Maneuver based testing of integrated vehicle safety systems Rudolf Ertlmeier 1 Kathrin Sattler 1 , Andreas Raith 1 , Thomas Brandmeier 1 Daouda Sadou 2 , Christian Schyr 3 1 Institute for Applied Research (IAF); Ingolstadt University of Applied Sciences 2 Continental Automotive GmbH 3 IPG Automotive GmbH "‘apply & innovate 2012"’ - IPG Technology Conference 18. / 19. September 2012
Motivations Test system Crash data feeding Outlooks Agenda / Contents 1 Motivations Networking of automotive systems Integrated safety systems New test concept 2 Test system Realisation Example of continuous testing 3 Crash data feeding Selection and feeding Crash data scaling 4 Outlooks R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Agenda / Contents 1 Motivations Networking of automotive systems Integrated safety systems New test concept 2 Test system Realisation Example of continuous testing 3 Crash data feeding Selection and feeding Crash data scaling 4 Outlooks R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Networking of automotive systems Development of system complexity FlexRay CAN development in recent years MOST Diagnosis The number of various control units Gateway LIN CAN in vehicles is expanding extremely CAN CAN since the last few years CAN ⇒ system complexity is increasing constantly ⇒ testing is getting more and more extensive ... Kiesewetter T.: Der VW Touareg - Karosserieelektronik und Infotainment source: ATZextra, Nr. 2010-02, page 47, 2010 R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Integrated safety systems New safety system concept (e.g. SCU - Safety Control Unit) see hear e.g. CISS e.g. ACC (Crash Impact Sound Sensing) e.g. ESC e.g. Car-2-X feel communicate R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks New test concept Idea of a new test concept for safety systems idea of the new test concept vehicle- and combination of: environment crash data - vehicle simulation simulation - environment simulation - crash data feeding SCU SCU for MiL, SiL and HiL test environment project: VISAPS • modular flexible system for development and production release of networked systems (MiL, SiL, HiL - test environment) • consistency and automation of testing • project partners: R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Agenda / Contents 1 Motivations Networking of automotive systems Integrated safety systems New test concept 2 Test system Realisation Example of continuous testing 3 Crash data feeding Selection and feeding Crash data scaling 4 Outlooks R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Realisation Concept HiL (real time system) software hardware vehicle & environment sensor signals simulation interfaces (e.g. SCU SCU signals (safety control unit) algorithms .g. bus systems) • environment sensors • environment sensors (with vehicle dynamics, (with vehicle dynamics, trigger • chassis sensors object properties, …) • car2X communication • GPS/navigation SCU signals crash • laboratory crashes data • simulated crashes actuators • other relevant base (e.g. airbags, situations (misuses) belt tensioners) R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Realisation 1 st Generation: „CAN-Tester“ Data sources Testing of CAN based algorithm in an electronical control unit: • Replay of CAN-Traces • Rest bus simulation • CarMaker simulation CAN data manipulation • Cyclic Redundancy Check (CRC) • Message counter • Data Length Code (DLC) • Timeout • Data field (including init- and error-values) R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Realisation 2 nd Generation: „Airbag HiL-system“ programming, calibration, fault memory Safety Control Unit crash parameters • velocity • coverage • coverage • impact angle Crash DB • … current measurement crash signals CarMaker analog PSI5 SPI vehicle – environment bus systems (CAN, LIN, FlexRay) intelligent IO R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Example of continuous testing Collision in front of traffic lights New test system enables a continuous testing throughout all phases of driving: Normal Driving , PreCrash and InCrash t -2 ≈ -0,8s t -1 ≈ -0,75s t -3 = -2s t 0 = 0s v 0 ≈ 40km/h v -3 = 60km/h v -2 = 60km/h v -1 = 60km/h belt tensioner emergency brake airbag t t t t Normal Driving PreCrash InCrash R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Agenda / Contents 1 Motivations Networking of automotive systems Integrated safety systems New test concept 2 Test system Realisation Example of continuous testing 3 Crash data feeding Selection and feeding Crash data scaling 4 Outlooks R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Selection and feeding Feeding test system with required crash data crash trigger specify crash parameter by using simulation parameter Normal Driving / PreCrash: at 1 collision time • SCU is being fed with vehicle dynamics Angular 30° 43 km/h ? ? and environmental sensor data from IPG CarMaker simulation InCrash: 2 • looking for corresponding real driven real driven crash crash data and feeding into SCU SCU crash data data base R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Crash data scaling Artificial generation of crash data What can we do if there are not enough or exactly the required real driven crash data in the database? • search for best fitting data set ⇒ inaccurate testing results • generate crash data by using FEM ⇒ not feasible in almost real time ⇒ generate data out of existing real driven crash data by scaling and interpolation front 30° right angle, v = 43km/h angular 30° 32 km/h angular 30° 32 km/h angular 30° 51 km/h angular 30° 51 km/h acceleration [g] longitudinal 0 -10 -20 reference signal generated signal -30 0 10 20 30 40 50 60 70 scaling / interpolation 0 0 velocity [km/h] v reference integrated angular 30° 43 km/h v generated -20 -40 0 10 20 30 40 50 60 70 time [ms] R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Agenda / Contents 1 Motivations Networking of automotive systems Integrated safety systems New test concept 2 Test system Realisation Example of continuous testing 3 Crash data feeding Selection and feeding Crash data scaling 4 Outlooks R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
Motivations Test system Crash data feeding Outlooks Next generation test system project: VISAPS 2 1 further development of current scaling and interpolation algorithm 2 realisation of secondary accidents simulation within CarMaker 3 further development of the new VISAPS test system: • implementation of AUTOSAR - requirements • ISO 26262 certification • integration of power measurement to measure the ignition circuit currents exactly 4 test strategies • development of an efficient test strategy for highly networked safety systems by combining different test methods such as maneuver-based or evolutionary tests R. Ertlmeier, K. Sattler, A. Raith, T. Brandmeier, D. Sadou, C. Schyr Maneuver based testing of integrated vehicle safety systems
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