© 2003-11 KPIT Cummins Infosystems Limited

KPIT Cummins Infosystems Ltd.

KPT MBD Capability (Case studies on production

Programs in PowertrainSub-domain)

Date: 08-Jun-2011Version: 1.0

AGENDA

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KPIT Model Based Development Overview1

Case Studies2

MBD Functional Excellence

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KPIT MBD Workflow Management Framework

Integrated Data Backbone (Third Party PLM Database OR Proprietary)

Requirements Management

Configuration Management

Change ManagementSystem DataManagement

Parameter Data Dictionary

KPIT Build Automation

Model Style Checker Tool

Auto-Code DD Generator Tool

MIL Testing SIL Testing

Pre-configured Build

Triggers/Events

PIL Testing

Design MIL Testing Auto-Coding SIL Testing PIL Testing

Off-The-Shelf Tool KPIT Tool

MBD based Feature Development WorkflowModel Coverage Tool

Product Management

Engineering Workflow Management

Code Coverage Tool

Universal Test Specification

Requirement Modeling

System Design

Specification

KPIT Model Based Tools - Roadmap

AGENDA

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KPIT Model Based Development Overview1

Case Studies2

Case Study: Engine Controls Component Development

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FS Driver AT Driver

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OS - AS Interface

CommunicationsMachine

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Engine SubsystemsEngine

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GeneralBuild Specific

HW - SW Interface

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ine C

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t(s)

Mach

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Accesso

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Flash Loader

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OSBoot Strap AH Driver

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Modeled and Auto-coded Component Hand-coded Component

Software Product Line Architecture

Achievement through Product Line Architecture and Process (1)

• ROI• The cost benefit was 10 times• The cost of product development gone down by 10 times

• Productivity • Increased by 3.6 times• With PLA allocated efforts team can generate 2.6 more output (Productivity units like

Features, Models)

• Development Life Cycle• New product development time reduced by 80-90% reduction

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Legacy Product LineApproach

Dev Life Cycle (Months)

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Legacy Product LineApproach

Productivity

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Legacy Product LineApproach

ROI

New Approach

New Approach

New Approach

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Achievement through Product Line Architecture and Process (2)

• Reusability• Reusability moved from Code reuse to Requirement/Feature Reuse• Improvement for 5% during Legacy to 75%

• SW Build Time• Validated components available with plug n play capability for integration and build• Improved from 320 hours build time to just 4 hours for new product build using existing

software

5%

75%

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60%

80%

Legacy Product LineApproach

Re-usability (%)

320

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Legacy Product LineApproach

S/W Build Time (Hours)

New Approach

New Approach

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European OEM: Engine Function Development for Powertrain Software

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CLIENT : A leading European OEM with global presence

SITUATION : Client wanted to develop complete application software at offshore and integrate application software with Tier-1 integrator partner like Bosch, Delphi and Valeo

CLIENT : A leading European OEM with global presence

SITUATION : Client wanted to develop complete application software at offshore and integrate application software with Tier-1 integrator partner like Bosch, Delphi and Valeo

DEVELOPMENT WORKFLOW :DEVELOPMENT WORKFLOW :

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European OEM: Engine Function Development for Powertrain Software

Our Role•Analysis of Simulink model and software specifications• Model in Loop simulation using behavioral test vectors•Development of manual code based on proprietary architecture•Unit Testing of manual code using RTRT•Generation of data description file for integration of component software • Software in loop simulation•Preparation of system test cases•Verification of software on HIL

How KPIT Cummins met customer expectations:q KPIT Cummins has vast experience in Model Based developmentq KPIT Cummins had vast the experience in conventional codingq KPIT Cummins has a vast experience on Engine control domain, which was successfully blended into

this project.q KPIT Cummins had good experience in Embedded software development of Powertrain software.q KPIT has experience in Dspace HIL systemq Developed 65 OEM component application software as on date

Tools used:i. Matlab, Simulink, Stateflowii. Ciii. RTRTiv. Proprietary tool for SILv. Dspace HIL hardware, Control Desk

Case Study: Engine Start-Stop Feature Development

• Engine Stop/Start Algorithm Development from High Level Requirements from OEM

• Fault Tolerant State Machine for critical components like Dual Position Clutch Switch

• Safety conditions, User comfort conditions, Environmental conditions considered while stopping/starting the engine

• Autonomous Engine Start feature designed to take care of critical scenarios like:

• Critical Battery Condition (Low SOC, SOH)• Brake Vacuum Depletion

• Starter Protection Algorithm built in to protect against Starter Motor Overheating due to repeated cranks, accidental Starter engagement while engine is rotating

• Executable Specification Development complete with behavioral testing

• Multiple System Configurations based on different vehicle platforms

• Coordination with ECU Suppliers for S/W integration

• System Test Plan development for ECU Suppliers to perform bench testing

• Coordination with OEM for Vehicle Integration Testing

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Case Study: OBD-2 attribute management and OBD monitor

Objective

An efficient attribute management system detecting the PENDING/ CONFIRM/ PERMANENT fault sates is essential for faultmanagement to be in compliance with OBD II regulations. Development of OBD monitors

Value Addition

• Document for gap analysis between OBD and EOBD

• Requirement management using model based executablespecifications

• Modularize OBD Fault management system

• Developed OBD monitors for Air Filter, CAC temperaturesensor, Coolant temperature, EGR position sensor, Fuel level,MAF Sensor, EGR Flow, Misfire detection, injector learning,knock control

• Bench testing with customer simulator

• Increased productivity and schedule adherence leading tofaster time to market and reduced cost

Challenges

• Understanding OBD requirement & monitoring document

• Faster learning curve required for the resources

Requirement Study &specifications

Model development & Autocodegeneration

Bench test

Customer handover forvehicle test

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Case Study: SPLA OEM Stage 1: Vehicle Test Strategy(1)

• Comprehensive benchmarking of

vendors for:

• HIL Test Hardware

• Test Framework

• Plant Modeling

• Quantitative Analysis - Feature

based score-card for vendors

• Conceptualize System Architecture

for Vehicle Simulation Framework

• Multi-Technology, Off-The-Shelf +

Custom products based solution to

address OEM specific test needs

Vehicle Test Strategy ArchitectureHighlights

13Supports Component Test/Functional Subsystem Test/Vehicle Integration Test

Backbone Abstraction Layer

Test Management Suite

Vendor 1 HIL rack forPowertrainSubsystem

Custom BuiltHIL rack forBodySubsystem

Vendor 2HIL rack forSecuritySubsystem

Vendor 3HIL rack forInfotaintmentSubsystemCAN/LIN/Flexray

High Speed Network like Ethernet, Firewire, USB2.0 High Speed etc

Case Study: SPLA OEM Stage 1: Vehicle Test Strategy(2)

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Benchmarking Report

Backbone Vendors

Attributes%

Weightage

MBTech

Micronova

ETAS

ScaleRTOpal-

RTNI IPG

Tracetronic

Berner Mattner

Functional Requirements 90 57 52 38 40 37 49 42 25 39

Test Management 60 39 38 28 31 25 36 27 18 32

Interfacing Capabilities (APIs) 25 15 11 9 8 10 10 11 7 10

User Interface Control 10 6 6 4 4 6 6 6 0 2

Backbone Architecture 5 3 3 2 3 1 3 3 3 1

Total: Functional Requirements 100 64 58 42 45 42 55 46 28 44

Non-functional Requirements 10 9 9 5 0 0 5 5 0 4

License Type 20 20 20 10 0 0 14 10 0 20

Performance 40 40 40 20 0 0 17 20 0 0

Support 40 34 27 20 0 0 3 18 0 18

Total: Non-functional Requirements

100 94 87 50 0 0 34 48 0 38

Final Total 100 67 61 43 40 37 53 47 25 43

Attributes%

WeightageVector ADI MicroMax

Quanser

dSPACE AVL ADD2A&D Tech

Functional Requirements 90 43 45 34 36 35 19 0 0

Test Management 60 30 35 27 26 31 13 0 0

Interfacing Capabilities (APIs) 25 7 13 9 12 6 5 0 0

User Interface Control 10 8 0 0 0 0 2 0 0

Backbone Architecture 5 3 2 2 2 2 1 0 0

Total: Functional Requirements 100 48 50 38 40 39 21 0 0

Non-functional Requirements 10 4 7 5 4 4 3 0 0

License Type 20 10 20 12 12 10 8 0 0

Performance 40 11 11 20 11 11 11 0 0

Support 40 17 34 20 20 17 14 0 0

Total: Non-functional Requirements 100 38 65 52 44 38 33 0 0

Final Total 100 47 51 40 40 39 22 0 0

Case Study: SPLA OEM Stage 1: Vehicle Test Strategy(3)

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Benchmarking Report

HIL Vendors

Attributes % Weightage ADD2 ETAS ADI Opal-RT Micronova NI IPG

Functional 90 57 63 43 51 46 39 54

HIL Hardware 70 48 50 37 46 41 36 47

HIL Controller Software 30 15 19 11 11 10 7 13

Total: Functional requirements 100 63 70 48 57 51 43 60

Non-functional Requirements 10 6 8 4 4 5 3 6

License Type 20 20 20 9 19 2 0 20

Performance 40 32 27 16 0 29 13 32

Support 40 11 28 17 17 20 18 10

Total: Non-functional Requirements 100 63 75 42 36 51 31 62

Final Total 100 63 70 48 55 51 42 60

Attributes % Weightage MBTech SCALE-RT AVL Quanser dSPACE BM Vector

Functional 90 38 36 32 28 28 22 18

HIL Hardware 70 31 28 25 19 28 20 14

HIL Controller Software 30 11 13 11 12 3 4 6

Total: Functional requirements 100 42 41 35 31 31 24 20

Non-functional Requirements 10 2 4 2 1 7 2 2

License Type 20 9 8 0 0 17 6 8

Performance 40 0 14 10 10 26 5 5

Support 40 12 17 6 4 23 5 6

Total: Non-functional Requirements 100 20 39 16 13 66 16 19

Final Total 100 40 40 33 30 35 24 20

Case Study : HIL Test Automation (2)

SOLUTION

• Development of Product Line Test Architecture that facilitates automated testing of System Architecture

• Development of Feature Based Test Sequences for regression tests using National Instrument Test Stand

• Creation of standardized test environment with modular tests that is portable across platforms and applications

• Designing the system to achieve repeatable and reproducible test results

SOLUTION

• Development of Product Line Test Architecture that facilitates automated testing of System Architecture

• Development of Feature Based Test Sequences for regression tests using National Instrument Test Stand

• Creation of standardized test environment with modular tests that is portable across platforms and applications

• Designing the system to achieve repeatable and reproducible test results

TECHNOLOGY

• NI Test stand

• NI Lab VIEW

• CyberAPPs

• MATLAB

• Simulink

TECHNOLOGY

• NI Test stand

• NI Lab VIEW

• CyberAPPs

• MATLAB

• Simulink

CLIENT BENEFITS

• Improved Productivity

• Regression testing achieved

• Traceability achieved between test case and software

• Reduced On-Vehicle testing resulting in cost saving

CLIENT BENEFITS

• Improved Productivity

• Regression testing achieved

• Traceability achieved between test case and software

• Reduced On-Vehicle testing resulting in cost saving

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Case Study :European OEMà Powertrain HIL Testing

BACKGROUND

• A leading European OEM wants to improve profitability, improve quality processes, accelerate the product time to market & focus on core engineering activities.

• In order to achieve this goal KPIT took over the HIL based functional validation of Powertrain software Components.

PROBLEM STATEMENT• Requirements & Change Management

• Testing of Powertrain features like engine idle, speed governor, torque governor etc

OUR ACTIVITIES• Test Automation Framework Creation in dSPACE Tools• Requirement Analysis• Test Strategy and Test Case Development• Test Script Development, Execution, Fault Logging and Reporting

TOOLS• MATLAB / SIMULINK • dSPACE ControlDesk/Automation Desk

CLIENT BENEFITS• Improved Profitability & Quality of Test Life Cycle Activities• Values Delivered through reporting anomalies leading to specification and design change. This was highly appreciated

by client

dSPACEAutomationDesk

dSPACEControlDesk

Matlab/Simulink dS

PA

CE

HIL

Set

up

Net

wor

ked

ECU

sAnalog IF

CAN IF

IF

Rea

l T

ime-

IF

IF

IF

HIL Automation Testing Framework

17 Dspace HIL Platform

Case Study : Powertrain ECU validation using LABCAR (1)

CLIENT

A leading US automotive OEM with global presence

CLIENT

A leading US automotive OEM with global presence

SITUATION

Client objective was to validate a complete Powertrain ECU using LABCAR

SITUATION

Client objective was to validate a complete Powertrain ECU using LABCAR

ENVIRONMENT

• Hardware in the loop systems integrate an ECU with a simulated ECU environment. The use of HIL systems , or lab vehicles, allows ECUs to be tested early on in a virtual test environment without real environment components.

• HIL technology has reached a good maturity level. However, the total cost of ownership for HIL technology remains high. Therefore, efficiency and cost reduction are important goals for any test set up used by the client.

• Client was looking for a partner with experience of the Powertrain and the testing domain who will help in achieving efficiency and cost reduction

ENVIRONMENT

• Hardware in the loop systems integrate an ECU with a simulated ECU environment. The use of HIL systems , or lab vehicles, allows ECUs to be tested early on in a virtual test environment without real environment components.

• HIL technology has reached a good maturity level. However, the total cost of ownership for HIL technology remains high. Therefore, efficiency and cost reduction are important goals for any test set up used by the client.

• Client was looking for a partner with experience of the Powertrain and the testing domain who will help in achieving efficiency and cost reduction

18 ETAS LABCAR Platform

Case Study : Powertrain ECU validation using LABCAR (2)

SOLUTION

• Development of Validation test procedure closely working with the client• LABCAR based closed loop testing setup selection for ECU Validation• Different I/O configurations were suggested to the models provided by customer to improve testing• Additional test components were integrated with the models for optimization• Process development for generation of complete test plan, anomaly reports and test summary

SOLUTION

• Development of Validation test procedure closely working with the client• LABCAR based closed loop testing setup selection for ECU Validation• Different I/O configurations were suggested to the models provided by customer to improve testing• Additional test components were integrated with the models for optimization• Process development for generation of complete test plan, anomaly reports and test summary

TECHNOLOGY

• LABCAR

• ASCET RS

• DSpace

• ATI Vision

• INCA

• Pi Autosim

TECHNOLOGY

• LABCAR

• ASCET RS

• DSpace

• ATI Vision

• INCA

• Pi Autosim

CLIENT BENEFIT

• Make educated design decisions

• Reduction in Total Cost of Ownership

• Increased test efficiency, coverage and flexibility

• Achieve greater testing capacity

• Value creation through KPIT’s domain expertise

CLIENT BENEFIT

• Make educated design decisions

• Reduction in Total Cost of Ownership

• Increased test efficiency, coverage and flexibility

• Achieve greater testing capacity

• Value creation through KPIT’s domain expertise

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Thanks

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“Companies that focus on what they are very good at can thrive despite thesedifficult times. That has been the case for software companies likeKPIT Cummins…” - Paul Hansen – Sept’08

“KPIT is fast-growing and ambitious and represents the sort of company that in a decade could seriously challenge existing automotive software providers” Paul Hansen –Jan’08