GlobalCrown Technology Co., Ltd.

Lionel Belmon, Liu Fei – Global Crown Technology, Beijing

Zeng Weihua - Jianglu Rongda, Changsha

CVT control software testing

议程

1• Motivation

2• Vehicle plant modeling

3• TCU embedded software

4• Simulation validation

5• TCU Testing

GlobalCrown Technology Co., Ltd.

Motivation

Develop and test TCU control software

High quality vehicle model

Realistic simulation

Interaction road - vehicle - hydraulics - TCU

Cover large number of test cases

Motivation and objectives

Vehicle plant model

GlobalCrown Technology (BeiJing) Co., Ltd.

Vehicle model overview

BOB

use

ctr1

ctr2

diff_inertia

ctrR1

ctrR2

Prim

Sec

KpKs_Offset

variator

SideShaftInput

grade_percent

rm_RoadCurve

vehicle

ctr1

ctr2

FinalDrive

ctrPC

ctrS

DR

DNR

ctrP

ctrTLC_force

TC

ctr1

xPLock

HYD

ctr1

to_D

to_R pri

sec

shaft

current

force

hyd_sys

ctr1 ctr2

PumpRatio

ctr1starter_signal

ignition

om

inj

brake

starter_torque

CAN

engine

ctr1

ctr2

in1

starter

position

starter

ignition

StarteKey

Mau

inj

driver

hap

Mau

driver

BrakeTorque

hbr

Mau

prnd

spo

CAN

EMS

EngSpd_MAXLimt_Value

EngSpd_MAXLmit_RQTorque_NCCLU_Value

Torque_ShortTermRe_Value

CAN

TCU

prnd

D_BOB

N_BOB

P_BOB

R_BOB

fpo

BOB

npm

BOB

nse

BOB

ntu

FL

FR

wheel_speed

BOB

pdc

BOB

prc

BOB

ptc

pri

sf

BOB

upm

Driver

speedprofile

realspeed

brake

accel

mode

driver

f(x)x

y

car_speed

f(x)x

y

speed_profile_kmh

Driver CAN Hydraulics

Longitudinal

Vehicle dynamics

with left/right tyre

slip

Variator

BeltEngine/EMS

Torque

converter

RND clutch

Platform : SimulationX

Hydraulic module

Main flow pressure dynamics

Spool valves characteristics

Solenoid valve - pilot pressures

Torque converter lock-up

Primary /

Secondary

pistons for

variator

Extraction of CAD parameters

RND clutches

Solenoid pilot valves

GlobalCrown Technology Co., Ltd.

Hydraulic Unit tests and validation

Primary cylinder pressure

Solenoid current

Adjustment of solenoid characteristics

Variator belt model concept

secsec

sec2

cos

AR

TP

pri

pri

mx

=

)( *pripriprii FFnK

dt

di−=

Variator ratio change by controlling

primary/secondary pressure

Max torque limit depends on pressure !

steady-state force required

Actual force

Adjustment of hydraulic volumes and mechanical stiffness

Fixed-step solver – 0.5 ms

~80 ODE state variables

~200 inputs/outputs variables (CAN, sensors, actuators)

Code generation from SimulationX to FMU cosimulation

Execution in QTronic Silver

Real-time simulation

TCU embedded software

TCU software generation process

Functional requirements

ETAS ASCET model

Embedded c-codeA2L and

calibration data

ECU hardware

ETAS INCA

Virtual TCU with Silver

Functional requirements

ETAS ASCET model

Embedded c-codeA2L and

calibration data

Silver virtual ECU

ETAS INCA

Virtual TCU platform

Validation of vehicle simulation

~20 test drive cases to test various model characteristics :

10% pedal acceleration – coasting

30% pedal acceleration – coasting

…

Lever position changes : N-R-N-D-N-R-P-R-N…

Heavy braking with ABS

Tip-in , Tip-off

…

Test cases for simulation validation

GlobalCrown Technology Co., Ltd.

Example of test drive validation

car speed :

measurement - simulationengine speed :

measurement - simulation

turbine speed :

measurement - simulation

Hydraulic primary – secondary pressures

TCU embedded software testing

Usual test drive cases

NEDC, 100km/h acceleration…

Calibration parameters

Software functions activation/deactivation

Various environment conditions :

- slope, snow/water…

Fault monitoring and reaction

Test requirements

Fault insertion

Solenoid and hyd faults

bus faults

Wheel sensor faults

Speed sensors faultsTemperature sensors faults

Fault insertion – how it works

TCU application

software

Vehicle modelTarget current

Example on solenoid valve fault

Feedback current

TCU Basic software

Fault flag

Fault insertion – how it works

TCU

application software

Vehicle model

Current

target

Example on solenoid valve fault

Current

feedback Pyth

on

Fault mode selection

Short to GND

Short to UBat

Open line

TCU BS emulation

python

Fault flag from BS

Fault insertion – how it works

TCU ASW Vehicle model

Current

target

Example on solenoid valve fault

Current

feedback Pyth

on

Fault mode selection

Short to GND

Short to UBat

Open line

TCU BS emulation

python

Fault flag from BS

=0

=0

=3

- Formal requirements monitoring

- Hand written test scripts

- Automatic test cases generation

- Automatic test report generation

Use of QTronic TestWeaver

ABS simulation example

Belt slip

Clutch locked + Strong braking → Wheel block → strong engine deceleration

→ Transmission torque exceeded → belt Slip !

Vehicle speed

Wheel speed

Belt slip ratio

→ Belt slips are reported automatically in TestWeaver reports

Test case generation

Low mu high mu

High traction force

Wheel slip

Belt slip

QTronic TestWeaver automatically generates drive sequences

Example of Belt Slip found by TestWeaver

Vehicle speed

Wheel speed

MC/DC coverage

Code coverage with CTC++

Conclusion

Vehicle model + TCU + calibration :

validated simulation , reproduce very well the actual

execution of TCU in the real vehicle

Fault insertion and validation of TCU fault management

Automatic generation and evaluation of test cases

TestWeaver + requirements modeling

Very efficient support for TCU development and testing !

Realistic simulation – complex scenarios

GlobalCrown Technology Co., Ltd.

谢谢！Thank you ！