CAE-based Homologation

of ESC-Systems
using IPG CarMaker

Karl Michael Hahn

Dr. Henning Holzmann, Dr. Michael Kochem

Adam Opel AG

apply & innovate 2012

Karlsruhe, September 19th, 2012
www.opel.com
 Agenda
Background ECE-R 13-H
Motivation
Simulation Environment at GM Europe
Vehicle Dynamics Simulation
Chassis Controls Simulation
Project Scope
Validation of the Simulation Environment
Static Measurements
Dynamic Measurements
Validation Results
Sine-with-Dwell Test Results
Conclusions

2 September 19th, 2012 K.M. Hahn

 Background
Test Procedure ECE-R 13-H
Electronic Stability Control (ESC) systems have
proven to be very effective in reducing accidents
and fatalities
European Commission decided that all new vehicles
have to be equipped with a functional ESC
ECE-R 13-H specifies the basic requirements of an
ESC and how this can be tested and certified
ECE-R 13-H currently does not evaluate the control
quality of the ESC

3 September 19th, 2012 K.M. Hahn

ECE13H Homologation through Simulation
Background
Use of CAE in Homologation Process ECE-R 13-H

When one physical vehicle has been tested according to ECE-R 13-H, other vehicle
variants or versions based on the same vehicle type may be subsequently
homologated through simulation.

Process to be applied:
Test a Target Vehicle according to ECE-R 13-H Sine-with-Dwell test
Generate a vehicle simulation model of the target vehicle and correlate it
to an acceptable level of accuracy requested by Type Approval Agency
Simulate critical variants and versions to identify worst case examples
Present results to obtain homologation for all configurations

4 September 19th, 2012 K.M. Hahn

 Background
Test Definition According to ECE-R 13-H (Sine-with-Dwell Test)
Test Procedure
Pre-Test: A is the steering wheel angle at ay = 0.3g
Steering Wheel Angle

Vehicle coasting in high gear at 80 ± 2 km/h

time Steering amplitude for the initial run is 1.5 A
In each series of test runs the steering amplitude is
increased from run to run by 0.5 A
Max. steering amplitude ~ 270 deg
Yaw Rate

time

Sine-with-Dwell

5 September 19th, 2012 K.M. Hahn

ECE13H-S7 Homologation
Background
Evaluation Criteria ECE-R 13-H
Effectiveness of ESC is determined by Performance Criteria
Vehicle must comply with all 3 performance criteria to achieve Homologation

Stability (yaw rate ratios) Responsiveness (lateral deviation)

Wheel Angle
Steering

time

w/o ESC
Yaw Rate

w/ ESC
time

T0 T0+1 T0+1.75

at T0+1 35%

at T0+1.75 20%

6 September 19th, 2012 K.M. Hahn

 Background
Regulation designed for Simulation

7 September 19th, 2012 K.M. Hahn

 Background
Difference to FMVSS126

FMVSS 126:
Self certification
OEM Government

Verification

ECE R13-H:
Witness testing Confirmation
OEM Certifier Government

8 September 19th, 2012 K.M. Hahn

 Motivation
Project Complexity
Astra (2009 - )

Insignia (2008 - )

Corsa (2005 - )

ABS / ESC
Damping
ABS / ESC ABS / ESC
Radar
Damping
AWD ~400 Variants
~150 Variants
~70 Variants

10 September 19th, 2012 K.M. Hahn

 Motivation
Increasing Test Requirements
Homologation test requires steering robot
At least one day test time per vehicle (setup & test execution)
Weather dependency
Cost for tracks and travel

Cost comparison

Travel
Equipment
Manpower

Vehicle only Vehicle + Simulation

11 September 19th, 2012 K.M. Hahn

 Motivation
Road-Lab-Math (RLM) Strategy applied to Chassis Controls

Driving Test HiL - Simulation SiL - Simulation

(Road) (Lab) (Math)

Controller Application Performance Validation Architecture Development

Random Testing Diagnosis / Failsafe System Integration
Validation Parameter Optimization
Certification

12 September 19th, 2012 K.M. Hahn

 Simulation Environment at GM Europe
Virtual Vehicle Development (Timing)

SORP
Effort

Virtual
suspension Virtual Control
and brake ride & handling systems
development optimization validation

Virtual Development Time

13 September 19th, 2012 K.M. Hahn

 Simulation Environment at GM Europe
Vehicle Dynamics Simulation
Suspension
Process for data generation and transformation defined Virtual Vehicle
Simulation
Suspension Data Kinematic
Interfaces between tools established
Geometry Processing and verified
Analysis Chart

Maneuver Compliance Characteristic

Definitions Analysis Plots
Suspension
Topology Reliable data for certification
Equations Compiler
Builder
of motion Linker
Body Vehicle Handling Virtual Vehicle
Topology Simulation Analysis Chart
Component Ride Characteristic
Models Analysis Plots
Body Data Roll-over
Geometry Processing Analysis
Ground HyperWorks
Clearance MotionView
Tire Data

Road Data SiL-/HiL

Simulation
ASCII ADAMS ANSI-C CarMaker
Mesaverde Simulink Pro

14 September 19th, 2012 K.M. Hahn

 Simulation Environment at GM Europe
Chassis Controls Simulation
ECU- & Actuator Models

ESC
Test-
Parkbrake automation

Vehicle Dynamics Model Software-in-the-Loop

Simulation (SiL)
Aero
PT
Chassis
Sensors
Tires
CAD

Actuator Models

ESC Simulation Results

Parkbrake

Hardware-in-the-Loop
Simulation (HiL)

15 September 19th, 2012 K.M. Hahn

 Simulation Environment at GM Europe
Hardware-in-the-Loop
Pump
Motor
Emulator
ESC ECU
ESC
Hydraulic

Current
Measure-
ment Card

16 September 19th, 2012 K.M. Hahn

 Project Scope
Cooperation project Opel <-> Applus IDIADA

Project was defined in close

IDIADA IDIADA
cooperation between Homologation Simulation
departments

Many steps were conducted

together (e.g. measurement
setup, validation)
Opel Opel
Joint approach improves Homologation Simulation

transparency

18 September 19th, 2012 K.M. Hahn

 Project Scope
Execution

19 September 19th, 2012 K.M. Hahn

 Validation of the Simulation Environment
IDIADA provided Testing and Simulation Support in the Process

Comprehensive testing of reference vehicle

Static Measurements
Dynamics Measurements

Construction of passive model

Focus on suspension & steering
Tires

Validation of passive model

According to IDIADA criteria
Extended validation program

20 September 19th, 2012 K.M. Hahn

 Validation of the Simulation Environment
Comprehensive Testing of Reference Vehicle
Static Measurements
K&C test of front and rear axles
Additional sensors for suspension parameters
Extended test matrix to generate complex
suspension maps based on multiple inputs
Center of Gravity
Static geometry and corner weights

Dynamics Measurements
Handling tests to characterize handling response
Brake tests to characterize braking system
ABS & ESC tests
Test Manoeuvres Reps Weight configs ESC configs Sides Setup Total runs
Number of manoeuvres to execute Number of GVM ESC ON, ESC OFF Left, Right See Channel Executions
the test repetitions for List
each manoeuvre

Steady-State Cornering Const. Speed 1 AY = 0-lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 12
Frequency Response Linear Range 1 AY = ± 3 3 1 GVM 1 OFF 1 -- Setup 1 3
Step steer + Free control release 6 AY = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 72
On-centre feeling weave 1 3 1 GVM 1 OFF 1 -- Setup 1 3
Power-off reaction 6 AY = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 2 ON, OFF 2 Left, Right Setup 1 72
Braking in a turn 6 AX = 2 - 4 - 6 - 7 - 8 - lim 3 1 GVM 3 ON, OFF, No YRS 2 Left, Right Setup 1 108
Double lane change 7 V = 80-85-90-95-100-105-lim 3 1 GVM 2 ON, OFF 1 -- Setup 1 42
Dwell sine test 20 20 steps of SWA) 2 1 GVM 2 ON, OFF 2 Left, Right Setup 1 160
472

21 September 19th, 2012 K.M. Hahn

 Validation of the Simulation Environment
Construction of a Vehicle Passive Model
Complex suspension maps generated by an in-house
tool for conversion of K&C tables to IPG CarMaker model
Supplemented with vehicle data supplied from Opel
(powertrain, body, aerodynamics)
Accurate representation of load & instrumentation
Validated against K&C tests

22 September 19th, 2012 K.M. Hahn

 Validation of the Simulation Environment
Final Validation Results
Steady State parameters

Frequency Response parameters

Sine with Dwell parameters

Ready for Active Model validation

24 September 19th, 2012 K.M. Hahn
 Sine-with-Dwell Test Results
Vehicle Response for an exemplary Sine-with-Dwell Maneuver

25 September 19th, 2012 K.M. Hahn

 Sine-with-Dwell Test Results
ESC pressure response for an exemplary Sine-with-Dwell Maneuver

26 September 19th, 2012 K.M. Hahn

 Sine-with-Dwell Test Results
Summary Report of a Sine-with-Dwell Test

28 September 19th, 2012 K.M. Hahn

 Conclusions
Pilot project between Opel and IDIADA to achieve CAE-based
homologation of an ESC-system according to ECE-R 13-H
Setup of a high-quality simulation environment (HiL) is possible,
but requires advanced integration solutions and expertise
Validation of the simulation environment by extensive static and
dynamic measurements proves good correlation
Simulation results of Sine-with-Dwell
maneuver are very close to real
measurements
Quality of simulation allows the
homologation of ESC systems
Process from testing to simulation
to homologation is well understood
and documented
Approach allows OEMs to significantly reduce the number of
real tests during the ESC certification process

29 September 19th, 2012 K.M. Hahn