N ) D G _ N (P WM _N ) T T P A D S _ PB ± D A C ± D A C ± A D C ± A D C D A C _ F x V B A T T P A D S _ PA N J G N D G _O U T D G _ O U T (D G _ C A M + ) T T P A D S _ PB C A N + ± S WA V /C D G _ C A N X D/ T X D P WM _ O U T T P A D S _ P S V B A T + D A C D S P D A C P WM _ o u t H P A D S _ T P A D S _ T P A D S _ T T P A D S _ T P A D S _ T T P A D S _ T H P A D S T T T T T T T T T H H H H H P_ P_ P_ P_ P_ P _ F U S F U S F U S F U S F U S F U S + V + V V F U F U F U F U F U F U / / / / / F A A m A m A m A le c fu s e e s e t P o w e r s w itc h / / / / / F A A m A m A m A le c fu s e e s e t P o w e r s w itc h / / / / / F A A m A m A m A le c fu s e e s e t P o w e r s w itc h F U S F U S F U S F U S F U S F U S + V + V V SCSupply SCSupply rror Channel D S _ rror Channel D S _ F U F U S P A _F U S P A _ F U T T T T T T T T T T S P A _F U Main CAN A Local CANA Main CAN B Local CANB WD T T T T T T T T T Spare Spare BCM BCM TCM_ T T Main CAN A Local CANA Main CAN B Local CANB T T TCM_ T Knürr Miracel H mm H PX A H PA DS PB DS T T PA DS PB DS T T T T DS H T D S T D S H P PA DS PB DS T T T PA DS PB DS T T T DS P H F U S e s e t F K /L K x x F U S e s e t F K /L K x x F U S e s e t F K / L K x x F U S e s e t F K/ L K x x F U S e s e t F K /L K x x T T LA M B D A P O W H V A A V C V C C V O L T A G L M T C U N T L M T DLTA LKTONCA d O U T P U T / O F F M O T L O C A L D S P L A Y L M T S D S P L A Y S T T N G S A C F A L D C F A L S D P O W S N K O L O V T M P M O T C C M O T C V O U T P U T POW POW SUPPLY SM C C C V > > U H H T / O FF T H T O pen in O FF Posit ion O F F T B B B T T MGNCY STOP AÊT D 'UGNC NOT AUS M GNZA T T F A VDC Cont r ol Volt age B B B T T T T T T T T T T HYP M ST HYP DC HYP BCM HYP BCM HYP PS HY P MS HY P spare Knürr Miracel H mm H PX A H PA DS PB DS T T PA DS PB DS T T T DS H T D S S T T D S T H P PA DS PB DS T T T PA DS PB DS T T T T DS P F U S e s e t F K /L K x x F U S e s e t F K /L K x x F U S e s e t F K/ L K x x F U S e s e t F K /L K x x T H T H F U F U F U F U F U F U H T F U F U F U F U F U F U H PA DS PB DS T T PA DS PB DS T T T F U S e s e t F K / L K x x F U S e s e t F K /L K x x F U S e s e t F K /L K x x F U S e s e t F K/ L K x x F U S e s e t F K /L K x x Spare MSBC F U S F U S F U S F U S F U S F U S + V + V V C M B H O BD T T T T AUTOAC_SDL PC SAS LS NAV SP ACC Airbag Airbag AC ACpanel Knürr Miracel H mm H T P A D S _ PA A U X /A U X x U b a t P WM _ N D G _ N ( P WM _ N ) D G _ N (P WM _N ) T T P A D S _ PB ± D A C ± D A C ± A D C ± A D C D A C _ F x V B A T T P A D S _ PA N J G N D G _O U T D G _ O U T (D G _ C A M + ) T T P A D S _ PB C A N + ± S WA V /C D G _ C A N X D / T X D P WM _ O U T T P A D S _ P S V B A T + D A C D S P D A C P WM _ o u t H L B /F U F A A m A m A m A le c fu s e e s e t P o w e r s w itc h rror Channel D S x x LA M B D A P O W SC Supply H / O FF T H O pen in O FF Posit ion O F F T B B B T T MGNCY STOP AÊT D 'UGNC NO T AUS MG NZA T T F A VDC Cont r ol Volt age H H H T LO AD M O DUL S T O P A T O L U T LO AD M O DUL S T O P A T O L U T LO AD M O DUL S T O P A T O L U S M T LO AD M O DUL S T O P A T O L V T LO AD M O DUL S T O P A T O L V T LO AD M O DUL S T O P A T O L V T LO AD M O DUL S T O P A T O L V T LO AD M O DUL S T O P A T O L U T LO AD M O DUL S T O P A T O L W T LO AD M O DUL S T O P A T O L W T LO AD M O DUL S T O P A T O L W T LO AD M O DUL S T O P A T O L W H H PX A DS Slo t Slo t DS DS _ /P DS _ /P DS _ /P DS V DS V Slot Slot Slot Slot Slot Slot Slot Slot Slot H dspac Simulator T T T T T T SC Supply x+v T A A A T T B B B ack eal loads eal loads eal loads ack ack ack ack Auxilary Supply MST Suzuki motor corporation page dspac as a Tool Supplier Suzuki wanted to direct its efforts into developing the test target CUs and network testing, but doing all the design work for the test equipment would have been very timeconsuming To save time, its virtual vehicle simulator was built up in cooperation with dspac engineers Suzuki s engineers assembled the parameters and made the virtual vehicle compatible with Suzuki s existing simulators These efforts paid off, and as soon as the new simulator was completed, full CU function testing and network testing started High rates of operation have been maintained right up to the present Suzuki s workload was reduced because dspac is a onestop supplier of simulator development tools, including turnkey engineering cases to the virtual vehicle With the test automation software AutomationDesk, it was easy to program and extend the test sequences graphically, using highlevel library functions The test data is read from Microsoft xcel files which were already used for test data handling For timecritical operations, AutomationDesk also parameterizes and controls Python code, which runs in real time parallel to the Simulink models By combining powertrain, vehicle dynamics, electrical system and environment models from the ASMs, an entire vehicle simulation system was constructed for the virtual vehicle The ASMs provide the conditions needed for vehicle drive control, to develop functions such as SP, traction control, and adaptive cruise control dspac ModelDesk is the graphical user interface for intuitive parameterization and parameter set management for the ASMs The many different variants involved can be handled fluently and easily by changing parameter sets in ModelDesk Complete engine types, and parameters like engine displacement or distances for the ACC, were defined by graphical means and handled as parameter sets Suzuki s entire test track was replicated in ModelDesk to run virtual vehicle dynamics tests and compare them with results from real test drives This was done for conditions like summer and winter, and for different types of road surfaces The state of the vehicle can be observed in D animation Motion Desk, making verification simple and clear Compared with a realworld vehicle, verification on the dspac Simulator was easy and our benefits of being able to run automated and reproducible tests were huge Katsuhiko Douhata, SUZUK MOTO COPOATON Setup of the virtual vehicle simulator for testing the complete CU networks of the new Suzuki models Kizashi and Swift dspac Magazine / dspac GmbH, Paderborn, Germany info@dspacecom wwwdspacecom

6 page We were able to handle variants more easily than we had imagined by changing virtual test tracks, engines, transmissions, and other parameters fluently with dspac ModelDesk Yasuhiro Hayashi, SUZUK MOTO COPOATON Future Development To cope with the challenges of reducing fuel consumption, and electric current consumption, it s important to simulate the behavior of the respective systems early on n addition to the ASMs already installed, Suzuki will use the ASM lectric Components simulation model to accurately calculate the power consumption of the electric devices that are planned for future developments Suzuki is promoting partnerships using HL with other divisions not only the electrical components division The more tests that can be implemented across different divisions, the greater the data s usefulness and the higher its validity Katsuhiko Douhata Yasuhiro Hayashi SUZUK MOTO COPOATON, Japan We appreciate the convenient test creation in AutomationDesk s graphical user interface Conclusion By using the dspac virtual vehicle for a large number of CUs, the functions and loads were tested very efficiently The virtual vehicle was well designed, with the relays operated via the PC, the replaceable parts arranged on tables in front of the simulators, and the parameters able to be processed via a database For example, the accuracy of ACC simulation was confirmed The distance and attenuation were compared with the values for an actual vehicle and found to be correct Yasuhiro Hayashi, SUZUK MOTO COPOATON dspac Magazine / dspac GmbH, Paderborn, Germany info@dspacecom wwwdspacecom