This paper describes a model-driven approach to support heat monitoring and predictive maintenance of an automotive braking system. This approach includes the creation of a simulation-based digital twin, or numerical model, that combines different modeling formalisms into an integrated model of the braking system that can be used for monitoring, diagnostics, and prognostics. The paper provides an overview of the basic models including Modelica models, reduced order models for various key components of the system model, and controls and sensor models. The Modelica models are implemented in the ANSYS Simplorer simulation to leverage existing modeling work and connections with other ANSYS finite element software to utilize reduced order models. The simulation results include both baseline results for the system and the results of injecting failures into the system for monitoring and predictive maintenance.

Virtual evaluation of complex Cyber-Physical Systems (CPS) [1] with a number of tightly integrated domains such as physical, mechanical, electrical, thermal, cyber, etc. demand the use of heterogeneous simulation environments. Our previous effort with C2 Wind Tunnel (C2WT) [2] [3] attempted to solve the challenges of evaluating these complex systems as-a-whole, by integrating multiple simulation platforms with varying semantics and integrating and managing different simulation models and their interactions. Recently, a great interest has developed to use Functional Mockup Interface (FMI) [4] for a variety of dynamics simulation packages, particularly in the automotive industry. Leveraging the C2WT effort on effective integration of different simulation engines with different Models of Computation (MoCs), we propose, in this paper, to use the proven methods of High-Level Architecture (HLA)-based model and system integration. We identify the challenges of integrating Functional Mockup Unit for Co-Simulation (FMU-CS) in general and via HLA [5] and present a novel model-based approach to rapidly synthesize an effective integration. The approach presented provides a unique opportunity to integrate readily available FMU-CS components with various specialized simulation packages to rapidly synthesize HLA-based integrated simulations for the overall composed Cyber-Physical Systems.

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Performance and range optimization of electric vehicles are challenging targets in the design of contemporary automobiles. This paper illustrates that the thermal system and the development of the related control logic are key factors in achieving these targets. Both subjects benefit from the support of modeling and simulation. The paper describes our approach applied to a real case study. The activity is the result of a cooperation between Dallara, responsible for the case study, and Modelon, developers of the libraries used to build the simulation model.

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