Vehicle Dynamics Simulation in the Application Process of ESP Systems

CarMaker USER Conference 2006,

Karlsruhe, June, 01, 2006
Vehicle Dynamics Simulation in the Application
Process of ESP-Systems
Robert Bosch GmbH
Albert Lutz

Chassis Systems Control

CC/EPI-Lutz | 23/05/2006 | Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of
disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

Overview
1. Introduction
2. ESP-System
3. Application Process
4. Vehicle Dynamics Simulation for Mechatronic Systems
5. Usage of Simulation in the ESP Application Process
6. Example: Threshold Consumption
7. Summary

Chassis Systems Control

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

1. Introduction

Mechatronic systems, like ESP, working at the limit of physics, have to confirm
z safe design for extreme operating conditions
z ensure that no mis- or early interventions occur
Due to complexity of such systems
modelbased design process has become more and more important
vehicle dynamics simulation is used for analysis and as a basis for
synthesis
today simulation is state-of-the-art
The application process becomes more and more complex due to
z number of vehicle variants, short timeframe, missing prototypes
z interaction of various mechatronic systems
Therefore computer based methods become more and more important too
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Vehicle Dynamics Simulation in the Application Process of ESP Systems

2. ESP System
2.1 Task of the ESP System

Frequent cause for accidents:

The driver loses control of his vehicle.
I.e. through
z speeding
z mis-interpretation of the course
or the road condition
z sudden swerving

ESP improves:
z stability
z steerability
z includes ABS and TCS function

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

2.2 Components of ESP

1
2
3
4
5

Hydraulic unit with attached ECU

Wheel speed sensors
Steering angle sensor
Yaw rate and lateral acceleration sensor
Communication with DME
2
5
3

2
4

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

2.3 Function of ESP

ESP continuously monitors

z The vehicles behavior
(longitudinal and lateral dynamics)
The drivers inputs
(Steering angle, brake pressure, engine torque)

Recognizes critical situations

ESP intervenes by:

z Wheel-individual brake pressure
application to generate a stabilizing moment
z

Intervention in the engine management to adjust output torque

Chassis Systems Control

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

3 Application Process
3.1 General Aspects

Taking into operation and adaption of a mechatronic system into the target
vehicle
z ensuring performance, safety and comfort aspects according to the
specification
z considering characteristic features of the vehicle and its subsystems
CAN Protocoll
Friction

Elasticities,
Damping,
Compliance

Geometry,
Inertia,
Kinematics

Braking System

Oscillations

Environmental
Thermal Effects
Safty ConceptsConditions

ECU, SW

Nonlinearities

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

3.2 ESP Application Process at BOSCH-CC

Definition
Preparation
Basic
Application
Application
Verification
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Vehicle Dynamics Simulation in the Application Process of ESP Systems

3.3 Why simulation in the ESP Application Process?

Vehicle tests at an early stage of application:

z Done with prototypes (mule cars) far away from series definition
z reconcurrent tuning necessary with prototype update
z not all vehicle variants available as prototype
z small number of prototypes for all testing aspects

Vehicle dynamics simulation promises:

z infinite number of virtual prototypes
z permanently available winter and summer condition
z testing under reproducable conditions
z automated testing 24h a day, on weekends, during holidays
z

BUT

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

4. Vehicle Dynamics Simulation for mechatronic Systems

4.1 Requirements:
Application of an ESP System by vehicle dynamics simulation requires:
Multidisciplinary approach
z Mechanics (chassis, drivetrain, tyres)
z Hydraulics (brake system, hydraulic unit)
z Electronics (sensors, ECU, )

Effects relevant for application have to be considered

Generic vehicle-models are not sufficient
Therefore:
z Each supplier of a component has to provide a validated model
according to specification
z Mirrored virtual environments at OEM and supplier simplifies the usage
of simulation during the application phase
z Updates have to be done automated, in-time and reliable

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

4.2 Simulation embedded in Project Plan & Team

Project definition

Project phase

Supply of vehicle
model and vehicle
components

Asessm.

Offer

Def. of WP
simulation
Supply virtual ESP
component models
methods and tools
project support

OEM simulation runs

project specific virtual
platform integration

Project

OEM project team

SOP

Model updates for simulation

Simulation runs at Bosch-CC

Bosch-CC project team

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

4.3 Model Requirements

4.3.1 MBS Models

Amplitude

Functional MBS
Model

Handling
< 5Hz

Structural
MBS Model

US
ER
Comfort

Structural
MBS Model
with FEM

Sp
De

eci

ve l

alis

o pe

Oscillations

ts ,

of Bodies

Structural

<50Hz

Oscillations
<100Hz

Frequency
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Vehicle Dynamics Simulation in the Application Process of ESP Systems

4.3.2 ESP Controller Model

ESP PSW

Sequencing

CAN,
FPS,
SIS(HW),
I/O Task Management,
Process List

ESP ASW
Cntrl,
SIS(SW),
HIM,
GA, SIF,
CRS

EEPROM

Messages

OMCL-MG
S-Fct.
Receive
U-/Y-Vektor Write

De-/
Scaling

Glob.
Variables

Model of the Task Management

Process List
RFP
MT
FPS EEPROM
Cntrl
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Vehicle Dynamics Simulation in the Application Process of ESP Systems

4.3.3 Workflow for Modelling of the complete System

Modeling
Vehicle,
Chassis,
Drivertrain,
Engine

OEM
Vehicle
model

Project
Preparation
1

Specification
of Vehicle
Simulation

RB: Sensors
& Actuation
Component
models

Vehicle
Program

Vehicle
Simulation
Running

Vehicle
Simulation
Ready

Supplier
Simulation
Ready

Parameter
Acquisition,
Verification

Specification
of Component
Simulation

Acquisition Supplier
Validated Simulation

Validation

Modeling
Hydraulics,
Brakes,
Sensors,
ECU, ...

Project
Preparation

Supplier
mech. Comp

Parameter
Acquisition,
Verification

Validation

Verification

Validation

Module
Program

Component
Simulation
Running

Component
Simulation
Ready

System
Simulation
Integrated

System
Simulation
Running

System
Simulation
Ready

RB:
CSM-controller
CSMcontrol SW

Assembling
ESP Control
Software

Project
Preparation
1

Specification
of ESP
Control

Parameter
Acquisition,
Verification

Validation

Control
Software,
PMSC

Control SW
and PMSC
Running

Control and
PMSC
Ready

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Virtual Plattform for

CSM-Development
ready for Application

Vehicle Dynamics Simulation in the Application Process of ESP Systems

4.3.4 Complete System implemented in SIMULink

Bosch
HiL-PSW
LabCAR
CAN, IF,
Diagnosics

SiL-ASW
SIMULink

Bosch

OEM

Hydraulics 4)

Function,
Variants,
Robustness

Plugin
ESP- 3)
1)
ASW
MATLAB / SIMULink vehicle
dll
Sensors 2)
1)

PMS/C

5)

MM6-MT 6)

OEM vehicle model/data incl. driver & environment

Sensor models (DLL or modified state variables
of vehicle model)
3) ESP controller SW-dll as S-function
2)

4)

ESP internal model

5) Parameter tuning system PMS/C
6) MM6 measurement system
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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

5. Usage of Simulation in the ESP Application Process

Application activity

Starting-up and Basic Application

Take over predecessor-SW
z Project-spec. parametrisation
z Implementation of functions
z Vch-determination and HIM-application
z

Usage of simulation
SW-Check
- Runability
- Completness
- Correctness
- Function check

Application
New functions
Parameter tuning
z Check vehicle variants
z Robustness analysis

Projekt-spec.

z
z

Verification
z

Driving maneuver catalog

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disposal such as copying and passing on to third parties.

Absolut or relative
Absolut or relative
OEM and Bosch criteria

Vehicle Dynamics Simulation in the Application Process of ESP Systems

5. Usage of Simulation in the ESP Application Process

Method
z Automation of
z Simulation run
z Evaluation
z Documentation
z

Continuous model check w.r.t. to available prototype

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

6. Example: Threshold Consumption

6.1 Problem
Confirm application robustness against too early ESP interventions
e.g. oversteering provoques perceptible brake interventions
Definition of target functional sensitivity, e.g. where interventions
z are not desired
z have to be checked
z are desired
6.2 Target/Benefits
Objective evaluation of measurements and basis for discussions
Simplification of parameter tuning
Improved quality of parameter application
Objective judgement of application w.r.t. reference car
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Vehicle Dynamics Simulation in the Application Process of ESP Systems

6.3 Threshold Consumption Method

VGI = VGIist VGIsoll

ESP Intervention

VGI > AnreguHA

VGI
* 100% = ThresholdConsumption(TC )
AnreguHA
0%
No oversteering
0..100 % Oversteering situation
>100 % ESP-Intervention
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Vehicle Dynamics Simulation in the Application Process of ESP Systems

6.3 Threshold Consumption Method

Finish

Cross country road

Length ~ 43 km, driven 2 ways

many different curves

different track surface
AY < 0.6g
Starting point

Automated evaluation of measured data in MATLAB

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

6.4 Threshold Consumption Simulation

Vehicle model:
Setup of a vehicle dynamics simulation environment in SIMULink
z Plug-in of target vehicle model using IPG/CM
z Implementation of an ESP system model (ECU, SNS, ACT)
z Validation of the components and the complete system

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disposal such as copying and passing on to third parties.

Vehicle Dynamics Simulation in the Application Process of ESP Systems

6.4 Threshold Consumption Simulation

Track model:
Using IPG/Track definition:
z X-, Y-, Z-data derived from GPS-measurement
z Signal conditioning (discontinuity, curves, )
z Road signs with speed limits
z No elevation considered
z Homogeneous and flat road surface

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

6.4 Threshold Consumption Simulation

Driver model:
Using IPG/Driver:
z Adaption to the car behaviour
z Definition of driver typ:
z normal driver:
z AX < 0.3g
z AY < 0.6g
z Curve cutting coefficient: 0.2

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

6.5 Threshold Consumption Results

Analysis of driving situation: vehicle speed vs. lateral acceleration
Experiment

Simulation

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

Threshold Consumption (VGI/AnreguHA[%]) vs. lateral acceleration
Experiment

Simulation

Simulation (Generic Tyre)

E: 5579 (4.8%), Avg: 10.4%, Max: 60%

E: 179 (0.2%), Avg: 12.3%, Max: 64.3%

E: 21190 (22.8%), Avg: 14.3%, Max: 106.3%

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

Driver influence:
Simulation:
Normal driver
Agressive driver
Defensive driver
Experiment:
Real driver

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

6.6 Threshold Consumption Application Scenario

Virtual Threshold Consumption does not substitute vehicle tests

z Vehicle tests are used as continuous reference of the quality of the
virtual environment

Virtual Threshold Consumption can be used for:

z Increased testing with test track variants (mue, elevation)
z Vehicle variants
z Automated check of new ESP SW releases before vehicle tests
z Specify max. tolerable range, e.g. in case of suspension modification
short before SOP
z Testing with 90% up to 300% of realtime capability (PC: 3.2GHz,
1GByte RAM)

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

7. Summary

Model based methods, e.g. SiL-simulation show a high potential for

improvements of the application process of mechatronic systems

Validated models of the complete system are required to make best use
of this potential

The setup of the models needs a well defined process between all
partners

Objective criteria will allow the automated testing

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Vehicle Dynamics Simulation in the Application Process of ESP Systems

Thank You for Your Attention

Questions?
Remarks, Comments, Proposals?

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disposal such as copying and passing on to third parties.