Introduction of practical uses of
Plant Model in Model Based Development
AISIN AW CO.,LTD
ADVANCED ENGINEERING GROUP
ELECTRONIC ENGINEERING DEPARTMENT
SENIOR SPECIALIST
TAKAYUKI KUBO
AISIN AW CO., LTD..
Agenda
3 June 2008
1. Introduction
2. Status of activities for Model Based Development
1. ＨＩＬＳ development
2. ＨＩＬＳ engineer curriculum
3. MATLAB basic text
3. Control system development
1. The first try to Control logic development
2. NEW Control logic development
4. Plant model development
5. Examples of application
6. Expectations for SimDriveline
7. Activities for Automatic Code Generation (ACG)
8. Closing
Page 2
AISIN AW CO., LTD..
1.Intoducion : Company summary
3 June 2008
Company Name
AISIN AWCO.,LTD.
Establishment May 15 , 1969
Consolidated sales 958,300,000,000 Yen
≒US$ 9,583 million
(Unconsolidated sales 876,400,000,000 Yen)(FY2007)
≒ US$ 8,764 million
Number of employees 16,750 (31-Mar-2008 )
(US 1dollars = 100Yen)
Page 3
AISIN AW CO., LTD..
Main three products of AISIN AW
3 June 2008
Comfort and environment-friendly driving
快適で環境に優しい走り
High-spec
multi-step AT
｜高性能多段ＡＴ
Automatic Transmission (AT)
｜先進的ハイブリッドシステム
Advanced hybrid system
Comfort
and safety driving
快適で安全な走り
｜高機能カーナビゲーション
High-spec car- navigation system
Page 4
AISIN AW CO., LTD..
Offices
3 June 2008
Europe
Asia Pacific
ＡＷＴＣ－Ｅ
ＡＷ Europe
Engineerin
g
Production
Service
TIANJIN
AW
AISIN AW
ＡＷ Headquarters
ＡＷＴＣ
－Ｅ
ＡＷ Europe
America
ＡＷＴＣ－ＵＳ
Ａ
ＡＷＴＥＣ
ＡＷＮＣ
ＡＷＴＣ－Ｕ
ＳＡ
ＡＷＮＣ
AWQUIS JAPAN
ＡＷ Europe
Page 5
ＡＷＴＥ
Ｃ
AISIN AW CO., LTD..
Current Business Status
Million
Units/year
3 June 2008
World No.1 share
6
World Share 2007
OTHERS
5
18.1
39.9
7.7
4
F
5.84 Mil
(2007)
9.5
13.2
11.8
G
J
D
3
Business start
with Volvo (‘75)
Business start
with US Ford (‘03)
2
Joint Venture with
Borg-Warner(‘69)
1
Termination of
Joint Venture(‘87)
0
'69
'75
'80
Page 6
'85
'90
'95
'00
'07
AISIN AW CO., LTD..
Introduction of latest new products
3 June 2008
Introduction of latest new products
FF CVT
FF 6AT
FR 6AT
FR 5AT
HV
FR 4AT
FF 6AT
FR 6AT
Page 7
FF CVT
FF CVT
FR 6AT
FR 6AT
HV
HV
FR 8AT
AISIN AW CO., LTD..
- 38 CUSTOMERS AROUND THE WORLD EUROPE
EUROPE
* VOLVO
* Ford of Europe
* JLR
* PSA
* VW
* Audi
* Porsche
* Opel
* Vauxhall
* Saab
* Renault
* BMW
* Fiat (Pininfarina)
* SEAT
* SKODA
SOUTH
SOUTH AFRICA
AFRICA
* VW South Africa
Page 8
3 June 2008
JAPAN
JAPAN
* Toyota
* Mazda
* Mitsubishi
* Isuzu
* Suzuki
* Nissan
ASIA
ASIA &
& OCEANIA
OCEANIA
* Changan Ford
* Ford Lio Ho
* Hyundai/ Kia
* GM Daewoo
* Renault
Samsung
* GM Shanghai
* VW Shanghai
* FAW-VW
* Changan Automobile
* SMMC
NORTH
NORTH AMERICA
AMERICA
* Ford U.S.
* VW Mexico
* CAMI
* GM Mexico
SOUTH
SOUTH AMERICA
AMERICA
* Ford Brazil
* GM Brazil
AISIN AW CO., LTD..
Agenda
3 June 2008
1. Introduction
2. Status of activities for Model Based Development
1. ＨＩＬＳ development
2. ＨＩＬＳ engineer curriculum
3. MATLAB basic text
3. Control system development
1. The first try to Control logic development
2. NEW Control logic development
4. Plant model development
5. Examples of application
6. Expectations for SimDriveline
7. Activities for Automatic Code Generation (ACG)
8. Closing
Page 9
AISIN AW CO., LTD..
2．Status of activities for Model Based Development
3 June 2008
•Reason of why activities for Model Based
Development were started from Hardware In the
Loop Systems (HILS) development
１
Simulation (model)
SILS
Code generation
Write on TCM
HILS
real
Simulation (model)
Control
plant
Rapid
Prototype
Page 10
Evaluation on vehicle
real
AISIN AW CO., LTD..
2.1 HILS development
3 June 2008
Background of ＨＩＬＳ development
•
•
In 1998, we succeeded in production of five-speed A/T.
At this time, amount of control specification increased to ten times of
four-speed A/T’s one.
• And same time, software size and necessary man-hour for software
testing increased more.
Page 11
5speed A/T
AISIN AW CO., LTD..
2.1 HILS development
3 June 2008
• Around 2000, HILS development was started.
• In 2002, we started the use of the HILS device.
FF6AT
FF5AT
FR8AT
Production
start
1998
2002
2000
2007
HILS
Start to
develop
Start to
use
over 100 projects
The number of the projects
that We can test.
20-30 projects
Page 12
AISIN AW CO., LTD..
2.1 HILS development
3 June 2008
• Two types of HILS were developed.
– Multi-node HILS
– Small-scale HILS
CPU:
CPU:
Pentium-M2.1GHz
Pentium-Ⅳ
3.4GHz×2
purchasing cost is half
can't simulate
electrical failure
Page 13
can simulate
electrical failure
AISIN AW CO., LTD..
3 June 2008
HILS system
HILS models
Page 14
AISIN AW CO., LTD..
2.2 HILS engineer curriculum
3 June 2008
• Necessary man-hour for software testing was reduced
• Other effects
– Skill definition for education based on Embedded
Technology Skill Standards - Japan Matlab Automotive
Advisory Board (ETSS-JMAAB)
• Basic curriculum for HILS engineer was established
• Beginner’s text of MATLAB/Simulink was completed
– MBD was recognized in our company
• Effect of HILS is recognized in our company too.
In 2006, application of MBD for control
logic development was started.
Page 15
AISIN AW CO., LTD..
2.2 HILS engineer curriculum
3 June 2008
Based on ETSS-JMAAB, basic curriculum was
established.
1.
2.
3.
4.
Distinguish engineers by level
Analyze engineers
Specify necessary skills for each level
Establish curriculum
Page 16
AISIN AW CO., LTD..
2.2 HILS engineer curriculum
3 June 2008
Distinguish engineers by level
• Comparison of hours for same work
9
Level 2
Number of persons
8
7
6
5
4
3
2
Level 4 or Level 3
higher
Level 1 or lower
1
0
1h
2h
4h
8h
Distinguish engineers by seven degrees of levels
Page 17
AISIN AW CO., LTD..
2.2 HILS engineer curriculum
3 June 2008
About items on basic curriculum
• In order to find the correlation between level and skill,
multivariate-analysis was used.
Page 18
AISIN AW CO., LTD..
2.2 HILS engineer curriculum
3 June 2008
Example of basic educations for HILS engineer (guidance for Level 1)
MATLAB/Simulink
basic training
5days
practice
State flow
training
1day
Plant model
training
practice
HILS system
training
Communication
system (CAN)
training
Small-scale
practice
development
5days
4days
practice
1day
practice
10days
Before curriculum was established, some engineer could not reach to
Level 1 in three month.
However, after well-organized curriculum was established,
novice could reach to Level 1 in a month.
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AISIN AW CO., LTD..
2.3 MATLAB basic text
3 June 2008
How MATLAB basic text was created.
Example : 100 + α kinds of blocks which are used in
HILS models were investigated.
Level 1 : Limited to 40 kinds of blocks. However they
covered 95% of whole HILS model.
35+5(Sources)=40
20 blocks cover 90%
of all blocks
5% consist of 15 blocks
As for last 5%,
60 blocks are used.
Page 20
AISIN AW CO., LTD..
2.3 MATLAB basic text
3 June 2008
Blocks which are defined on Level 1
In case of control specification model :
90% is covered by Level 1 blocks.
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AISIN AW CO., LTD..
Agenda
3 June 2008
1. Introduction
2. Status of activities for Model Based Development
1. ＨＩＬＳ development
2. ＨＩＬＳ engineer curriculum
3. MATLAB basic text
3. Control system development
1. The first try to Control logic development
2. NEW Control logic development
4. Plant model development
5. Examples of application
6. Expectations for SimDriveline
7. Activities for Automatic Code Generation (ACG)
8. Closing
Page 22
AISIN AW CO., LTD..
３．
About control logic development
3 June 2008
１
Simulation (model)
SILS
２
Code generation
Write on TCM
HILS
real
Simulation (model)
Control
plant
Rapid
Prototype
Page 23
Evaluation on vehicle
real
AISIN AW CO., LTD..
3.1 The first try to Control logic development
3 June 2008
• Activities for control logic development and
Automatic Code Generation was started from 2002.
• In this development, C source code was
automatically generated.
Size
Model
675Kbyte
Number of
blocks
1056
Generated
C-code
162k
(7 files)
Page 24
AISIN AW CO., LTD..
3 June 2008
Control logic specification development
Automatic Code Generation
Know-how
HILS development
Know-how
New group for Control logic specification
developing was established.
Area to which MBD is adopted
and its schedule are decided
Page 25
AISIN AW CO., LTD..
3 June 2008
• Conventional method and MBD are :
– Not same levels
– Not same processes
Therefore, strict comparison is impossible.
Same work can cause ten times of
man-hour difference in engineer’s level
9
8
Experimental opinions and feelings
are regarded as important
7
6
5
4
We decided to attach a great deal of importance
3
on the opinions of MBD engineers
1
2
0
through their experience.
Page 26
1h
2h
4h
8h
AISIN AW CO., LTD..
3 June 2008
Adopting area is decided based on MBD engineer’s opinions.
Only control specification design
Automatic code generation is included
in control logic developing team
started from 2006.
It was decided MBD was mainly
used for only control logic design.
The Rapid Prototype is utilized
for control logic development.
As for Automatic Code Generation, feasibility study was continued.
Page 27
AISIN AW CO., LTD..
3.2
NEW Control logic development
3 June 2008
１
Simulation (model)
SILS
２
Code generation
Write on TCM
HILS
real
Simulation (model)
Control
３
Rapid
Prototype
Page 28
plant
Evaluation on vehicle
real
AISIN AW CO., LTD..
System which has been tried since 2006
3 June 2008
Bypass Rapid Prototyping method which uses CANoe/CANape
CAN
A/T controlling function
A part of control logic is described by using Simulink/Stateflow.
Corresponding part of production part is replaced by it.
Each signal is sent to and received from ECU on CAN
Page 29
AISIN AW CO., LTD..
Size of controller and plant model
3 June 2008
Case 1
Size
Number of blocks
Controller
387Kb
634
Plant model
146Kb
947
Size
Number of blocks
Controller
500Kb
433
Plant model
440Kb
589
Case 2
Numbers of blocks are investigated by using sldiagnostics('sys','CountBlocks').
Page 30
AISIN AW CO., LTD..
Size of controller ( no Plant model )
3 June 2008
Case 3
Controller
Plant model
Size
Number of blocks
392Kb
390
－
Case 4
Controller
Plant model
Size
Number of blocks
404Kb
598
－
Numbers of blocks are investigated by using sldiagnostics('sys','CountBlocks').
Page 31
AISIN AW CO., LTD..
Agenda
3 June 2008
1. Introduction
2. Status of activities for Model Based Development
1. ＨＩＬＳ development
2. ＨＩＬＳ engineer curriculum
3. MATLAB basic text
3. Control system development
1. The first try to Control logic development
2. NEW Control logic development
4. Plant model development
5. Examples of application
6. Expectations for SimDriveline
7. Activities for Automatic Code Generation (ACG)
8. Closing
Page 32
AISIN AW CO., LTD..
４．Plant model development
3 June 2008
In control logic development, if plant model design
takes long time, benefits of MBD become thin.
Since our main purpose is
Man-hour ratio of
control logic design, we would like
control logic development (case 1)
to make plant model design
time as short as possible.
Plant model
プラント
モデ
design
ル
38%
Control logic
制御仕様設
Specification design
計
49%
reports作成
レポート
design
時間
However, in this case, since design and test
cannot be separated, their summation time is shown.
Page 33
AISIN AW CO., LTD..
Merits of using SimDriveline
3 June 2008
• SimDriveline is different from Simulink. By only
combining icons, for example, planetary gear,
complicated equations can be solved.
• By using SimDriveline, we could construct
convenient plant model for Automatic Transmission
control specification development in short time.
Page 34
AISIN AW CO., LTD..
Example : How to construct vehicle model
3 June 2008
• About vehicle model
Run resistance
Brake torque
Road traction
Force caused by vehicle
inclination Wgsinθ
Output torque
Force affects to tire Wgcosθ
Page 35
Vehicle weight×
gravitational
acceleration Wg
AISIN AW CO., LTD..
Vehicle modeling
3 June 2008
Tire inertia
Vehicle inertia
Output
torque
Brake
torque
Road traction
•Run resistance
Roadμ
Page 36
•Force caused
by vehicle
inclination
AISIN AW CO., LTD..
Vehicle model on SimDriveline
3 June 2008
Road μ
configuration
ABS controller
model
Page 37
AISIN AW CO., LTD..
Tire slip simulation
3 June 2008
Solver：ODE1
Vehicle speed
Tire speed
Fixed-step
1000Hz
Doted line shows tire speed
solid line shows vehicle speed
Acceleration with tire slip
is correctly simulated.
Vehicle
speed
time
Page 38
AISIN AW CO., LTD..
Vehicle stop simulation
3 June 2008
Brake ON
ABS OFF Vehicle speed
ABS OFF Tire speed
ABS ON Vehicle speed
ABS ON Tire speed
Vehicle
speed
Difference of stopping
distance between tire locked
case and no tire lock case is
correctly simulated.
Tire locked
With
ABS
Without
ABS
time
Simulation result shows that the case with ABS stops faster
than the case without ABS.
Page 39
AISIN AW CO., LTD..
3 June 2008
• About examples of SimDriveline application, please refer
materials of CDA seminar or MATLAB EXPO in 2005
About these materials, please contact to
CYBERNET SYSTEMS CO.,LTD
Page 40
AISIN AW CO., LTD..
Agenda
3 June 2008
1. Introduction
2. Status of activities for Model Based Development
1. ＨＩＬＳ development
2. ＨＩＬＳ engineer curriculum
3. MATLAB basic text
3. Control system development
1. The first try to Control logic development
2. NEW Control logic development
4. Plant model development
5. Examples of application
6. Expectations for SimDriveline
7. Activities for Automatic Code Generation (ACG)
8. Closing
Page 41
AISIN AW CO., LTD..
５．Example of application
3 June 2008
• An example of SimDriveline with Parameter
Estimation combination.
– By setting actual vehicle data to input and output for sixspeed A/T model constructed by using SimDriveline,
transmission efficiency, loss, inertia were calculated by
Parameter Estimation.
Page 42
AISIN AW CO., LTD..
SimDriveline and Parameter Estimation
3 June 2008
• Parameter Estimation is different from general
system identification tool. By using PE tool, optimal
values of variables in equation can be calculated.
Therefore, by using this tool, accuracy of existing
plant model can be improved.
Y=a'X+b'
Estimation
Y=aX+b
Estimation
System Identification tool
Page 43
Parameter Estimation
AISIN AW CO., LTD..
Without Parameter Estimation
Engine revolution
3 June 2008
(initial value)
Simulation
Input revolution
Actual vehicle
Output revolution
Simulation
Actual vehicle
Page 44
Output torque
AISIN AW CO., LTD..
With Parameter Estimation
3 June 2008
Estimate parameters to make these 4 simulation measurements
accord with actual vehicle measurements.
Engine revolution
Simulation
(after convergence)
Actual vehicle
Input revolution
Output revolution
Simulation
Actual vehicle
Page 45
Output torque
AISIN AW CO., LTD..
Comparison of output torque waveform
3 June 2008
Simulation
Without PE
(initial value)
Actual vehicle
Simulation
With PE
(after convergence)
Actual vehicle
Page 46
AISIN AW CO., LTD..
Table of estimation result
3 June 2008
Without PE With PE
Variable
(initial value)
(after convergence)
Inertia of inputting shaft
0.2
0.2241
A（T/M Efficiency ）
1.0
0.8859
B
1.0
1.0652
C
1.0
1.1104
Stiffness of outputting shaft
300
10824
Damping of outputting shaft
10
60
Page 47
AISIN AW CO., LTD..
Summary of results
3 June 2008
• Conventionally, unknown parameters were adjusted
manually. However, by applying Parameter
Estimation, optimal parameters were calculated
easily.
• By combining Parameter Estimation and physical
modeling tool, such as, SimDriveline, more efficient
MBD application is possible. This combination will
expand benefits of MBD.
Page 48
AISIN AW CO., LTD..
Agenda
3 June 2008
1. Introduction
2. Status of activities for Model Based Development
1. ＨＩＬＳ development
2. ＨＩＬＳ engineer curriculum
3. MATLAB basic text
3. Control system development
1. The first try to Control logic development
2. NEW Control logic development
4. Plant model development
5. Examples of application
6. Expectations for SimDriveline
7. Activities for Automatic Code Generation (ACG)
8. Closing
Page 49
AISIN AW CO., LTD..
6.Expectations for SimDriveline
1.
2.
3.
4.
5.
6.
3 June 2008
Complete prevention of simulation stop
Function to calculate energy loss
Attaching simple hydraulic controller
Attaching simple hydraulic pressure circuit model
Increasing default gear trains
Adaptation of unit for torque converter to Japanese
standard
Page 50
AISIN AW CO., LTD..
6.1 Complete prevention of simulation stop
3 June 2008
• Before gear-shifting, after gear-shifting, and vehicle
stop by braking cause simulation stop.
• In case of automatic test on HILS, simulation stop is
critical defect.
Dumper added only to prevent
simulation stop is meaningless
Dumper shall be used when simulation
which includes shaft stiffness is executed.
Page 51
AISIN AW CO., LTD..
6.2 Function to calculate energy loss
3 June 2008
• About planetary gear efficiency calculation, when input and
output are reversed, efficiency also changes. Therefore,
correct torque efficiency cannot be calculated currently.
• By adopting method to transform meshing losses of gears to
thermal loss and so on, system to calculate transmission
efficiency correctly is expected to be implemented.
Written on Jidousya-Gijyutsu handbook
P235
Input
Output
Fixed
Efficiency
Ring gear
Carrier
Sun gear
(1+ρ ηO)/(1+ρ )
Carrier
Sun gear
Ring gear
ηO(1+ρ )/(1+ρ ηO)
Carrier
Ring gear
Sun gear
ηO(1+ρ )/(η O+ρ )
Sun gear
carrier
Ring gear
(η O+ρ ) /(1+ρ )
Page 52
AISIN AW CO., LTD..
6.6 Adaptation of unit for torque converter
3 June 2008
While capacity factor which is set up by JSAE cannot use,
data cannot be implemented to SimDriveline.
Capacity factor
SimDriveline
JSAE
rad/s/sqrt(Nm)
N・m/rpm2 ×10-5
Written on Jidousya-Gijyutsu
handbook P219
Page 53
AISIN AW CO., LTD..
Agenda
3 June 2008
1. Introduction
2. Status of activities for Model Based Development
1. ＨＩＬＳ development
2. ＨＩＬＳ engineer curriculum
3. MATLAB basic text
3. Control system development
1. The first try to Control logic development
2. NEW Control logic development
4. Plant model development
5. Examples of application
6. Expectations for SimDriveline
7. Activities for Automatic Code Generation (ACG)
8. Closing
Page 54
AISIN AW CO., LTD..
７． Activities for Automatic Code Generation 3 June 2008
•There is much work to be done by manually.
Problems of Automatic Code Generation
– Options must be configured. If option configuration is
forgot, generated code becomes different from
guessed one. And it takes long time to investigate
cause of differences.
– By customizing, expected C code can be generated.
However, we don’t read generated code. Currently,
much man-hour is spent customizing C code which is
not read.
If expert engineer does all work alone, there is no problem.
However, for novice, amount of works to do is too much.
Therefore to retain code quality becomes difficult.
Page 55
AISIN AW CO., LTD..
Goal
3 June 2008
•
Our target concept for ACG is to have complete
automatic process including checking for the
generated code.
• As a rough estimation, deeper investigations on
the following two items are necessary.
1. Testing
– Automatic verification and validation by using Simulink
Design Verifier is planned.
2. Quality checking for generated code
Page 56
AISIN AW CO., LTD..
Quality checking for generated code.
3 June 2008
Key-points from now are as follows
• Automate simple works as much as possible.
• Quality assurance by using model checker.
• Confirmation of defect detection ability of static code
checker, PolySpace and so on.
Within a few years, we will build up the system which can
generate high-quality code even by beginner
Page 57
AISIN AW CO., LTD..
8.Closing
3 June 2008
• Our activities for MBD were introduced.
• Our control logic developments were introduced.
• Practical use examples of Plant model were
introduced.
• Expectations for SimDriveline were shown.
• Our activities for Automatic Code Generation were
introduced.
Since this presentation includes some
confidential matters, if there is some question,
please ask by e-mail via The Math Works.
Page 58
AISIN AW CO., LTD..