cmc india - etas paper
DESCRIPTION
Frontloading through virtualization presented at Controls, Measurment and Calibration organised by AUTOMAKER Media GroupTRANSCRIPT
1 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization Stay Real, Start Virtual
Ms. Shruthi Ananthachar
Mr. Nithin Nath
2 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
1975 1985 1995 2005
Electronic fuel injection
Cruise control
Gearbox control
Traction control
Anti lock brakes
Electronic fuel injection
Cruise control
Airbags
Electronic stability control
Active body control
Adaptive gearbox control
Adaptive cruise control
Emergency call
Gearbox control
Traction control
Anti lock brakes
Electronic fuel injection
Cruise control
Tele-diagnostics
Internet browser
Apps
Car-2-car communication
Road trains
Software updates
Adaptive headlights
Active steering
Curve warning
Stop and Go
Lane keeping assistance
Automated parking
Collision mitigation
Hybrid powertrain
Emergency call
Airbags
Electronic stability control
Active body control
Adaptive gearbox control
Adaptive cruise control
Gearbox control
Traction control
Anti lock brakes
Electronic fuel injection
Cruise control
− Pressure to differentiate through innovative functions
− Many innovations are either safety-relevant and/or involve connectivity to the outside world
− Restrictive legal and standard requirements
− Cost and time-to-market pressures, high penalties for
poor quality
2015
Frontloading through Virtualization
Increase in Control System Complexity
3 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Increase in Calibration Complexity
Increased inter-domain connectivity
Battery Management
Transmission Management
Engine Management
Brake Management
Vehicle Motion Management
ECU Hardware
Microcontroller Abstraction
Basic Software Module (BSM)
AUTOSAR-RTE
SW- Component 1
AUTOSAR Interface
SW- Component 2 AUTOSAR Interface
SW- Component 3 AUTOSAR Interface …
New layered standard architecture
New functions and variants
Engine control complexity
1997 2002 2004 2007
40
00
90
00
12
00
0
16
00
0
Effort Number of calibrations
100%
0%
25
00
0
2010
40
00
0+
2020
4 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
…leads to significant cost reduction
Benches Vehicles
Effo
rt
Today – 5%
2015 – 20%
Simulation
Today – 70%
Today – 25%
2015 – 40% 2015 – 40%
Reduce Cost for Function Development and Calibration
6 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Edit-Integrate-Validate-Update
Validate the function in Virtual or real environment
Change specification,
Debug SW,
Change parameter
Integrate Functions with base SW,
Simulation Environment
Develop Concept,
Implement Concept,
Calibration,
Fine tuning
Edit Integrate
Validate Update
Validation Feedback Loop is a key towards efficiency
Frontloading through Virtualization
7 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Motivation
Frontloading through Virtualization
8 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Compressing the V-cycle
9 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Motivation
11 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Validating new vehicle functions today…
Reserve a test vehicle
Flash software or configure hardware
for prototyping
Validate against requirements
Failed Make required
adjustments Passed
Frontloading through Virtualization
Function development Frontloading
12 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Compile
Validating new vehicle functions in the future…
Virtual Prototype Validate against requirements
Failed Make required
adjustments Passed
Frontloading through Virtualization
Function development Frontloading
13 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
F
F
New developed functions, e.g. in ASCET or Simulink®
4
7
Solution
− Create a complete virtual prototype to allow detailed validation
− Execute virtual prototype on a standard windows PC
− Experiment and calibrate with existing tools e.g. INCA
− Better quality models streamlines collaboration ETAS INCA
+ Automotive Production OS
+ Measure Data Files (Stimuli) + Plant Model + Calibration Infrastructure
Production Function Componentss (FCs)
+
F
F
OS
MDF Stimuli
Plant Model
ECU FCs
14 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Co-simulation during modeling
15 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Rea-time-PC MCAL
OS
Rea-time-PC MCAL
OS
Rea-time-PC MCAL
OS
ECU MCAL
OS
Basic SW
RTE
Application Software
Basic SW
RTE
Application Software
Basic SW
RTE
Application Software
Basic SW
RTE
Application Software
Virtual PC MCAL
OS
Real-time PC MCAL
OS
Real-time-PC MCAL
OS
Taking Benefit of AUTOSAR: same SW under test in all environment
Frontloading through Virtualization
Software development Frontloading
16 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Function development Frontloading
Virtual ECU
17 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Testing Frontloading
18 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
ETAS approach
19 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Calibration Frontloading
20 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Conventional Calibration Approach
Calibrator Workstation
Vehicle Environment
I don’t believe in virtualization… I don’t think it even works!
I prefer to work on a “real” target
21 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Users of Conventional Approach expect…
• Very high accuracy – Best trade-off between model-error & no. of training data.
• Global engine models for calibration possible.
• Best model is built automatically.
• Easy and descriptive rating of model quality – Only basic DoE and statistic knowledge needed
• Many optimization features for calibration, e.g: multi-criteria (pareto) or fast cycle-optimization
• Easy & flexible data import & export: xls, txt, csv, dcm …
• Open Matlab interface for scripts, extensions or test bench connection. Model export e.g. to C, Matlab, Simulink, Excel, …
Frontloading through Virtualization
Conventional Calibration Approach
22 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Model Based Calibration with
ASCMO ®
Injection
Ignition
P-rail
EGR
Outlet-cam
Inlet-cam
AFR
Injection
Ignition
P-rail
EGR
Outlet-cam
Inlet-cam
AFR
T-exhaust
Soot
Roughness
Torque
NOx
HC
Consumption
T-exhaust
Soot
Roughness
Torque
NOx
HC
Consumption
Guided Calibration with
INCA-FLOW ®
Frontloading through Virtualization
Model & Automation based Calibration Approach
Integrated solution for the calibrator
Advanced Simulation for Calibration Measurement Optimization
23 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Calibration Frontloading – model based approach
24 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Calibration Frontloading – model based approach
Po
we
r
Engine Speed
250 230 200 180 160 130 100
Scalability & re-use of global data • Varied Torque • Payload • Fuel Economy target • ….
Pictures courtesy Ashok Leyland
25 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
25
Principle:
Search in a complete function space:
Automatic determination of the most likely function
Advantages High flexibility without assumptions or expertise
Gives local confidence interval (model variance)
Robust against outliers
Principle:
Search in a given class of functions (polynomial, neuronal net, ...)
Fit the model parameter by experts and validation measurements
Disadvantages: Limited flexibility & danger of over-fitting
High expertise and assumptions necessary
Training Data
Model Prediction
Training Data & Model Prediction
Modelvariance & Validity
Modeling a complex 1-D signal with classical DoE-Models („Advanced Polynomials“)
Modeling a complex 1-D signal with new statistical machine learning methods
Polynomials or Neuronal Nets Statistical machine learning methods
Frontloading through Virtualization
Calibration Frontloading – model based approach
26 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
ECU software
Hex + A2L+
ES592
Engine Speed
To
rqu
e
Driver Demand
Full-Load Curve
Smoke Limit Curve
Smoke Limitation Optimization on a Diesel platform Visual Optimization Method – Partial Online
Frontloading through Virtualization
Calibration Frontloading Use-Case
27 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
ECU software
Hex + A2L+
ES592 INCA FLOW®
Sequence
INCA On-line Environment
Frontloading through Virtualization
Calibration Frontloading Use-Case
28 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Calibration Frontloading Use-Case
DoE-Plan
Optimising outputs
based on the model System-
inputs
System-
outputs
Model training using measured data from DoE-Plan
150
200
250
300
350
20
40
60
80
100
145
150
155
160
165
CO2 Ordnung 3, Minimum bei (170Nm,30kW)
Mathematical Model
29 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Model based & Guided Calibration reduces calibration effort by roughly 70% for this use case!
Frontloading through Virtualization
Calibration Frontloading Use-Case
30 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Summary – Advantages
31 Public| ETAS India| 2014-05-29 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Frontloading through Virtualization
Stay Real, Start Virtual