Simulation-aided Homologation of ESP Systems
for NAFTA Vans by Software-in-the-Loop
Simulation
Klaus Wüst, Daimler AG
Albert Lutz, Robert Bosch GmbH
IPG Technology Conference
Ettlingen, 18.-19. September 2012
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Agenda
• ESP homologation by simulation –
background of legislation
• Simulation environment SiL exchange platform OEM/supplier
• Proof of functionality for vehicle variants
on the basis of a validated “MasterCar”
• Results of the survey, robustness
• Banked curves robustness check
• Conclusion
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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ESP homologation by simulation – background
• In Europe:
Mandatory introduction of ESP systems for passenger cars
and for trucks or buses via ECE-R13 and ECE-R13H
• ECE-R13 and –R13H allow homologation by simulation –
either by HiL test stands or by SiL simulation
• Type approval by simulation at Daimler Trucks since 2011 –
Simulation tool EBSim (Simpack models with SiL codes)
• Various driving maneuvers without precise criteria for trucks,
maneuver “sine with dwell” for passenger cars, including
pass/fail criteria
• For NAFTA region:
Mandatory introduction of ESP systems for passenger cars
via FMVSS 126, maneuver “sine with dwell”,
self-certification (no type approval by authorities)
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Overview of Simulation Environment
System & Function Level
Calibration
System Req.
System &
Function
Design
Release
MiL
SiL
Rapid
Prototyping
Component
Requirements
Component
Design
Component Level SW
System
Validation
HiL
SiL
SiL
SiL_generic
SiL_generic
OOL
System
Verification
Component
Validation
Component
Verification
Implementation
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Set-up simulation environment
Vehicle dynamics simulation tools



ESP-Simulation tool
Vehicle, road, driver model
OEM control systems
OEM test automation



Control, sensor, brake model
New braking system models
Driver assistance
CSSim
Vehicle, Driver,
Environment, OEMcontrol inputs
Actuation & ESP signals
Animation
Daimler
ESP internal
signal trace
*.d97
CM-Signal trace
*.erg, *.info
Combined trace file
Parameter
modification
BOSCH
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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MasterCar - Approach
Vehicle Variants
B,C, ..=Virtual Cars
Vehicle Variant A
= Master Car
Simulation-Workshop
In-Vehicle
Tests
physical
DFP - Digital
FingerPrint
Correlation
Measurement
driven
simulation
virtual
virtual
virtual
virtual
virtual
Application-Process
Real Test
Drive
Virtual Test
Drive
RPM - Robustness &
Performance Monitoring
Correlation
Virtual Test
Drive - with
parameter
variations
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Validation of van vehicle
dynamics using the “MasterCar”
• Step 1:
Proof of tire characteristics (MFTYRE)
• Step 2:
Measurement of 4 vehicle variants
• Step 3:
Validation of steady state driving behavior
40
• Step 3:
Validation of transient driving behavior
20
G ie rg e s c h w in d ig k e it
• Step 4:
Validation of sine with dwell with ESC
interventions
Comparison Measurement with ESC / Simulation
with ESC / Simulation without ESC,
Vehicle yaw velocity as a response to 200°
steering wheel amplitude
Yaw Velocity vs. Time
30
10
0
-10 14
16
18
20
22
24
-20
-30
-40
-50
Zeit
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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The simulation covers a wide range of vehicle
variants
•
•
•
Examples for the vehicle variety (Sprinter for NAFTA market):
2 GVW variants, 2 wheelbases, 2 heights, 2 versions of rear overhang,
bus or goods transport, 4 suspension variants, 3 tire variants
 approx. 120 possible variations
Additional: variation of loading conditions (laden/unladen, c.o.g position)
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Results of the survey, robustness
• All simulated vehicle variants have fulfilled the evaluation criteria
• Step-by-step identification of worst case vehicle variants
• Example result:
Comparison between ESP8 and ESP9 code for one vehicle variant
Vergl ESP8 ESP9
Nafta KAWA 3.88t R2 LH2 CF2 C39
Vergl ESp8 ESP9
Nafta KAWA 3.88t R2 LH2 CF2 C39
4
Seitenversatz 1.071s nach Lenkbeginn
3.5
3
2.5
ESP8
2
ESP9
1.5
1
0.5
Norm. Giergeschw 1s nach Manöverende
100
80
60
40
20
ESP8
0
ESP9
-20
-40
-60
-80
-100
0
0
50
100
150
LW- Am plitude
200
250
300
0
50
100
150
200
250
300
LW-Amplitude
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Additional ESP-Robustness Check: Banked Curves
Elevation
Final
radius
Tracks:
• Synthetic (S-Curve)
• Test-center (PBx)
• Public Road (cross-country
up to Great Ocean Road)
Curvature
Initial
radius
Elevation [rad]
Track Y-Coordinate [m]
Trajectory
Track X-Coordinate [m]
Track Length [m]
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Additional ESP-Robustness Check: Banked Curves
Measurement
Simulation
Yaw Rate [rad/s]
Track Analysis:
Elevation ≥ x°
Time [s]
Banked Curve Detection:
Counter-Values
Lat. Acceleration [m/s2]
Counter 1
Counter 2
Curve Entering
Counter 1
Counter 2
Covering
Yaw Rate
Covering
Criteria
Time [s]
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Conclusion
• Daimler and Bosch have successfully established an exchange platform for the simulation
of van vehicle dynamics with active systems.
• The SiL platform is used for type approval
investigations of ESP system as well as for
investigations of a large amount of vehicle
variants and for robustness investigations.
• In future, this SiL process will also be used for
other driver assistance systems, furthermore
implementing additionally the tools IPG TestManager and QTronic TestWeaver.
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Thank you for your attention!
Questions?
Public | K. Wüst u. A. Lutz | 19/09/2012 | © Daimler AG u Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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