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Development of an Experimental and Test Environment for

Vehicle Real-Time Simulations

Dr.-Ing. Gerd Bitsch

Bonn - Bad Godesberg,

November 20th-21st 2007

Department MDF

• Simulation of mechatronicsystems

• CAE Durability (MBS, FEM, durability life prediction)

• Statistical testing / design target loading

Fraunhofer ITWMat Fraunhofer-Zentrum Kaiserslautern

• 150 employees

• Operating budget 2006: 11 Mio Euro

Department MDF @ Fraunhofer ITWM

Simulation of mechatronic systemsFull vehicle simulations

Wheeledexcavator

Field cropharvester

Simulation of mechatronic systems

Servo – hydraulic test rigs

• Joint innovation project of Fraunhofer Institutes with industrial partners

• Research

• Method development

• Transfer and application (application projects)

• Funding: 10 Mio. € for first 3 years

• Bund (BMBF) – preparation: 700.000 €

• Rheinland-Pfalz: 3 Mio. €

• Fraunhofer: 3 Mio. €

• Industry: 4 Mio. €

• Operational since April 2007

Fraunhofer Innovation Cluster ‚Digital Engineering for Commercial Vehicles’

• DaimlerChrysler (Wörth & Stuttgart)

• John Deere (Mannheim & Zweibrücken )

• Schmitz Cargobull (Altenberge)

• Keiper (Kaiserslautern)

• GE Transportsysteme (Bad Dürkheim)

• Volvo CE (Trier)

• Haldex Brake (Heidelberg)

• MB-tech (Sindelfingen)

• Robert Bosch (Schwieberdingen)

Industrial partners

Development of an Experimental and Test Environment forVehicle Real-Time Simulations: Objective

Objective: Providing an experimental and test environment for real time simulations in combination with the physical world. The two main parts are:

Micro-Autobox and a 3 GHz AMD Opteron

Real time simulation environment:on the one hand high-performance, on

the other mobile in a vehicle forprototyping

Vehicle-Hardware-Infrastructur:physical vehicle model, CAN-Bus, data logging…

Physical model of the truck (scale 1:10)

• a ready to use model was not available(most components have beenmanufactured individually)

• realistic scale, e. g. for axes(air suspension, hydraulic brakes,…)according to a Mercedes-Benz ACTROS

History:

• Concept end of year 2006

• Aquirering components until april 2007

• April 2007- September 2007: building the vehicle as part of student research project

Real time simulation environment (dSpace)

• 2 hardware real time environments

– dSpace MicroAutobox(mobile, 800MHz, several interfaces as CAN, A/D- and D/A-converters etc.)

– dSpace DS1006 (stationary, 3GHz Opteron)

History:

• Obtaining hardware may 2007

• Initation of the system june-august 2007

dSpace ControlDesk and MotionDesk combined with Matlab Simulink

• End of august 2007: first working models on dSpace using CodeExport and Simpack

SIMULINK model

SIMPACK Element library for dSpace (ds1005, ds1006)

<model>.ppc for ds1005

<model>.x86 for ds1006

Control Desk

CodeExport

RTW

Real time simulation environment (dSpace)Work flow

<model>.data_base

Code

Export

<parameter>.m

licensed SIMPACK Element Library

for Windows

SIMPACK USER Elements lib

p)u,t,f(x,=xɺ

p)u,t,g(x,=yRTW


for HIL target

Automatic generation of dynamic equation of arbitrary SIMPACK models as source code

Real time simulation environment (dSpace)Codegeneration


for HIL target

code_export_f90.libfor Windows

code_export_C.libfor Windows

code_export_C.libfor HIL-target

<model>.f Create S-function

<model>.c Create S-function

convert (ForC)

compile for HIL-target

Licensed libraries in

SIMPACK installation

RTW HIL

SIL

Real time simulation environment (dSpace)Libraries

Truck model (physical und virtual) Controls

CAN BusCAN Bus

Wireless-CAN

remote control RC-Receiver

ControlDesksteering

Micro-Autobox and/or3GHz AMD Opteron

Truck model (physical) Actuators

CAN BusCAN Bus

Wireless-CAN

microprocessor

gear box

cruise control

air spring – servo valve

steering

Truck model (physical) Sensors

CAN BusCAN Bus

angular speed(Hall-Sensors)

microprocessor

accelerations(ICP-Sensors)

real time hardware

A/D

Wireless-CAN

signal-conditioning

Truck model (physical) Example for coupling sensors/aktuators

CAN BusCAN Bus

Wireless-CAN

Disc brake – brake actuator

rotary speed(Hall-Sensors)

Truck model (virtual) Simulation

CAN BusCAN Bus

Wireless-CAN

Micro-Autobox and/or3GHz AMD Opteron

ControlDesksteering

MotionDesk

PC (Visualisation)

Real time Real time Real time Real time simulationsimulationsimulationsimulation

Summary

• ITWM/MDF: until now mostly simulation of complex mechanical and mechatronicsystems (full vehicles, test rigs,…)

• real time simulation environment established in 2007:

– two real time hardware platforms (MicroAutoboc, DS1006)

– physical vehicle model, including wireless CAN-Bus, measurement equipment

• current and future work

– development of model based monitoring solutions

– studies concerning complexity of models vs. computing hardware

– studies concerning solver technologies

– several real life applications with OEMs

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