Brake-by-Wire System Development: Technology and Development Process

Brake-by-Wire system development
Technology and development process
Davide Colombo
Vehicle Systems - Active Control Systems
Head of Advanced Brake & Steering System Group
Torino, 18 Gennaio 2007 Mod. 25-P02-00

Contents
• Introduction on by-Wire Technology
• Focus on CRF Brake-by-Wire Project

• System architecture
• Main components
• Control development and Validation (Brake-by-Wire Application)

• Application development process
• Software-in-the-Loop
• Hardware-in-the-Loop
Torino, 18 Gennaio 2008 BBW Development and Applications This document contains information which in proprietary to CRF. Neither this document nor 2
the information contained herein shall be used, duplicated nor communicated by any
means to any third part, in whole or in party, except with the prior written consent CRF
X-by-Wire (XBW) – The Origins
• Systems for electronic control of vehicles

• Replace mechanical linkages with wires
• Originally Fly-by-Wire
Fly-by-wire Airplane: There is no mechanical or hydraulic connection between the pilot

controls and the control surfaces.
XBW in automotive – Why?
XBW represent a great opportunity to improve:
• Safety
• Fuel Consumption and Emission
• Performance
• Driving Pleasure
• Ergonomics
• Costs through modularity Ref.: http://www.crf.it/B/B1_2.html
Brake-by-Wire Application – Fiat Panda Improving Area
Fixed F.d.T.
Systems Integration
Fixed F.d.T. BBW Flexbile F.d.T.

x
V ECU
XBW in automotive – Where?
In a vehicle a lot of mechanical links can be substituted by electronics.

Some X-by-wire applications are already present in our vehicle and other are under development.
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X-by-Wire (XBW) – Fiat experiences and applications
Throttle-by-wire
• Drops mechanical connection between gas pedal and the throttle;
Clutch and Gearbox -by-wire (Selespeed) ALREADY on the MARKET

• Drops mechanical connection between: FAIL SAFE REQUIREMENTS
(Low Redundancy Requirements)
• Clutch actuator and Pedal;
• Gearbox and gear lever. • Single Fail Safe Actuator
• Single Fail Safe ECU
• Double Fail Safe Sensor (Driver Req)
• No Power Redundancy Needed
Throttle-by-wire Selespeed
(Actuator)
X-by-Wire (XBW) – Fiat experiences and applications
Steer-by-Wire & Brake-by-Wire

• Drops mechanical connection between steering wheel and the wheels;
• Drops hydraulic connection between brake pedal and
UNDER DEVELOPMENT
the actuators
FAIL OPERATIONAL REQUIREMENTS
(High Redundancy Requirements)
Steer-by-wire & Brake-by-Wire Architecture
• Single Fail Operational Actuator (SBW);
• Double Fail Safe ECU (SBW)
• Triple Fail Operational Sensor (Driver Req)
• Power Redundancy Needed
Full by Wire vehicle
Main Aim: New vehicle architectures, interiors and HMI

By- Wire: Enabling Technology allowing Driving Controls Architecture reconfigurations
• Gas, Brake, Clutch Pedal and Steering Column dropped;
• HMI with all Controls on Steering Wheel;
• Others advantages from By-Wire

• Vehicle Dynamic:
• Vehicle Control Integration
• Ergonomics:
• Adjustable HMI
• Fuel Consumption and Emissions

• Engine, Gearbox and Brake Integration
• Automatic Gear Box
• Steering system with variable steering ratio
• Integrated EPB for Hill Holder and Drive Away
Functions
• Ready for ADAS systems

• Parking AID
Full By Wire - Design and development process
THE IDEA BY WIRE

New Vehicle Concepts
An Enabling Technology
• Architecture and Interiors
• Complex system (Redundancy)
• Ergonomics
• Safety and Reliability to be guaranteed
PROS • Costs
• Performance CONS
Design,
Development,
Validation
Process
PRODUCT
Contents

• Main components

System over view: architecture
Local Layer Vehicle Layer Local Layer
WSpeed
HMI WSpeed
RHF RHR
EMB2_RHF EMB4_RHR
BRK2 VCS BRK4

RHF BCU2_RHF BCU4_RHR RHR
POWER
TT-Network Power
POWER
BCU1_LHF BCU3_LHR
EMB1_LHF BRK1 BRK3 EMB3_LHR

WSpeed WSpeed
LHF LHF LHR LHR
Local Layer Local Layer
Main Characteristic
Power and Network Components
• TT Network • 1 VCS, Vehicle Control System
• C-CAN Service Network; • 4 BCU, Brake Control Unit
• Double Power Supply (12 V); • 1 HMI, Human Machine Interface
System over view: main components
Electro-Mechanical Caliper Brake by Wire Brake Pedal Control ECU

• Supply Voltage 12 V • Position sensors: 3 • MPC555 controller
• Max current 15 A • Force feedback: passive • On board BLDC driver (25A @ 12 Volt)
• Clamping Force 13 KN • Time Triggered Network
Contents

• Main components

V-cycle: By Wire System Development Process
Architecture & System

System Design Calibration
Modeling &
Identification
Safety assessment
System Control (eg. Fault injection)
Target Design
SIL (Software In the Loop)
Setting
Tuning
Diagnosis Design Revision phase
Risk
Assessment
System CIL (Component In the
Recovery Design Loop)
Set-up & Debug
Constraints HIL (Hardware In the Loop)
(Cost, Power,...)
“Rapid Prototyping” Code generation
Design Flow
Target ECU
Code
Generation
(fixed point, ..
Controlled systems Validation methods
• Software in the Loop Simulation: • Test on track Seganli di misura

COMPONENTE
Comandi
DA TESTARE
• System Hardware Model; • Real Hardware (ECU,

• Vehicle Model. actuators, …);
• Real Vehicle. Sensori Attuatore
From WorkSpace:
From
• Simulazione manovre;
• Simulazioni Fault;
Revision phase Grandezze da misurare
WorkSPace Attuazione
Revision phase BBW_System Simu lin k Model
Vehicle Simulink Mo del
Libreri a CAE di
Sistemi Control lo Aut ot elai o
To WorkSpace:
To WorkSPace
• Risultati;
Seganli di misura Comandi

COMPONENTE
DA TESTARE
• Hardware in the Loop

Attuatore
HARDWARE Attuazione
• Real Hardware (ECU,
Revision phase
Emulazione Sensori
actuators, …);
Sensori HDW to SFW
• Vehicle Model (emulated in
Software Real-Time
Input simulatore
real-time simulation);
Output simulatore
SOFTWARE DI
SIMULAZIONE
Application development process: validation methods pros and cons
Seganli di misura Comandi

COMPONENTE Seganli di misura Comandi
From WorkSpace:
DA TESTARE COMPONENTE
From
• Simulazione manovre; DA TESTARE
• Simulazioni Fault;
WorkSPace
Attuatore
HARDWARE Attuazione
BBW_System Simu lin k Model Sensori Attuatore

Vehicle Simulink Mo del Emulazione Sensori
Sensori HDWto SFW
Libreri a CAE di
Sistemi Control lo Aut ot elai o
Software Real-Time
Output simulatore Input simulatore
To WorkSpace: Grandezze da misurare
• Risultati; Attuazione
To WorkSPace SOFTWARE DI
SIMULAZIONE
Simulation in the Loop Hardware in the Loop Test on track
Environment Simulated -- Real HW - Real +
Test Flexibility Hign + High + Low -
Data reliability Low -- Good - High +
Timing and costs Low ++ Low + High -
Test repeatability High ++ High + Low -
Scene simulation No limits ++ Low limits + High limits -
Operators Safety High ++ High + Low -
Contents

• Main components

Simulation-in-the Loop phase
Software in the Loop validation

method needs a platform to simulate
manoeuvres and fault injections.
This platform is made by:
• Vehicle Model;
• Brake-by-Wire System Model;
• Fault Injection Generator Box

Model.
SIL – Brake-by-Wire System Simulink Functional Model
SIL Example: Sensor fault while bending
Active EBD – Fault on LHF Wheel Speed – NO DIAG Active EBD – Fault on LHF Wheel Speed – DIAG
Fault Fault Diag
Contents

• Main components

Brake-by-Wire System HIL Bench
HIL Example: BBW ABS tests
• To verify:
• Vehicle Speed Estimation Algorithm
• ABS modulation capability
• Safety of the ABS Algorithm
• EMB modulation capability
Full ABS on High Friction Full ABS on Low Friction
HIL Benchmark: ABS comparing - BBW versus conventional
• Simulations are done using the same vehicle (model)

• The control law are similar (slip regulation)
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Initial Vehicle Speed : 60 km/h


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Brake-by-Wire system development

Technology and development process

Torino, 18 Gennaio 2007 Mod. 25-P02-00

• Introduction on by-Wire Technology

• Focus on CRF Brake-by-Wire Project

• Control development and Validation (Brake-by-Wire Application)

• Systems for electronic control of vehicles

Fly-by-wire Airplane: There is no mechanical or hydraulic connection between the pilot

XBW represent a great opportunity to improve:

Brake-by-Wire Application – Fiat Panda Improving Area

Fixed F.d.T. BBW Flexbile F.d.T.

In a vehicle a lot of mechanical links can be substituted by electronics.

Clutch and Gearbox -by-wire (Selespeed) ALREADY on the MARKET

Steer-by-Wire & Brake-by-Wire

Main Aim: New vehicle architectures, interiors and HMI

• Others advantages from By-Wire

• Fuel Consumption and Emissions

• Ready for ADAS systems

THE IDEA BY WIRE

• Introduction on by-Wire Technology

• Focus on CRF Brake-by-Wire Project

• Control development and Validation (Brake-by-Wire Application)

Local Layer Vehicle Layer Local Layer

BRK2 VCS BRK4

EMB1_LHF BRK1 BRK3 EMB3_LHR

LHF LHF LHR LHR

Local Layer Local Layer

Electro-Mechanical Caliper Brake by Wire Brake Pedal Control ECU

• Introduction on by-Wire Technology

• Focus on CRF Brake-by-Wire Project

• Control development and Validation (Brake-by-Wire Application)

Architecture & System

“Rapid Prototyping” Code generation

• Software in the Loop Simulation: • Test on track Seganli di misura

• System Hardware Model; • Real Hardware (ECU,

Revision phase BBW_System Simu lin k Model

Vehicle Simulink Mo del

Seganli di misura Comandi

• Hardware in the Loop

Seganli di misura Comandi

BBW_System Simu lin k Model Sensori Attuatore

Simulation in the Loop Hardware in the Loop Test on track

Environment Simulated -- Real HW - Real +

Test Flexibility Hign + High + Low -

Data reliability Low -- Good - High +

Timing and costs Low ++ Low + High -

Test repeatability High ++ High + Low -

Scene simulation No limits ++ Low limits + High limits -

Operators Safety High ++ High + Low -

• Introduction on by-Wire Technology

• Focus on CRF Brake-by-Wire Project

• Control development and Validation (Brake-by-Wire Application)

Software in the Loop validation

This platform is made by:

• Brake-by-Wire System Model;

• Fault Injection Generator Box

Fault Fault Diag

• Introduction on by-Wire Technology

• Focus on CRF Brake-by-Wire Project

• Control development and Validation (Brake-by-Wire Application)

• Simulations are done using the same vehicle (model)

Initial Vehicle Speed : 60 km/h