Virtualization X Real Component: The Advantages of System Modeling on the Automotive Development Process

Santos, Jeeves Lopes dos; Vieira, Gabriela; Vasconcelos, Felype Nery de Oliveira; Silva, Elaine Cristina Guglielmoni; Guimaraes, A. R.; Queda, Marcel Liberato

doi:10.4271/2017-36-0229

Cited by 5 publications

(2 citation statements)

References 11 publications

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“…To meet these challenges, simulation is used as an important tool in the development of electric vehicles [1,2]. HIL real-time simulation is a testing technique that can be employed in the development of electric powertrain systems.…”

Section: Introductionmentioning

confidence: 99%

HIL based Real-Time Co-Simulation for BEV Fault Injection Testing

Konzept,

Reick,

Pintaric

et al. 2023

SAE Technical Paper Series

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<div class="section abstract"><div class="htmlview paragraph">Battery electric vehicle (BEV) adoption and complex powertrains pose new challenges to automotive industries, requiring comprehensive testing and validation strategies for reliability and safety. Hardware-in-the-loop (HIL) based real-time simulation is important, with cooperative simulation (co-simulation) being an effective way to verify system functionality across domains. Fault injection testing (FIT) is crucial for standards like ISO 26262.</div><div class="htmlview paragraph">This study proposes a HIL-based real-time co-simulation environment that enables fault injection tests in BEVs to allow evaluation of their effects on the safety of the vehicle. A Typhoon HIL system is used in combination with the IPG CarMaker environment. A four-wheel drive BEV model is built, considering high-fidelity electrical models of the powertrain components (inverter, electric machine, traction battery) and the battery management system (BMS). Additionally, it enables validation of driving dynamics, routes and environmental influences and provides a precise analysis of the effect of powertrain system faults on driving behavior. A possible case for a fault injection is to introduce a shoot-through fault in the inverter. Through the co-simulation, it is possible to analyze the effects on the powertrain and the vehicle dynamics in different driving situations (e.g. snow). This work demonstrates that co-simulation is a valuable tool for the development and validation of BEVs, and presents specific fault cases introduced into the powertrain and the resulting effects tested under different driving conditions. In addition, the study discusses the system's limitations and future possibilities such as controller hardware integration (Controller-HIL) and autonomous driving system validation.</div></div>

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Section: Introductionmentioning

confidence: 99%

HIL based Real-Time Co-Simulation for BEV Fault Injection Testing

Konzept,

Reick,

Pintaric

et al. 2023

SAE Technical Paper Series

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“…Kuhn 6 discusses the basics of a digital twin. Santos et al 7 describe general possibilities for the use of virtual development in the PDP. El-Sayed 8 presents the basic principles of a transformation away from the hardware-driven development process toward a process based on virtual development.…”

Section: Introductionmentioning

confidence: 99%

Virtual powertrain development

Fietkau¹,

Kistner²,

Munier³

2020

Proceedings of the Institution of Mechanical Engineers, Part D:

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This article presents the new system of virtual powertrain development introduced at Porsche AG that incorporates all phases of the development process, as well as all components and simulation disciplines. The system enables a powertrain in its entirety to be designed and tested virtually. Most activities can be planned and budgeted at the beginning of the project, and interactions that occur are systematically taken into consideration. The hardware-driven development process used until now is completely transmitted to the digital world. Powertrain development is divided into thirteen digital powertrain systems (DPSs), which contain different components and disciplines and are developed throughout the entire product development process. For each DPS, tasks, links, time schedules, reporting scopes, and responsibilities are precisely defined. Finally, a digital vehicle prototype is built from several DPSs. The results are aggregated in several stages, ensuring that core statements are consistently incorporated at all assessment levels, from the individual component to the overall vehicle. Furthermore, this article discusses in detail DPSs that are especially important for battery electric vehicles. For most of the examples, the powertrain of the Porsche Taycan is used. The Driving Performance and Load Spectra DPS provide the necessary design parameters for a new drive system. In the Electric Motor DPS, active parts of the electric motor are designed and all structural components are verified. In the Transmission DPS, all gear set parts are designed and verified. In the Cooling, Lubrication and Actuation DPS, all temperatures are calculated and the lubrication circuit is designed. The Powertrain Dynamics DPS provides information on powertrain vibrations. The article closes with a look at future development trends. The aim is not just to design and verify components but also to completely virtualize function and software development. Therefore, this article presents a system for creating and using a virtual development environment and tracking the results.

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