Real-Time Simulations with LMS Virtual.Lab Motion: Speed and Accuracy When It Truly Matters!

Real-Time Simulations with LMS Virtual.Lab Motion: Speed and Accuracy When It Truly Matters! Joris De Cuyper LMS International, Virtual.Lab/Motion Sr. Product Line Manager Matthew Forman LMS USNA, Virtual.Lab/Motion Product Manager Bill Prescott LMS USNA, Virtual.Lab/Motion Solver Development Manager Valerio Cibrario LMS Italiana, Manager Automotive Industry Solutions June 4 th -6 th, 2013

Challenges for Real-Time models Applications requiring real time vehicle models Drivingsimulators Driver actuator feedback Integrated vehicle controls testing Real time communication models models Vehicle model Model Developers models 2 models Real time computing Test Engineer

Trends at automotive OEMs and suppliers 2000 2005 2010 2015 Control departments How to frontload controls testing? Vehicle department How to frontload attribute testing? Testing by prototypes Testing by prototypes V&V using simplified Simulink models to test controllers and control integration & introduction of MIL SIL HIL testing Install large driving simulators to test vehicles with low functional vehicle models for only low frequency reproduction Use geometric vehicle models with integrated detailed subsystem actuator models Drivers for new trend Higher dynamics important for calibration of active subsystems Design modifications to be done during virtual attribute evaluations 3

Driving Dynamics in need of a mechatronic Systems Approach Multi-disciplinary, covering wide frequency range, interconnected Handling Vibration Harshness Ride-comfort (Primary & Secondary) Noise Chassis Suspension ISO & NHTSA maneuvers Pitch Roll Comfort Chassis shake Jerking Harshness Shimmy NVH Road noise Tires Scanning, Rolling Controls Brake Steering Engine Powertrain Stopping distance Parking On centre feeling Tip in Steer ability Back out Idle vibrations Drivability Brake judder Steering shudder NVH Powertrain noise Hz 1 2 4 7 10 20 40 70 100 Simple to complex models Increased CPU time Few parameters to many parameters required 4

Challenges for the Simulation of Ride & Handling Simulation technology: Maturity of the simulation models for Ride & Handling: Validation of the models Verification of parameters in the process Simulation predictions match up with the subsequent measurements in physical tests Competent evaluation (subjective / objective) of performance evaluation: Handling (agility, driving stability) Ride (driving comfort) Human skills and perceptions determine the design of the vehicles 5

Challenges for the Simulation of Ride & Handling Simulation technology: Maturity of the simulation models for Ride & Handling: Validation of the models Verification of parameters in the process Simulation predictions match up with the subsequent measurements in physical tests Competent evaluation (subjective / objective) of performance evaluation: Handling (agility, driving stability) Ride (driving comfort) Human skills and perceptions determine the design of the vehicles 6

Conflict of Objectives Ride & Handling Ride-Comfort Over land: country roads (e.g. comfort roads, pavè) highways obstacle (e.g. harshness) Handling Performance of: on-center feeling driving stability 7

LMS Process & Data integration Data Collection LMS Driving Dynamics Value: Swift vertical Vehicle and Bushings Data LMS Virtual.Lab Composer Value: Cost-effective customization LMS Virtual.Lab Motion LMS Imagine.Lab AMESim Reporting LMS Test.Lab LMS Motion Real-Time LMS AMESim Real-Time MS Excel 3d party tool support 8

Modular Assembly Concept with Virtual.Lab Motion 9

Challenges for the Simulation of Ride & Handling Simulation technology: Maturity of the simulation models for Ride & Handling: Validation of the models Verification of parameters in the process Simulation predictions match up with the subsequent measurements in physical tests Competent evaluation (subjective / objective) of performance evaluation: Handling (agility, driving stability) Ride (driving comfort) Human skills and perceptions determine the design of the vehicles 10

MBS-Tool for Ride Comfort: Virtual.Lab Motion Intel Xeon Processor X5570 clock speed: 2.93 GHz Simulation of ride comfort up to 30 Hz and elasticities of the body, the subframes,, real time factor 200-300 Challenge: ride comfort has to be simulated up to 30 Hz tool Virtual.Lab Motion 11

Next Generation Ride & Handling Tool: Real-Time MBS Advantages of a real time MBS-Tool: 1. Only one model has to be validated 2. Automation of the data processing has to be done only once 3. One simulation tool for different applications means higher quality of the results 1. Higher efficiency in the development process 2. Higher maturity of real prototypes due to a better simulation forecast 201X one model for Ride & Handling Simulation including HiL: Real-Time MBS-Tool 12

Motivation and long-term vision Benefits of Real-Time MBS models Simplified, 15-DOF model Real-time vehicle simulations vehicle data Detailed, 150-DOF multi-body model Off-line vehicle simulations Handling OK? Ride OK? AS-IS status Handling assessment - HIL-simulator Acceptable up to 5 Hz not enough vehicle detail available to match real-life conditions Detailed, 150-DOF multi-body model Real-time vehicle simulations R&H OK? Expanding capability with: More realistic HIL testing: vehicle models valid until 20Hz, matching real-life conditions 13

Virtual.Lab Motion: true Real-Time capable! Solver run time [s] 50 45 40 35 30 25 20 15 10 5 0 Duration maneuver Duration (J-turn): maneuver 10s (J-tur 45 Motion solver improvements 30 NEW technology: Modellink 16 9.8 no split no split 1 split 2 splits 2008 2009 2009 2010 Lumped Chassis compliance (front and rear chassis) representations: ModelLink: New element allowing to split model in such way that it can run on different processor (2 or more processors) VL Bushing: Connects front and rear part of chassis as reference model (runs on 1 processor) ModelLink has the same properties as the VL Bushing Core 1 ML m6m3 ML m31 Core 3 Hardware: Desktop PC: W3520 Xeon quad core 2.67 GHz, i7 chip 32-bits OS Core 1 ML Core 2 ML m31 ML m16m13 Core 2 14

LMS Motion Real-Time: Speed And Accuracy When It Truly Matters! CPU 1 150 DoF CPU 2 Speed 15

LMS Motion Real-Time: Speed And Accuracy When It Truly Matters! Motion Mechanical System AMESim Steering Assist Geometrical Effects Compliances Suspension Bushings Steering linkage Steering mounting Steering shafts Friction Location 1D Model Integration Active Systems Multi-physics models Accuracy 16

LMS Motion Real-Time: Speed And Accuracy When It Truly Matters! C P U tim e [s] 0.007 0.006 0.005 0.004 0.003 0.002 0.001 0 Results Nov 2010 Classical multi-body solver Real-Time Threshold 0 2 4 6 8 10 12 Integration time [s] Solution step overruns Turnaround time per integration step [s] 0.0014 0.0012 0.001 0.0008 0.0006 0.0004 0.0002 SIL performance LMS Motion Real-Time solver Real-Time Threshold 0 0 5 10 15 20 Integration time [s] 1ms Communication Requirement When It Truly Matters 17

Generation of C-code: Process flow 1 Directly Test Motion Results, e.g. for speed up of solver 2 3 Test S-Function Results e.g. including other subsystems Directly go to HIL Environment (IPG, ETAS) 1 SIL LMS Motion Result file RUN WITH generation of results file 4 Go though S-Function to HIL (Opal-RT,dSpace) Virtual.Lab Simulink S-function Virtual.Lab Motion Post-processing Motion Virtual.Lab Motion submodel1, e.g. front suspension Solver input file1 C-code.dll 2 Resul ts OK? Virtual.Lab Motion submodel2, e.g. rear suspension Solver input file2 C-code.dll 3 HIL Real-time HW platform ECU testing Virtual.Lab Motion submodel Solver input file3 NEW technology: Modellink element C-code.dll 4 Simulink S-function Real-Time Workshop DOWNLOAD and RUN WITHOUT generation of results file 18

Typical customer pains that require Real-Time vehicle models Applications requiring real time vehicle models Driving simulators Driver actuator feedback Integrated vehicle controls testing Real time communication models models Vehicle model Model Developer models 19 models Real time computing Test Engineer

LMS supported configurations for Real-Time vehicle modeling CURRENT STATE OF THE ART Functional RT vehicle model NEW TREND Geometric RT vehicle model Simulink/C Controls model 1 AMESim model1 Simulink/C Controls model 1 AMESim model1 AMESim Vehicle model Motion Vehicle model Simulink/C Controls model 2 AMESim model2 Real time computing Model reduction AMESim model3 Simulink/C Controls model 3 Simulink/C Controls model 2 AMESim model2 Res-use model AMESim model3 Simulink/C Controls model 3 Real time computing MBS Vehicle model Model Developer 20 MBS Vehicle model

LMS Real-Time 3D + 1D models Mechatronics Testing at Japanese OEM LMS Demonstrator LMS Virtual.Lab Motion 157 DoFs vehicle model LMS Imagine.Lab AMESim Powertrain ABS/ESC Steering Assist Concurrent RT Platform, 1KHz sampling rate

Real-Time vehicle modeling: LMS offering Attribute dynamics DRIVING SIMULATORS attribute evaluation COMPONENT TEST RIGS V&V and attribute evaluation VEHICLE TEST RIGS V&V & attribute evaluation 40Hz Longitudinal (drive-ability) GEOMETRIC VEHICLE MODELS GEOMETRIC VEHICLE MODELS Motion-centric RT vehicle model 30Hz Secondary ride (comfort) 20Hz Primary ride (comfort) 10Hz Lateral (handling, safety, fuel eco) FUNCTIONAL VEHICLE MODELS FUNCTIONAL VEHICLE MODELS System Subsystem Component Subsystem System Simulation Testing 22 FUNCTION VEHICLE MODELS AMESim-centric RT vehicle model Development timing

Driver Simulators Handling Simulator Real time C-code Ride Simulator Challenge: Time-to-Production reduction for early phases in the design cycle to test new chassis functionalities, including chassis subsystems (such as regenerative braking, driveability, electric engines,... Unique point: LMS has advanced technology for supporting mechatronic engineering with integrated 1D-3D real-time models Output: from 15 till 100 DoF vehicle model able to run Real-Time; implementation in HiL solutions Time-to-Production reduction of the ECU semi-active suspension (hydractive) Old process: 2 years New process: 6 months, with a total of 25 automatized testing manoeuvers running RT on 2-4 CPUs Rethinking upfront & detailed engineering processes in support of brand value appeal of electrical vehicles, Eric Landel, LMS Automotive Conference Europe, Munich May 10th-11th 2011 23

Integrated vehicle controls testing Full vehicle Real-Time multibody modeling supporting SIL, HIL Real-time Enabling Challenge: considering the suspension architecture in the SiL and HiL development Unique point: LMS has advanced technology for supporting mechatronic engineering with unique 3D MBD based high-precision real-time models Output: about 100 DoF vehicle model able to run Real-Time; implementation in SiL and HiL hardware solutions Using High Fidelity Multi-body Vehicle Models in Hardware in the Loop simulations, W. Prescott, M. Furman, LMS International, Yamamoto, Toyota, JSAE 2012, Yokohama, Japan Using High-Fidelity Multibody Vehicle Models in Real-Time Simulations, L. Dragon, A. Lippeck, H. Brauner, Daimler AG, W. Prescott, M. Furman, J. De Cuyper, LMS International 24

The LMS Driving Dynamics offer A methodology in building blocks 1D-3D fully integrated platforms, LMS Imagine.Lab/AMESim & Virtual.Lab/Motion, with modular solution, from simple to full trimmed body vehicle modeling Superior 3D model accuracy for non-linearities with LMS-SAMCEF Mecano Processes and solutions for multi-attribute chassis balancing through Primary & Secondary ride, Harshness, Handling and Road noise Across vehicle engineering levels: Advanced testing (R&H body deformation) From Concept to Detailed Engineering From Components to Full vehicle Managing the growing complexity of control & electronic systems Software Services Engineering Innovation 25

Thank You! Questions? June 4 th -6 th, 2013