virtual ESC protection Design and implementation of new tool chain - PowerPoint PPT Presentation

Design and implementation of new tool chain for virtual ESC protection

Design and implementation of new tool chain for virtual ESC protection 01 Elektronische Fahrwerksysteme | EFS-34 chassis simulation 02 Tool chain requirement 03 Tool migration project 04 Results and expertise EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 2

Elektronische Fahrwerksysteme 01 EFS-34 chassis simulation EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 3

Company at a glance Company Fields of activity Founded 2009 System integration Divisional Director - Markus Brummer Location Ingolstadt/Wolfsburg Interest GIGATRONIK Group (51%) Audi Electronics Venture (49%) System software development Divisional Director - Stefan Sollmann Employees 315 (April 2016) Company Wilhelm Schmitt, Audi AG Interdisciplinary functions management Divisional Director - Raimund Hofmayer Dr. Edwin Tscheschlok, GIGATRONIK Group IN/VE – Innovation management and pre-development Divisional Director - Stefan Sollmann EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 4

Audi Electronics Venture GmbH cooperation network Prof. Gustafsson e.solutions Das Joint Venture von Elektrobit und Audi AEV cooperation platform To increase the speed of automotive electronics innovations and developments, AEV enters into collaboration with technology companies. EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 5

EFS-34 chassis simulation Real Environment Virtual Real-time capable Multibody test drive simulation test drive vehicle dynamics systems EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 6

02 Tool chain requirement EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 7

Required test scopes in virtual test drive MLB 3 Scope [%] MLBevo crosslinking 2 MLBevo crosslinking 1 300 Today Collective functions 250 Movement manager Topics 200 transfer 2. Supplier 150 EFS pACC Assistance 100 crosslinking of systems chassis control unit 50 FlexRay B channel crosslinking of 0 control units 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 8

Personnel and resources planning Scope [%] Employees [%] Starting point 300 300 Planning from 2011 250 Topics 200 200 transfer 150 EFS 100 100 50 0 0 Personnel development 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 9

ESC test field structure and standardisation Universal Universal simulator Standardisation of vehicle dynamics models ESC cubes variant reduction Combination of Connection to dry/wet Audi IT ESC cubes Implementation of night run Occupational Structuring Health and Safety of test area EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 10

Personnel and resources planning Scope [%] Employees [%] Starting point 300 300 Planning from 2011 250 Topics 200 200 Option 1 transfer planning without 150 EFS change to tool chain 100 100 Option 2 planning with tool chain 50 Adaptation required change 0 0 Personnel development 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 11

Tool chain requirements State of the art & Potential Professional Connection to Group Flexible & intuitive standardised for certification tool environment standards (e.g. EXAM) operation interfaces EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 12

Tool chain for business process outsourcing Internally developed Matlab environment for ESC simulation Simulation tool • No standardised interfaces • veDYNA as vehicle dynamics model • Error-prone, low stability Project Model management management  30% night run abort rate HAP H IL workstation • Over 400 functionally dependent scripts  Time-consuming training and maintenance Test- Test- Test-  Certification not possible development execution evaluation • No connection to ODIS & EXAM Test automation Tool chain requirements not met EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 13

Target tool chain Results management Versioning Database Test Report Test task result evaluation creation Sub version During Simulation tool Manoeuvre Vehicle dynamics development development model Framework Manoeuvre control Model management Interface simulator/ Requirements- Test automation hardware based EXAM Doors ControlDesk (Test control) Interface MM6 ODIS Control unit Datalyzer EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 14

Catalogue specifications comparison Simulationstool Requirement Provider 1 Provider 2 Provider 3 Standard components models    Own models integration    dSPACE hardware platform    Signal manipulation    Measurement simulation    Adaptive driver    Animation    Manoeuvre creation (graphical)    Roads definition (graphical)    Process automation    FMI/FMU    EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 15

Evaluation to prototypical implementation Criterion Provider 1 Provider 2 Provider 3 Test creation effort 100 % 50 % 25 % (test catalogue #2) Test execution duration #2 100 % n.r. 15 % Test migration effort 100 % n.r. 35 % Development phase testing - n.r. + Tech. Support - + + Familiarisation time - - + Operability, usability - o + Model changes effort - n.r. + Debugging - n.r. o n.r. = not rateable EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 16

Financial expenditure for simulation tool migration Provider 1 Provider 2 Provider 3 Licences 2 1 3 Migration expenditure 3 1 1 Internal migration costs 1 2 2 Maintenance per year 3 1 2 Total costs 2 1 3 Ranking: 1 = best in comparison, descending order EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 17

Personnel and resources planning Migration start Scope [%] Employees [%] Starting point 300 300 Planning from 2011 250 Option 1 Topics no change 200 200 transfer 150 EFS Cost benefits 100 100 Option 2 planning with tool chain 50 Adaptation required change 0 0 Personnel development 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 18

03 Tool migration project EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 19

Test case migration for test catalogue #2 example Test cases [%] 100% 0 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 Migrated Total Before = after Evaluations EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 20

EFS-34 chassis simulation tool migration status (27/04/2016) #01 #02 #03 #04 #05 100% 100% 100% 100% 100% 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 #06 #07 #08 #09 #10 100% 100% 100% 100% 100% 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 #11 #12 #13 #14 #15 100% 100% 100% 100% 100% 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 6.1 20.1 3.2 17.2 2.3 16.3 30.3 13.4 27.4 EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 21

Number of vehicle variants Body Axles Steering Wheel sys Brake Engine Transmission Sensors Restbus Platform # Drivetrain Transmission A1 Conventional Four-wheel drive Automatic A2 conv. Four-wheel drive Manual gearbox B2 conv. Front Manual gearbox B3 PHEV Four-wheel drive Automatic B4 conv. Four-wheel drive Automatic D1 EV Four-wheel drive E1 conv. Four-wheel drive Automatic E2 PHEV M1a Four-wheel drive Automatic E3 conv. Four-wheel drive Automatic F1 MHEV Four-wheel drive Automatic J1 PHEV Four-wheel drive Automatic J2 conv. Four-wheel drive Automatic J3 MHEV Four-wheel drive Automatic J4 conv. Four-wheel drive Automatic J5 MHEV Four-wheel drive Automatic J6 conv. Four-wheel drive Automatic EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 22

04 Results and expertise EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 23

ESC simulators utilisation Documented downtime not including setup time Total Productive test bench operation Resource coverage [%] Migration: 30 % reduction in 100 % active simulators 100 % 50 % 50 % effective utilisation approx. 40 % effective utilisation approx. 75 % 0 % 0 % 3 4 5 6 7 8 9 10 11 12 13 14 15 16 CW 14 15 16 17 18 19 20 21 22 23 24 25 26 27 CW 2016 2015 average utilisation available resources EFS-34 chassis simulation | Christoph Kossira, Dr. Paul Spannaus 24