dipl.-ing. thorsten pendzialek dipl.-ing. matthias mrosek · 2016-10-20 · linde material handling...
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Linde Material Handling
Linde Material Handling
Dipl.-Ing. Thorsten PendzialekDipl.-Ing. Matthias Mrosek
Assistance Systems for Counterbalance Forklift Trucks
Model-Based Testing of Driver
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� Motivation for the Introduction of Model-Based Testing at Linde Material Handling
� Linde Safety Pilot Driver Assistance System
� Modeling Requirements for Testing the Linde Safety Pilot Driver Assistance System
� Model Validation
� Model-Based Testing Framework
Outline
Linde Material Handling
Evolution of Software-Testing at LMH
Functions & Complexity
Manual Testing
Reporting -
Time -
Quality -
Flexibility -
Partly Automated Testing
Reporting +
Time +
Quality +
Flexibility –
Fully Automated Testing
Reporting +
Time ++
Quality ++
Flexibility +
Electronic Control Unit (ECU) Testing
Vehicle-Based Model-Based
Vehicle in the loop
„Tessy“ systemECU in the loop
HiL system
Plain testing
1990 1995 2000 2005 2010 2015
BR335-02BR350 BR39x BR386 BR387
BR1120
LSP
BR387
LSP
BR39xBR336-03 BR39x
update
BR1120
DMC
??
Main Drivers to Introduce Model-Based Testing
� More projects
� More variants
� Higher function complexity
� Shorter development cycles
� Stricter regulations e.g. functional safety
� Increased test effort to validate future assistance systems e.g. LSP
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� Motivation for the Introduction of Model-Based Testing at Linde Material Handling
� Linde Safety Pilot Driver Assistance System
� Modeling Requirements for Testing the Linde Safety Pilot Driver Assistance System
� Model Validation
� Model-Based Testing Framework
Outline
Linde Material HandlingAccidents with Counterbalance Forklift Trucks Happen– And Often the Drivers are not Aware Why
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Who is Responsible?
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BGV D27-§§§§8 Stability Against Collapse:„Counterbalance trucks have to be operated in a way,that stability against collapse is preserved. “
Responsibility of the Forklift Driver� Load?� Load center of gravity?� Maximal allowed lifting height?
Producers are liableto indicate thestationary carryingcapacity in eachtruck.
Operator
Driver
Producer
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Stationary Carrying Capacity
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Stationary Carrying Capacity is Often Hard to Determine
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Linde Safety Pilot - ActiveMeasured Quantities and Sensors
Lifting Height
Load Force
Rear-Axle Force
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Pressure Sensor
Wire-ActuatedEncoder
Axle-Force Sensor
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Video LSP-WOM
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� Motivation for the Introduction of Model-Based Testing at Linde Material Handling
� Linde Safety Pilot Driver Assistance System
� Modeling Requirements for Testing the Linde Safety Pilot Driver Assistance System
� Model Validation
� Model-Based Testing Framework
Outline
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HIL Design
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HIL Design – Modeling WorldModeling, Data Acquisition
8/22/2014 13
- Mast+Attachment Data
- Working Hydraulics Model
- Sensor Characteristics
- Steering Model
- Brake Model
- CAN Restbus
- Powertrain Models
-electric
-hydraulic
- Powersource Models
-Battery
-ICE
DUT
Road Environment
Chassis
Tires
Vehicle dynamics
+ Mast dynamics
Responsibility Linde Responsibility IPG
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10.01.2012 | Team 387/388 DOC00015050 Page 14
Huge Truck VarietyActual Series BR387/388
Capacity E20 E25 E30 E35 E40 E45 E50
Truck height flat high flat high flat high flat high flat high flat high flat high
387
CompactStandard
OHG 440 Ah 560 Ah 440 Ah 560 Ah 440 Ah 560 Ah
CompactComfort OHG 440 Ah 560 Ah 440 Ah 560 Ah 440 Ah 560 Ah
LongStandard
OHG 550 Ah 700 Ah 550 Ah 700 Ah 550 Ah 700 Ah
LongComfort OHG 550 Ah 700 Ah 550 Ah 700 Ah 550 Ah 700 Ah
388
CompactStandard
OHG 700 Ah 700 Ah 700 Ah
LongContainer
OHG 840 Ah 840 Ah 840 Ah
LongComfort OHG 840 Ah 840 Ah 840 Ah 840 Ah
LSP500 LSP600
Trucks: 34
Masts: 4
Height Range: 3-7m
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10.01.2012 | Team 387/388 DOC00015050 Page 15
Huge Truck VarietyActual Series BR387/388
Capacity E20 E25 E30 E35 E40 E45 E50
Truck height flat high flat high flat high flat high flat high flat high flat high
387
CompactStandard
OHG 440 Ah 560 Ah 440 Ah 560 Ah 440 Ah 560 Ah
CompactComfort OHG 440 Ah 560 Ah 440 Ah 560 Ah 440 Ah 560 Ah
LongStandard
OHG 550 Ah 700 Ah 550 Ah 700 Ah 550 Ah 700 Ah
LongComfort OHG 550 Ah 700 Ah 550 Ah 700 Ah 550 Ah 700 Ah
388
CompactStandard
OHG 700 Ah 700 Ah 700 Ah
LongContainer
OHG 840 Ah 840 Ah 840 Ah
LongComfort OHG 840 Ah 840 Ah 840 Ah 840 Ah
LSP500 LSP600
Trucks: 34
Masts: 4
Height Range: 3-7m
Reference Vehicles
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� Motivation for the Introduction of Model-Based Testing at Linde Material Handling
� Linde Safety Pilot Driver Assistance System
� Modeling Requirements for Testing the Linde Safety Pilot Driver Assistance System
� Model Validation
� Model-Based Testing Framework
Outline
Linde Material HandlingHardware In The Loop – HILValidation Process
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Bild HIL
Schublade
DataAcquisition
SystemModeling
TestExecution
Setup HILEnvironment
ModelValidation
Discussionof Results
DiscussionOf ResultsApprovedModel
Linde Material HandlingVehicle Dynamics ValidationTest Execution - Validation Driving Maneuvers
Quelle: Schyr, Fa IPG 18
Linde Material HandlingVehicle Dynamics Validationx,y Coordinates
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Real Input
Real vs Simulated Results
Steering wheel
Pedal
speed
axay
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13.7.2012 Fußzeile 20
Lifting Dynamics ValidationForklift z Coordinate
Mast Stage Transition
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� Motivation for the Introduction of Model-Based Testing at Linde Material Handling
� Linde Safety Pilot Driver Assistance System
� Modeling Requirements for Testing the Linde Safety Pilot Driver Assistance System
� Model Validation
� Model-Based Testing Framework
Outline
Linde Material HandlingHardware In The Loop – HILDriving & Lifting Maneuver Testing
• Define maneuver• Define various conditions in which to test:
• Loads• Load center of gravity• Mast type + attachment• Vehicle variant• Environment (Road inclination, surface…)
• Program test script• Decide on which physical quantities to focus
for automated test case evaluation �Criteria!
1. Requirement 2. Setup Model
3. Test case generation
• Execute test scripts + store results • Check if specified boundaries have been violated• Automated protocol with highlighted deviations
including illustrations• No user interaction required• Remote usage of analyzing tools (e.g. Matlab)
4. Test case execution on Hil
„Drive speed shall be reduced smoothly when forklift condition is potentially dangerous e.g. lifted load while driving…“
Physically:• Inertia of Vehicle• Center of Gravity• Mast type and data• Mast attachment• Geometries• Powertrain• Hydraulics• Tires
Electrically:• Additional sensors• Additional control units• Additional data and
teaching effort for ECUoperability
Linde Material HandlingHardware In The Loop – HILState Diagram & Electrical Failure Testing
• Collect test cases A, B, …• Specify expected behavior• Review previously generated
result files and re-specify behavior
1. Requirement 2. Test case
3. Test case schedule
• Load schedule + execute test cases A, B, …• Store results• Compare to expected behavior given by test
case schedule(automated/interactively)• Highlight deviations
4. Test case execution on Hil with test manager software
+
• Straightforward• Mouse click programming• Predefined macros• Configurable macros
Linde Material HandlingVielen Dank für Ihre Aufmerksamkeit
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