support of automobile transmission development …...integration test prototype co-simulation of...

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Michael Matthäi, Christian PetschaelisZF Friedrichshafen AG

Support of automobile transmission development with co-simulation of vehicle and driver behaviour at virtual driving tests

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Agenda

Where do we come from? What should the journey be like?

Demo video

Measurements and analyses of the Co-Simulation environment

Summary

Structure of the Co-Simulation

Co-Simulation of Vehicle and Driver, 18.09.2012 & 19.09.2012

Motivation

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predictive Control

Thinkable uses of the SiL-co-simualtion at ZF

Load collective

driving strategy

Design of new developments

Co-Simulation of Vehicle and Operator, 18.09.2012 & 19.09.2012

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Analysis of:

• the number of the gear shifts

• the type of the gear shifts

• the quality of the gear shifts

The gear shifts depend on: • the environment(course of curve, slope, weather conditions)

• driver (slow, normal, aggressive)

• loading of the vehicle (with trailer, loaded, empty)

Load collective data for thetransmission


Measurement Load collective data

Analysis of

relevant damaging

parameters

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Motivation for the SiLCo-Simulation environment

Vehicle HiL test bench SiL test bench

Behaviour of the driver -- --

Vehicle characteristics -- --

Environment -- --

Reproducibility

Availability

Time for tests

Danger for tester


?

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Agenda


Demo video


Summary



Motivation

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Driver controller

• Controller retraces speedprofile

• No route information

• Fitful pedaling action

• Type of driver just via speedprofile


Throttle

Brakes

Desired speed

RoadThrottle

BrakesDesired speed

• Test approach based on events

• Controller shall retrace the real route

• Different types of drivers haveto be installed

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Structure of the SiL test environment

Vehicle

Transmission Hydraulics

Engine

Environment

Driver controller

3D Environment

Measuring software(external)

Road

Components of the vehicle

Driver controller

Traffic

Memory area

Controlelements

Test object:Transmission software

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SoftCar (ZF-Friedrichshafen)


Environment

Memory areaCcontrolelements

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SoftCar im V-Model

Model-in-the-Loop

100

v_Fahr [km/h]

3

4

1

2

Spur

Lenkradwinkel

M_Lenk_soll

Gemessener Lenkradwinkel

Motormoment LRA

Lenkmoment

Lenkradaktuator

Lenkmoment [Nm]

Gemessener Lenkradwinkel

Spurstangenkraft

Spurstangenweg

Motormoment LA

Lenkaktuator

Spurstangenweg

Fahrzeuggeschwindigkeit

Spurstangenkraft

Schwimmwinkel

Gierwinkel

Fahrzeug

Lenkradwinkel

Fahrer

Software-in-the-Loop

Hardware-in-the-Loop

Integration Test

Prototype


RequirementsElicitation

System RequirementsAnalysis

System ArchitecturalDesign

Software Requirements Analysis

Software Construction

Software integration& Integration Test

Software Design

Software Test

System integration& Integration Test

System Test

Validation

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CarMaker (IPG)


3D Environment

Road

Vehiclecomponents

Driver controller

Traffic

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Vehicle (Simulink)(ZF-Friedrichshafen)

TransmissionHydraulics


VehicleTransmission Hydraulics

EngineDriver

controller

PSM 8PxHEngine

Engine Wheel on toothed, infinite road

Transmission (Hardware)

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Agenda


Demo video


Summary



Motivation

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Modification of the vehicle for the SiLCo-Simulation

PSM

Engine8PxH

Contribution ofIPG to CarMaker

Contribution ofZF to SoftCar

• Single-track model

• Accelaration only in direction x

• No slip

• Multitrack modell

• Accelaration in direction x, y, z

• Slip at the wheels

PS

MEngine8PxH

Original model

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Complete SiL-Co-SimulationsEnvironment

TCP/IP

Reference macro

of SoftCar

Vehicle

Environment3D

Environment

Measuringsoftware (external)

APO-Client(Application Online)

Hardware Simulation

Control unitemulation

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Operating principle of the APO-Client

SoftCar

APO-Client

CarMaker

APO-Client


- Triggers APO

- Provides required

values

- Triggers CarMaker

- Hands over increment

- Hands over required

values from SC

- Hands over calculated

values after request

- Hands over end flag

- Hands over calculated

values from CarMaker

Interrupt

Polling

- Demands

for…

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Simulation (Route and Vehicle)

• Vehicle:

• Audi Q5 Hybrid

• System capacity: 245hp = 180kW (155kW engine + 40kW electric motor)


• Route:• Deggenhausertal

• Distance ~13km

• Country road with small towns

• Difference in altitude ~230m

• Maximum slope ~10%

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Simulation (Types of drivers)


Names / Characteristics

Hudson Hornet(Doc)

„The Grandpa“

Sally„Average Joe“

LightningMcQueen„Racer“

Maximum speed 100 km/h 150 km/h 300 km/h

Accelaration low (~2 m/s²) normal (~4 m/s²) large ( ~6 m/s²)

Pedal changing

timeslow (~1s) normal (~0,5s) fast (~0,25s)

Cut a corner not at all rarely all

Quelle: http://www.pixarcars.tv

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Analysis of the SiL Simulation(Number of gear shifts)


120125130135140145150155160165

Doc Sally McQueen

Analysis of the gear shifts

Anzahl Schaltungen Co-Simulation

0 20 40 60 80 100 120 140 160

Co-Simulation

Fahrzeug

Mean values

Error< 5%

Number of gear shifts Co-Simulation

Vehicle

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Summary


Reality Simulation

• The Co-Simulation works and delivers results which are close to reality

• Simulations in x-fold real-time (till 8-fold on office PC)

• Comparable simulation by real transmission software with real

application data

• The types of drivers have to be adjusted to the real driver• The type of driver has great influence on the gear shifts

• APO-Client and CarMaker have to be reprogrammed on interrupt• Better performance

support of automobile transmission development …...integration test prototype co-simulation of...

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