SOLUTIONS FOR VIRTUAL TEST DRIVING

ESC-HIL TEST SYSTEM

2

Table of Contents

Motivation 3

System at a Glance 4

General Description 5

Block Diagram (example configuration) 6

Use Cases 7

Verification and Validation of ESC Systems

Variant Testing, Validation and Homologation

Best-in-Class Features 8

Add-ons and Integration Potential 9

Synergy Effects Using CarMaker / HIL platform

Integration of Further ECUs and the FailSafeTester

Integration of Further Mechanical Components

Scope of Delivery 10

Appendix: Test Bench Results 11

Virtual Test Driving

Vehicle Dynamics

Global Vehicle Requirements Released Vehicle

Integration

of ECU(s) or complete vehicle systems

in a virtual prototype

Powertrain

Integration

of multi domain models from different development tools in a virtual prototype

ADAS

Figure 1: Early validation of components and systems along the V-model

Validation against global vehicle target

The key objective of developing electronics in automotive development projects is to ensure the reliability of the

individual components in any situation. Therefore, the increasingly complex development processes and interlinking

of the components require supporting simulation techniques. They assist in shortening development cycles and in

detecting sources of faults in the interaction of the components at an early stage. This is a challenge faced by both

automotive OEMs and suppliers. Hardware-in-the-loop simulation (HIL simulation) is a major element of optimizing

the development process.

Motivation

3

Real-world electronic vehicle control units and prototypes such as the electronic stability control (ESC) unit are

connected with real-time simulation models of the vehicle and the vehicle’s environment, or with a complete

simulation environment (CarMaker).

HIL simulation allows users to perform tests under real-word conditions in a laboratory environment. This not only

makes it possible to test electronic components in any conceivable failure mode, but to also conduct tests which

are often difficult to implement in real-world conditions. In the simulation environment, risk-free and reproducible

testing of dangerous worst-case scenarios is possible with just a minimal investment of effort and expense.

Due to this approach, final test driving can be accomplished with a significantly reduced effort. This ultimately

leads to major time and cost savings, as well as substantial quality improvement.

The correct functionality of ESC systems is important not only due to their mandatory use in all newly registered

passenger cars and trucks within the EU. In addition, ESC, as an interacting electronic control unit for numerous

other applications in the vehicle (e.g. ADAS, energy efficiency, steering systems), plays a central role and has long

ceased to be defined strictly as a vehicle dynamics control system.

The HIL method has long become established as the standard and essential technique that makes it possible to

manage the immense testing requirements of diverse functionalities.

4

Delivery of the fully functional test system in a 38” rack housing (see picture) is standard. This ensures ease of

integration and maximum future extensibility by further components and upgrades. However, if required, the setup

can also feature smaller test benches – through to portable desktop cases.

System at a Glance

Power Supply

Fully programmable,

optionally with Car Start

functionality.

Xpack4 Real-Time System

Including CarMaker/HIL and

relevant I/O-devices.

FailSafeTester

State-of-the-art solution

for automatic fault insertion

without manual patching

cables.

Plug-in Test Boxes

Connected customer ESC-

ECU(s) as device under test.

Test boxes can be exchanged

easily by “Plug & Play”.

Standard 19” Rack Housing

In different heights and pre-

configurations customized for

every use case.

5

The ESC-HIL test system is a turnkey solution for testing and validating real- world ESC units – enabling all ESC functionalities to be tested with a single HIL system.

The main components include:

� CarMaker simulation software

� Xpack4 realtime system with ESC-specific I/O

� Electrical, mechanical and functional integration of the customer’s ESC ECU

� Optional coupling with FailSafeTester

� Integration in a standard 19” rack with power supply unit

The ESC ECU is integrated as a real-world component, where the hydraulic system including the hydraulic pump

is modeled. The resulting elimination of mechanically moved components reduces power requirements and noise

development during operation.

The vehicle model with the corresponding driver and brake model generates the steering wheel angle, wheel

speed, yaw rate, lateral acceleration and primary brake pressure.

Thanks to specifically developed tools, the ECU residual bus simulation is automatically generated directly from

the database (e.g. the DBC file) for commonly used field bus systems such as the CAN bus. The valve activities

are measured by a special-purpose, high-precision analog signal acquisition box and fed back to the hydraulic

model (virtual valves).

Due to the high quality of the valve position measurement, the IPG SignalAcquisitionBox, makes it possible to run

all performance tests in addition to functional and fail-safe tests. Quick calibration and no need for re-calibration

after reinstalling the ECU, is a further advantage that saves time and costs.

In addition, the CarMaker/HIL environment offers extensive possibilities for ECU diagnosis directly from the Car-

Maker GUI. Access to and processing of internal ECU parameters is possible even during runtime thanks to CCP/

XCP access.

General Description

Block Diagram (example configuration)

User Interfaces (CarMaker Host-PC)

Simulation Framework (CarMaker Xpack4)

Driver ModelRoad Model

Vehicle Model

Ethernet

Engine / Hybrid Model

Hydraulic Brake Model

Trq

Re

qu

est

Tir

e M

od

el

Roadway Information

Steering Wheel

Pedals

Cockpit

Xpack4 I/O

FailSafeTester Power Supply

Ve

hic

le B

usYaw Rate

Wheel Speed

Lateral Acceleration

Primary Pressure

Ma

gn

eti

c V

alv

e

Po

sit

ion

s

Power Control

PCI Bus

ESC ECU Sensor Box

Device Under Test (Plug-in Test Box)

Hyd

rau

lic

Pu

mp

P

ressu

re

6

Software Components

Hardware Components

Fail-Safe Tests Function Tests Performace Tests

7

Verif ication and Val idation of ESC Systems

ESC-HIL test systems by IPG Automotive cover the entire range of ESC-related tests:

Fail-safe tests, functional tests and performance tests.

While simulation-based fail-safe testing has become well established due to low requirements regarding

simulation model quality and maneuver setup flexibility, simulation-based functional testing and performance

testing requires high model quality and a versatile way of setting up maneuvers, evaluation criteria, post-

processing routines and reporting functionality. Obviously, all of these requirements are covered by the CarMaker

product family. Performance tests make it possible to quantify the operational quality of a function and whether

the resulting vehicle performance matches the brand’s image (also frequently referred to as brand DNA).

Variant Testing, Val idation and Homologation

Utilization of the ESC-HIL test system fully supports simulation-based ESC homologation according to ECE-R

13H. As a result, the high correlation between measurement and simulation makes it possible to already validate

the growing number of variants and derivatives in vehicle development in simulation and HIL. Consequently, the

number of real-world vehicle tests can be significantly reduced.

Use Cases

� Sensor defect

� Backup mechansim

� Communication

� Diagnostic

� ...

� ABS/ASR/VSC

� Steering support

� Hill-hold control

� ACC functions

� ...

� Inlet speed

� Stability value

� Threshold consumption

� Braking distance

� ...

© fotolia.com

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� The CarMaker software environment not only provides an open and flexible platform for integrating the user’s

own models but also a state-of-the-art vehicle dynamics environment that enables physically correct behavior

up to the limit.

� Thanks to the modern FailSafeTester concept, electrical faults can be generated in fully automatic mode with

free selection of the failure modes. As a result, it is possible to reliably conduct targeted investigations even in

worst-case scenarios.

� The maneuver- and event-based approach to testing enables uncompromising transfer of test cases from the

SIL or even the MIL stage. Even highly complex closed-loop driving instructions can be easily executed and

fully reproduced – assisted also by the highly sophisticated IPGDriver model.

� The ESC-TestWare option combines the knowledge and expertise from more than 30 years of experience in the

vehicle dynamics environment in bundled test catalogs. Linking with the Test Manager makes it possible to fully

automatically run complete test series and test catalogs for hours and even days at a time.

Best-in-Class Features

Further Advantages at a Glance

� Open and robust architecture consisting of off-the-shelf industry components

� Extremely high computer and communication performance (5 -10 times faster than the benchmark)

� Intuitive use on PCs

� Stable test automation and test management

� Exact reproducibility of the results across extended periods of time

� Unrivaled turnaround times thanks to interaction between real-time node and host PC

� Support of all automotive-specific I/O interfaces such as CAN (FD), Ethernet, FlexRay, LIN, DAC, AD, PMW, etc.

� Vehicle-specific I/O modules for Chassis, Powertrain, ADAS and Body Control applications

� Matlab/Simulink-based modeling possible but not imperative

9

Synergy Effects Using the CarMaker / HIL Platform

Use of open integration opportunities on the highest

level:

� Simulation of the test vehicle and environment

in hard real-time conditions

� Easy use and integration of validated model

libraries (e.g. tires, suspension, MBS axles) and

users’ own models via C-Code, FMI, Simulink and

other interfaces

� IPGDriver model for sophisticated closed-loop

driving tasks

Integration of Further ECUs and the Fai lSafeTester

� The Xpack4 Integration HIL system provides

possibilities for further plug-in test boxes extending

the range of test cases of the entire system.

Functional tests and interactions between the ESC

system and other components of any kind such

as active dampers or electric power steering are

possible at the highest levels of reproducibility even

in complex settings.

� The FailSafeTester provides opportunities for testing

all kinds of electrical faults such as in power supply,

(wheel speed) sensor signals and CAN signals.

Integration of Further Mechanical Components

� For the interaction of ESC with EPB functions the

real-world EPB brake calipers can be integrated as

mechanical components as well.

� The ESC test system, with mechanical integration

of the brakes in their true locations at the front and

rear axle, can be extended to create a full-fledged

dual circuit braking system test bench.

Add-ons and Integration Potential

10

Scope of Delivery

Test systems by IPG Automotive are turnkey solutions.

Following the complete integration of the customer’s DUT, the system is delivered in fully operational condition.

After on-site commissioning, assistance by specialists who are familiar with the system will be available to custo-

mers at any time.

A possible configuration looks as follows:

HIL rack environment

Software HIL / DUT Engineering

Customer Services

Real-time system –

Xpack4 for ESC

� 19” subrack

� Carrier board and dual

or quadcore CPU

� I/O modules

� M410 – CAN

� M32 – Digital in

� M36 – Analog in

� M43 – Relay out

� M62 – Analog out

� M400 – wheel speed

generator

� M409 – Power Supply

Control

� Cabinet peripherals

� 80V / 100A Power supply

with car start option

� Cabinet 24 or 38 units

� Configured host PC

CarMaker / HIL pro

� IPGGUI

� IPGCar

� IPGTrailer

� IPGTire

� IPGDriver

� IPGRoad

� IPGTraffic

� ManeuverControl

� IPGControl

� IPGInstruments

� IPGMovie

� Test Manager

� ScriptControl

� FailSafeTester Tool

� Diagnostic Tool support

� CCP/XCP and Flash Tool

� CAN/FlexRay/LIN Tools

Plug-in test box for ESC

� Electrical and

mechanical level

� Software level

� Functional level of

integration

Integration in turnkey

HIL

� Planning

� Construction

� Implementation

Start-up

� On-site installation

� Customer instruc-

tion

Training

� CarMaker / HIL

training for ESC

Support

� Support and main-

tenance by qualified

experts worldwide

Appendix: Test Bench Results

54

56

58

60

62

64

66

68

300 310 320 330 340 350 360

Ve

hic

le V

elo

cit

y (

km

/h)

Position x (m)

-8

-6

-4

-2

0

2

4

6

8

300 310 320 330 340 350 360

Position x (m)

Ac

ce

l. L

at.

(m

/s²)

CarMaker simulation

Real measurement

Pressure master cylinder simulated

Wheel pressure font left

Wheel pressure rear left

Pressure master cylinder measured

Wheel pressure font right

Wheel pressure rear right

Pre

ssu

re (

ba

r)

Time (s)

1220

1314 15 16 17 18 19

200

175

150

125

100

75

50

25

0

Corr.: 99% Corr.: 92%

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Hydraulic brake model performance

Braking pressures while braking on µ-split (ABS function)

Vehicle model performance

Double lane change (ESC function)

As an innovation driver for virtual test driving, the company is a leading global provider of software and hardware products

for the automotive and supplier industry. With the areas Simulation Software, Real-time Hardware, Test Systems and

Engineering Services, IPG Automotive supports its customers in creating innovations and improving their development

process efficiently. The simulation solutions CarMaker, TruckMaker, and MotorcycleMaker, as open integration

and test platforms, facilitate great savings in time and cost for customers, in a continuous development process of

Model-, Software- and Hardware-in-the-Loop, all the way to the Vehicle-in-the-Loop method. The application

ranges from the general vehicle dynamics simulation, developing and testing of chassis control systems, as

well as interconnected systems such as chassis, powertrain, and steering in full electric and hybrid vehicles.

Another strength of IPG Automotive is the development of future-oriented solutions for the integration and testing of

advanced driver assistance systems.

© IP

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Simulation Software • real-time Hardware • teSt SyStemS • engineering ServiceS

SOLUTIONS FOR VIRTUAL TEST DRIVING

IPG Automotive GmbH • Bannwaldallee 60 • 76185 Karlsruhe • Tel.: +49 721 98520 0 • ipg-automotive.com

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