development 4.0: the future is connected – which ... · © ipg automotive gmbh, 2016 development...

SOLUTIONS FOR VIRTUAL TEST DRIVING© IPG Automotive GmbH, 2016

Development 4.0:The future is connected – which possibilities are available already today?


Agenda

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� What is Development 4.0?

� How to Test Connected Systems

� Virtual Prototypes: An Important Part of the Strategy

� Cross-Domain Use Cases

� Summary & Outlook


Milestones in the History of Manufacturing

From the first to the fourth Industrial Revolution

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Mass

production

Use of

electricity as driving force

IT use

enables further automation

Digital revolution

and networking

1.0 2.0 3.0 4.0


What is 4.0?

Characteristics of Industry 4.0

The real and the virtual worlds are constantly growing together.

� Networked production

� Internet of Things

� Processes can be individualized

� Clients and partners can be integrated more easily into the process

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What Are the Current Trends in the Automotive Industry?

Requirements for modern vehicles and vehicle systems

The universal topic: connected systems

� Autonomous Driving and Car-2-X

� Energy consumption is predicted and optimized based on environment data

� Vehicles communicate with our “smart home”

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How Does This Influence the Development Process?

We need Development 4.0We must meet the requirements arising from connected systems

� Connected systems need to be tested as early as possible

� Different departments and development partners need to be involved

� Processes need to be digital and networked

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Supplier 1

Supplier 2

OEM

Dept. 1

Dept. 2

Dept. 1

Dept. 2

Dept. 1

Dept. 2


ACC with Traffic Jam Assist

An example of a connected system

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Camera

Brakes

Radar

Engine

ECUs

Steering

Car-2-X


How to Test Connected Systems

Example: Testing ACC with traffic jam assist

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� A system is more than the sum of

its subsystems

� The system must be considered as a

whole (the whole context)

� Systems Engineering is synonymous

with the development of the whole product:

software, hardware, services

Systems Engineering – Definition

Applied to the automotive sector:

� Testing the whole system

� In the context of the full vehicle

� Under realistic test conditions

(scenarios, closed loop)


How to Test Connected Systems

Example: Testing ACC with traffic jam assist

Scenario-based testing:The key for testing connected systems in realistic conditions

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Signal-based testing

Single signal

…

Scenario-based testing

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Systems Engineering approach

NOT FULFILLED because:

� Only the system under test considered

(NOT in a full vehicle)

� System is NOT tested under realistic conditions

(NOT in scenarios)

Systems Engineering approach

FULFILLED because:

� Whole system under test considered

(in a full vehicle)

� System tested under realistic conditions

(in scenarios)


And What about Testing Autonomous Vehicles?

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Tasks: � Testing autonomous vehicles in unlimited realistic scenarios - reproducible

� Testing millions of kilometers every night to investigate

a possible negative impact of software & parameter changes

� Testing complete system in a full vehicle in realistic scenarios

� Powerful capabilities to integrate systems into the virtual prototype

� Efficient test automation + evaluation capabilities

� Testing huge maneuver catalogues using HPC (High Performance Computing) Cluster

Needs:

Automotive Systems Engineering = Development 4.0


CarMaker, TruckMaker, MotorcycleMaker

Open Platforms for Automotive Systems Engineering

The virtual vehicle prototype plays the essential role

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Integration platform

(SW / HW)Virtual test driving Visualization

Test automation

& evaluation

Road

Traffic

CLOSED LOOP

Driver

Vehicle


EVERYengineer has the opportunity to evaluate new systems in the full vehicle.

The Solution

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Instages of development, virtual prototypes are available.

ALL

VIRTUAL TEST DRIVING


Components and Characteristics of a Virtual Prototype

1. Components

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The virtual vehicle has the same components as the real-world vehicle

Vehicle Body

Aerodynamics

Suspension

Bodies

Brake

Powertrain

Sensors

Engine

Steering


Components and Characteristics of a Virtual Prototype

2. Characteristics

Important: The virtual vehicle has the same vehicle dynamics behavior asthe real-world vehicle

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How to Get a Virtual Prototype

Additional, customer-specific vehicle components and controllers will be integratedExisting vehicle components in CarMaker will be parameterized

Additional, customer-specific vehicle components and controllers will be

integrated

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Brake

Solution: Virtual prototype integration workshop – analogous to the real world

Powertrain

Engine

SteeringBodies

Suspension


Three Steps to Your Virtual Prototype

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2nd step: validation of the virtual prototype using typical vehicle dynamics maneuvers

Real-world

vehicle behavior

Virtual-world

vehicle behavior

Supplier 1

LDW ECU

OEM In-House

HMI interfaceSupplier 2

Camera

3rd step: integration of systems under test

…

1st step: basic parameterization (vehicle dynamics)

Vehicle data set

generatorANDOR

Test bench

measurements


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Automotive Systems Engineering in the Development Process

Providing internal departments + suppliers with virtual prototypes

Engineers can test and release their systems in a full vehicle: Automotive Systems Engineering!

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Internal dept. 1 or

supplier 1Component „A”

Internal dept. 2 or

supplier 2Component „B”

Internal dept. 3 or

supplier 3Component „C”

Internal dept. N or

supplier NComponent „Z”

Virtual Prototypes“Integration workshop”

Internal development depts. or suppliers

� Development + test of entire systemin full vehicles in scenarios

� Pre-calibration of the system

Test driving department

� Calibration (virtual + real)

� Release (also virtual)


Virtual Prototypes at Jaguar Land Rover

Tasks are e.g. simulation strategyCentral virtual engineering organization as strategic element at JLR

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Virtual Prototypes at Jaguar Land Rover

Typical application areas are vehicle dynamics, ADAS and powertrainVirtual prototypes are used in many different departments at JLR

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Virtual prototypes are handled in the same way as real production vehicleswith RPO (Regular Production Option) Codes

Management of Virtual Prototypes

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Management of Virtual Prototypes

Virtual prototype of CarMaker:

� Basic parameterization of virtual

prototype is ASCI-based

� Integrated vehicle

component models

available as

C code, Simulink, FMUs …

Typical situation:

� Clients of

IPG Automotive have

already established

databases in their

development processes

Virtual prototypes can be managed in existing or standard databases or PLM systems


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Using virtual prototypes in the entire development process

Reuse of virtual prototypes and maneuvers saves time and costs

Same maneuvers + same evaluation criteria


Virtual Prototypes at PSA

Using virtual prototypes additionally enables a reduction ofphysical prototypes by ~ 30 % and speeds up time-to-market

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Collaboration between OEMs and suppliers

Collaboration unlocks the full potential of Automotive Systems Engineering and

offers potential for improvement of development process, e.g. front-loading

OEMs Suppliers

� Encrypted virtual prototypes

� Maneuver catalogs

� Evaluation criteria

� Component / control unit models

� Maneuver catalogs

� Evaluation criteria


Hybrid Vehicle System

Well-founded decisions already during the conceptual phase

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Sourc

e:

BE

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MILSIL

HILVIL

SOP

Virtual hybrid vehicle concept

evaluation at the beginning of the

project:

� Driving dynamics

� Powertrain performance

� Overall weight and weight distribution

� Operating strategy

Layout & design


Dynamic Light Functions

Development + pre-calibration

Calibration in the real vehicle in the “valuable” nightIdentify and fix bugs with the help of virtual test driving during the day

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Vehicle model

Sensor and camera models Headlightactuators

Horizontal/verticalheadlight position

Light

FMU

Velocity, yaw rate

Light on/off, steering angle

Position of preceding andoncoming vehicles,environmental information

CarMaker integration platform

MILSIL

HILVIL

SOP

Driver model


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Trailer Stability Control (ESC)

Development + pre-calibration

Pre-calibration of Trailer Stability Control in CarMakersaves effort and costs for physical testing

MILSIL

HILVIL

SOP

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ESC

PSA profited from the experience of an Airbus expert (HIL method of aviation)Automated test & evaluation saves an enormous amount of time for validation

ESC software validation

(fail-safe, function, performance):

� In real-world test driving:

� Effort: 2 months

� Using the simulation (manually):

� Effort: 2 weeks

� Using the simulation

(automated test and evaluation):

� Effort: 2 days (!)

MILSIL

HILVIL

SOP

Validation


Real Driving Emissions (RDE)

Testing the engine on an engine test bench

Reproducibility of the tests is ensured even in complex scenariosInvestigations with different driver behaviors and in any kind of traffic situation

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Summary & Outlook

The use of virtual prototypes takes the development process to a higher level

� Automotive Systems Engineering facilitates the networked development process

� Virtual prototypes are the key component

� Organizational responsibility for building the virtual prototypes needs to be defined

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development 4.0: the future is connected – which ... · © ipg automotive gmbh, 2016 development...

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