cae-based homologation of esc-systems using ipg carmaker · astra (2009 - ) abs / esc damping radar...

www.opel.com

CAE-based Homologation of ESC-Systems

using IPG CarMaker

Karl Michael HahnDr. Henning Holzmann, Dr. Michael Kochem

Adam Opel AG

apply & innovate 2012Karlsruhe, September 19th, 2012

http://www.opel.com/

2 September 19th, 2012 K.M. Hahn

AgendaBackground ECE-R 13-H

Motivation

Simulation Environment at GM Europe

Vehicle Dynamics Simulation

Chassis Controls Simulation

Project Scope

Validation of the Simulation Environment

Static Measurements

Dynamic Measurements

Validation Results

Sine-with-Dwell Test Results

Conclusions


BackgroundTest Procedure ECE-R 13-H

Electronic Stability Control (ESC) systems have proven to be very effective in reducing accidents and fatalities

European Commission decided that all new vehicles have to be equipped with a functional ESC

ECE-R 13-H specifies the basic requirements of an ESC and how this can be tested and certified

ECE-R 13-H currently does not evaluate the controlquality of the ESC


ECE13H Homologation through Simulation

When one physical vehicle has been tested according to ECE-R 13-H, other vehicle variants or versions based on the same vehicle type may be subsequently homologated through simulation.

BackgroundUse of CAE in Homologation Process ECE-R 13-H

Process to be applied:Test a Target Vehicle according to ECE-R 13-H Sine-with-Dwell test Generate a vehicle simulation model of the target vehicle and correlate itto an acceptable level of accuracy requested by Type Approval AgencySimulate critical variants and versions to identify worst case examplesPresent results to obtain homologation for all configurations


Test Procedure

Pre-Test: A is the steering wheel angle at ay = 0.3g

Vehicle coasting in high gear at 80 ± 2 km/h

Steering amplitude for the initial run is 1.5 A

In each series of test runs the steering amplitude isincreased from run to run by 0.5 A

Max. steering amplitude ~ 270 deg

BackgroundTest Definition According to ECE-R 13-H (Sine-with-Dwell Test)

Sine-with-Dwell

Stee

ring

Whe

el A

ngle

Yaw

Rat

e

time

time


ECE13H-S7 Homologation

Effectiveness of ESC is determined by Performance CriteriaVehicle must comply with all 3 performance criteria to achieve Homologation

at T0+1 35%

at T0+1.75 20%

BackgroundEvaluation Criteria ECE-R 13-H

Stee

ring

W

heel

Ang

leYa

w R

ate

time

time

T0 T0+1 T0+1.75

Stability (yaw rate ratios) Responsiveness (lateral deviation)

w/ ESC

w/o ESC


BackgroundRegulation designed for Simulation


BackgroundDifference to FMVSS126

FMVSS 126:

OEM Government

Self certification

Verification

ECE R13-H:

OEM GovernmentWitness testing

CertifierConfirmation


MotivationProject Complexity

Corsa (2005 - )

ABS / ESC

~70 Variants

Insignia (2008 - )

ABS / ESCDampingAWD

~150 Variants

Astra (2009 - )

ABS / ESCDampingRadar

~400 Variants


MotivationIncreasing Test Requirements

Vehicle only Vehicle + Simulation

Cost comparison

Travel

Equipment

Manpower

Homologation test requires steering robotAt least one day test time per vehicle (setup & test execution)

Weather dependency

Cost for tracks and travel


Architecture DevelopmentSystem IntegrationParameter Optimization

SiL - Simulation(Math)

Controller ApplicationRandom TestingValidation

Driving Test(Road)

MotivationRoad-Lab-Math (RLM) Strategy applied to Chassis Controls

Performance ValidationDiagnosis / Failsafe

HiL - Simulation(Lab)

Certification


Virtual Development Time

Effo

rt

Virtual ride & handling

optimization

Virtual suspension and brake

development

Controlsystems

validation

Simulation Environment at GM EuropeVirtual Vehicle Development (Timing)

SORP


CarMakerSimulink Pro

SiL-/HiLSimulation

CompilerLinker

ComponentModels

ManeuverDefinitions

ANSI-C

Suspension Simulation

KinematicAnalysis

ComplianceAnalysis

Virtual VehicleChart

CharacteristicPlots

DataProcessing

BodyTopology

SuspensionTopology

Tire Data

BodyGeometry

Road Data

SuspensionGeometry

ASCII

Equationsof motion

Builder

ADAMSMesaverde

VehicleSimulation

HandlingAnalysis

RideAnalysis

Virtual VehicleChart

CharacteristicPlots

DataProcessing

Roll-overAnalysis

GroundClearance

ComplianceAnalysis

HyperWorksMotionView

Simulation Environment at GM EuropeVehicle Dynamics Simulation

Process for data generation and transformation definedInterfaces between tools established and verified

Reliable data for certification


Simulation Environment at GM EuropeChassis Controls Simulation

Vehicle Dynamics Model Software-in-the-LoopSimulation (SiL)

Test-automation

AeroPTChassisSensorsTiresCAD

Hardware-in-the-LoopSimulation (HiL)

ESC

Parkbrake

ECU- & Actuator Models

ESC

Parkbrake

Actuator Models

Simulation Results


Simulation Environment at GM EuropeHardware-in-the-Loop

Pump MotorEmulator

ESC ECU

ESC Hydraulic

Current Measure-ment Card


Project ScopeCooperation project Opel <-> Applus IDIADA

Opel Simulation

IDIADASimulation

Opel Homologation

IDIADAHomologation

Project was defined in close

cooperation between

departments

Many steps were conducted

together (e.g. measurement

setup, validation)

Joint approach improves

transparency


Project ScopeExecution


Validation of the Simulation EnvironmentIDIADA provided Testing and Simulation Support in the Process

Comprehensive testing of reference vehicle

Static MeasurementsDynamics Measurements

Construction of passive modelFocus on suspension & steeringTires

Validation of passive model According to IDIADA criteriaExtended validation program


Validation of the Simulation EnvironmentComprehensive Testing of Reference Vehicle

Static Measurements

K&C test of front and rear axles

Additional sensors for suspension parameters

Extended test matrix to generate complexsuspension maps based on multiple inputs

Center of Gravity

Static geometry and corner weights

Dynamics Measurements

Handling tests to characterize handling response

Brake tests to characterize braking system

ABS & ESC tests Test Reps Setup Total runs

Number of repetitions for each manoeuvre

See Channel List

Executions

Steady-State Cornering Const. Speed 1 AY = 0-lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 12Frequency Response Linear Range 1 AY = ± 3 3 1 GVM 1 OFF 1 -- Setup 1 3Step steer + Free control release 6 AY = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 72On-centre feeling weave 1 3 1 GVM 1 OFF 1 -- Setup 1 3Power-off reaction 6 AY = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 72Braking in a turn 6 AX = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 3 ON, OFF, No YRS 2 Left, Right Setup 1 108Double lane change 7 V = 80-85-90-95-100-105-lim 3 1 GVM 2 ON, OFF 1 -- Setup 1 42Dwell sine test 20 20 steps of SWA) 2 1 GVM 2 ON, OFF 2 Left, Right Setup 1 160

472

ManoeuvresNumber of manoeuvres to execute the test

ESC configs SidesESC ON, ESC OFF Left, Right

Weight configsGVM


Validation of the Simulation EnvironmentConstruction of a Vehicle Passive Model

Complex suspension maps generated by an in-house tool for conversion of K&C tables to IPG CarMaker model

Supplemented with vehicle data supplied from Opel(powertrain, body, aerodynamics)

Accurate representation of load & instrumentation

Validated against K&C tests


Validation of the Simulation EnvironmentFinal Validation Results

Steady State parameters

Frequency Response parameters

Sine with Dwell parameters

Ready for Active Model validation


Sine-with-Dwell Test ResultsVehicle Response for an exemplary Sine-with-Dwell Maneuver


Sine-with-Dwell Test ResultsESC pressure response for an exemplary Sine-with-Dwell Maneuver


Sine-with-Dwell Test ResultsSummary Report of a Sine-with-Dwell Test


ConclusionsPilot project between Opel and IDIADA to achieve CAE-basedhomologation of an ESC-system according to ECE-R 13-H

Setup of a high-quality simulation environment (HiL) is possible,but requires advanced integration solutions and expertise

Validation of the simulation environment by extensive static anddynamic measurements proves good correlation

Simulation results of Sine-with-Dwell maneuver are very close to real measurements

Quality of simulation allows the homologation of ESC systems

Process from testing to simulation to homologation is well understood and documented

Approach allows OEMs to significantly reduce the number ofreal tests during the ESC certification process

cae-based homologation of esc-systems using ipg carmaker · astra (2009 - ) abs / esc damping radar...

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