Next generation hil design tools for next generation vehicles
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ELECTRONIC PLATFORMS AND ON-BOARD SYSTEMS ON SMART VEHICLES: DEALING WITH INFORMATION IN "REAL TIME". Next-Generation HIL Design Tools for Next-Generation Vehicles. June 2005. Jean Bélanger , CEO Opal-RT Technologies Inc Montréal, Québec, Canada www.opal-rt.com. Opal-RT in Brief.

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Next-Generation HIL Design Tools for Next-Generation Vehicles

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Next generation hil design tools for next generation vehicles

ELECTRONIC PLATFORMS AND ON-BOARD SYSTEMS ON SMART VEHICLES:

DEALING WITH INFORMATION IN "REAL TIME"

Next-Generation HIL Design Tools for Next-Generation Vehicles

June 2005

Jean Bélanger , CEO

Opal-RT Technologies Inc

Montréal, Québec, Canada

www.opal-rt.com


Opal rt in brief

Opal-RT in Brief

  • Established in 1997

  • RT-LAB: Real-Time Simulation Platform for Simulink™ and SystemBuild™

    • Hardware in the Loop for Demanding Simulations

    • Distributed, Parallel Processing using Off-the-Shelf Technologies – PC, FireWire, QNX, NI, FPGA etc

    • Scalable Power for the most complex dynamic models

    • Comprehensive API for on-line tools for visualization and interaction, eg LabVIEW™

  • 50 Employees

  • Over 200 Customers Worldwide…


Core markets main customers

Core Markets & Main Customers

Automotive

  • GM, Ford, Toyota, Hyundai, Peugeot, Audi/VW

  • Tier 1: Delphi Delco, Bosch, Visteon, Allison Transmission

    Electrical & Power Electronic Systems

  • GE, ABB, Hydro-Quebec, Mitsubishi Electric etc

    Academic Research and Education

  • US: MIT, Berkeley, Michigan, Ohio State, Texas (UT and A&M) etc etc.

  • Canada: Windsor, Waterloo, Alberta, UQ (AM, TR, AC), Ecole Polytechnique, ETS, McGill etc etc.


Outline

Outline

  • Technology Convergence in the Automotive Industry

  • Modularization of Electro/Hydraulic/Mechanical Systems

  • The Challenges arising from increased in-vehicle electronics

  • Simulation, Testing and Validation Process and the Tool Chain to support it

  • Challenges and Opportunities for the Canadian Automotive Industry


Next generation hil design tools for next generation vehicles

Technology and Market Convergence

“Electronics represent more than 20% of an average vehicle's value. Since the majority of new automotive technologies being developed are electronic, this percentage is projected to double by the year 2010.”

Delphi Electronics, 2003


Technology and market convergence

Technology and Market Convergence


Next generation hil design tools for next generation vehicles

Technology and Market Convergence

“The global automotive semiconductor market will grow from a value of $12.3 billion in 2002, to just over $17 billion by 2007. The largest target application for automotive silicon is body and chassis control, which includes electronic traction, suspension and stability control systems. This segment commands approximately 26% of the automotive semiconductor market and will be worth $4.4 billion in 2007.”

ABI Research, 2002


Next generation hil design tools for next generation vehicles

Technology and Market Convergence

50% = $8.5bn

2007 Total: $17 billion

2002 Total: $12.3 billion


Automotive system modularization

Automotive System Modularization

  • Engine Control

  • Transmission Control

  • Active Suspension

  • Active Camber

  • Traction Control

  • Stability Control

  • Power Steering

  • ABS

  • “X-by-Wire”

  • Electric Drives

  • Energy Generation

  • Energy Storage

SystemModularization drives the need for standard dynamic components and control systems across vehicle platforms. Software determines system behavior and how the components interact with each other

Motorola (paraphrased from AEI Magazine)


Example electric power steering

Example: Electric Power Steering


More electronics more software

More Electronics = More Software!

Power Steering Error

CONTROLLER.exe has caused a fatal error. If the problem continues, please contact your vendor.

Press Ctrl, Alt, Del to restart


Challenges

Challenges

  • System complexity will dramatically increase with

    • The number of interconnected controllers

    • software functionality

    • Number of engineering teams

  • Complexity will increase even more with the introduction of fuel-cell and hybrid-electric vehicles

  • Safety margin will decrease

  • The total cost of failure will increase dramatically

  • User tolerance to failure will decrease

  • System will need to be designed for testability

How do we develop testing strategies to assess the reliability and safety of complex electro/mechanical/hydraulic systems while maintaining, or even reducing, costs?

“Our ability to design complex systems currently exceeds our ability to test these systems…”

Opal-RT Customer, GM


Solutions

Solutions

“Virtual” Prototyping through simulation will play an increasingly key role in system design, commissioning and test.

  • Automotive and electrical system manufacturers will increase the use of simulation

    • to reduce time-to-market and R&D cost

    • and to increase end-user functionality, quality, safety and reliability

      Connection to real components through Hardware-in-the-Loop (HIL) Testing is critical to this strategy

  • Validation of controller before integrating into the prototype vehicle reduces errors and costs

  • Validation of model against the real thing improves the whole process, dramatically reducing development cycles and time-to-market

This process is now well defined and widely adopted…


The v development process

THE ‘V’ DEVELOPMENT PROCESS

Highly iterative process

Design

Structural (CAD)

Dynamics

Maintenance

Plant commissioning

Deploy (Production)

Validate

FEA

Off-line Simulation

Test track in-vehiclecalibration(commissioning)

Virtual Prototype

HIL, Real-Time Simulation

Visualization

Lab TestingTest cells

With actual controller

Design and Development

Control Prototype

Physical Components

RT Simulation

+ HIL

Validation and Integration

Implementation

Production CodePrototype Component


Next generation hil design tools for next generation vehicles

THE ‘V’ DEVELOPMENT PROCESS

Complete Vehicle

Power Steering

Braking

Transmission

Engine

Multiple Concurrent Development Teams


Control system design tool chain

Control System Design Tool Chain

Production

& Quality

Control

Design Specification & Requirements

Definition

Hardware

in the

Loop

Plant

Simulation

“Virtual

Prototype”

Controller Integration,

Tuning,

Calibration

Controller Prototyping

Controller

Unit (ECU)Test

HILBOX:

Production

Code

RT-LAB MULTI-ECU SIMULATION CLUSTER

ECU Memory Interface

RT-LAB Simulation Server

mSTACK In-vehicle processor

RT-LAB Engineering Simulator

Design & Development

Validation & Integration

RT-LAB Rapid Prototyping Controllers

PC/104

3rd-Party I/O

FPGA I/O

Signal Conditioning

Specialized Interfaces (CAN, Flexwire, MOST etc)

RT-LAB TestDrive

Hand-Coding or

Automatic Code Generation…


Next generation hil design tools for next generation vehicles

RT-LAB™ Engineering Simulators

Vehicle Dynamics

Body Electronics

Transmission

Engine

Hardware in the Loop

From subsystem simulation…

Each engineer with his/her own simulator


Next generation hil design tools for next generation vehicles

RT-LAB™ Engineering Simulators

Vehicle Dynamics

Body Electronics

Transmission

Engine

Hardware in the Loop

…to virtual system integration

Subsystem simulations come together into one simulator


Challenge for canada

Challenge for Canada

  • Strategists must not lose sight of the growing trend towards the use of in-vehicle electronics, particularly for vehicle control – a $8.5bn US market by 2007

  • It will be critical to develop an automotive industry strategy that includes the ability to design and test advanced embedded car electronics for this market

  • If Canada doesn’t act now, emerging countries like India and China will soon compete through their low-cost, highly educated workforce, and rapidly developing R&D capability

Can we afford to be left out of this market?


Recommendation

Recommendation

Increase our expertise in all aspects of automotive software development, testing and implementation by

1) collaborating with major OEMs and Tier 1 suppliers on new product development and testing

2) attracting major OEMs and Tier 1 suppliers to carry out some of their R&D in world-class Canadian facilities

3) developing our own expertise through special projects, funded by Canadian partners, independently of OEMs, if necessary

For Example…


Next generation hil design tools for next generation vehicles

Example: Virtual Vehicle Test Cell Facility

Facility allows manufacturers to “road-test” new or modified vehicle components without a specialized test vehicle.

Dramatically reduces costs (at least $500k per test vehicle eliminated)

Automated, repeatable tests

Climatic extremes without driving to the Arctic or Arizona

The World’s First Virtual Vehicle Test Cell opened in September 2002 at SwRI, San Antonio, Texas

It is now fully booked for the next three years and work has begun on a second facility

Other automotive research organizations are now planning their own facilities around our technologies

Photos courtesy Southwest Research Institute


Next generation hil design tools for next generation vehicles

Virtual components

Driver/Road Course

RoadLoad(Test Track)

Driveline(Tires, suspension, driveshaft)

Trans-mission

Engine

ECU

Real components

Virtual Vehicle Test Cell Facility: How it Works

Using a Model-based approach means that component models that were developed at the design stage by different groups or suppliers can now be incorporated into an RT-LAB Engineering Simulator in the Test Cell

Photos courtesy Southwest Research Institute


Next generation hil design tools for next generation vehicles

Virtual components

Driver/Road Course

RoadLoad(Test Track)

Driveline(Tires, suspension, driveshaft)

Trans-mission

Engine

ECU

Dyna-mometer

Transmission

ElectricMotor

Real components

Virtual Vehicle Test Cell Facility: How it Works

As the test component becomes available from the manufacturer, it can be readily connected to the simulator via low-inertia dynamometers, bypassing the virtual component. This provides extremely high-fidelity simulation of the engine and test-track loads on the component, and allows the test program to commence with minimal delay

Photos courtesy Southwest Research Institute


Next generation hil design tools for next generation vehicles

Virtual components

Driver/Road Course

RoadLoad(Test Track)

Driveline(Tires, suspension, driveshaft)

Trans-mission

Engine

ECU

Dyna-mometer

Transmission

ElectricMotor

Real components

Virtual Vehicle Test Cell Facility: How it Works

As the test component becomes available from the manufacturer, it can be readily connected to the simulator via low-inertia dynamometers, bypassing the virtual component. This provides extremely high-fidelity simulation of the engine and test-track loads on the component, and allows the test program to commence with minimal delay

Photos courtesy Southwest Research Institute


Summary

Summary

  • Vehicular electronics is a rapidly growing market, particularly in Body & Chassis, and Powertrain Control

  • Demand for active electro/mechanical/hydraulic systems will drive the demand for more research into control development and integration

  • An $8.5bn market cannot be ignored and we need to plan for success in this market now

  • As an industrial region with all the right skills, Canada is well placed to become a leader in research in this area


Final message

Final Message

  • Professional-grade tools for ECU development and testing are already available and are being used by the major automotive players

  • Canada has a ready supplier of the right tools to facilitate the development process and help build the required R&D facilities to service this market

Don’t build the hammer, build the house!

Thank you


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