Microsoft Word - A_31_Enisz_R.doc
HUNGARIAN JOURNAL
OF INDUSTRIAL CHEMISTRY
VESZPRÉM
Vol. 39(1) pp. 57-62 (2011)
VEHICLE DYNAMICS BASED ABS ECU TESTING ON A
REAL-TIME HIL SIMULATOR
K. ENISZ , P. TÓTH, D. FODOR, T. KULCSÁR
University of Pannonia, Institute of Mechanical Engineering, Faculty of Engineering
8200 Veszprém, Egyetem u. 10., HUNGARY
E-mail: krisztian.enisz@gmail.com
Satisfying the ever increasing needs for safety and environmental issues the electronic control units (ECU) of today
vehicles become more and more complex [1, 2]. Regarding the controllability and safety requirements posed against
automotive industry, the cost efficient ECU testing and the development of the software sensors becomes an important
issue. The aim of this paper is to present the setup a HIL (hardware-in-the-loop) simulation environment which makes the
functional testing and development of ECUs possible, and test the realized hardware and software environment with the
integration of a General Motors Anti-lock Braking System ECU.
Keywords: HIL simulation environment, ABS, ECU
Introduction
The cost efficient ECU testing becomes an important
issue. The development of new algorithms and new
ECUs are necessary because the safety requirements are
ever increasing. The testing of the new methods with
real vehicle on a test track is very important but very
expensive and it takes too much time. To help the proof
of concepts developments it is necessary to implement a
test and simulation environment which makes easier to
create and validate new algorithm for different types of
vehicles and ECUs.
The aim of the research was to create a software and
hardware environment which is easily reconfigurable
and its training time for new users is relatively short.
The functions of the system will be introduced with
the hardware and software integration of ABS ECU.
The architecture of the simulation environment
The simulator has got modular architecture (Fig. 1 and
Fig. 2) which makes it easily reconfigurable. The first
part is a standard high performance PC with Windows 7
operation system. It can be used as standalone system
without the other part of the simulator and makes it
possible to test new algorithm without any ECUs of the
vehicle. The core of the system is a vehicle dynamics
based simulation software, the Tesis veDyna 3.10.4.
This software is based on Matlab/Simulink and the new
algorithms can be implemented under Simulink
environment, and capable to create new maneuvers,
parameterize different vehicle models and the environment
like road surface etc.
The interface for the real time hardware is the National
Instruments VeriStand 2010. It can handle the models
which were built by the veDyna, and can make the
connection between input and outputs of the model and
the hardware devices. The signal modification or override
is one of the most important feature of the VeriStand. It
can prepare the signals for the model or device inputs by
the modification of the signals by simple mathematical
algorithms or more complex LabView models.
Figure 1: The anatomy of the HIL simulation environment
58
The second part is National Instruments based PXI
real-time system. It has modular inputs and outputs and
can be extended by National Instruments PXI and Compact
RIO cards, like CAN, FlexRay, digital and analog IO
cards. The PXI system has external interfaces like Vector
MOST and TTech FlexRay interface which can be used
without the PXI system, with a standard PC.
Figure 2: The physical appearance of the simulation
environment
The third part is an electric motor emulator, which
can emulate different types of electric motors used by
electric cars driving systems.
The Integration of an ECU
After the realization of the simulation system, the very
important step was the integration of an ECU (Fig. 3).
Figure 3: The hardware integration of the ABS ECU
The hardware integration
The ECU was extended with simple and small electric
circuits to emulate the wheel speed sensors (Fig. 4), the
valves (Fig. 5) and the motor (Fig. 6). The motor and the
valves are controlled by the ECU, the Real-Time system
only measured the states of these components. The wheel
speed sensors are controlled by the simulator and a
digital output switching the voltage on/off according to
the provided wheel speed to generate the pulses with the
correct frequency for the ABS.
Figure 4: The emulation of the wheel speed sensors
Figure 5: The emulation of the valves
Figure 6: The emulation of the motor
The software integration into the Tesis veDyna
The brake system part of the original veDyna Simulink
model was modified to handle the incoming valve states,
and modify the brake pressure at the wheels according
to the valves position (Fig. 7), independently for each
wheel.
59
Figure 7: The software integration of the ABS ECU
into the Tesis veDyna
The main equation of the pressure modification
algorithm is (Eq. 1):
τ
)(
arg ))(()()(
nt
diffett enpnpnp
−
−= , (1)
where:
n – The current simulation step
p(n) – The modified brake pressure for the wheel.
ptarget(n) – The target brake pressure
pdiff(n) – The difference between the current and the
target brake pressure
t(n) – The current time of the cycle
τ – The time constant
The algorithm has six different part as can be seen
on the Matlab / Simulink chart (Fig. 8):
● state selection (Fig. 9)
● main pressure change check (Fig. 10)
● cycle interval calculation (Fig. 11)
● target pressure calculation (Fig. 12)
● pressure difference calculation (Fig. 13)
● brake pressure calculation (Fig. 14).
The state selection part sets the current state
corresponding to the valves position and sign that the
valves states is different from the previous valves state
(Fig. 9).
Figure 9: The calculation of the State(n) and
State changed(n) parameters
Figure 8: The pressure modification model for one wheel
60
The main pressure change check is necessary because
if the driver increase or decrease the brake pressure the
model cannot follow correctly this linear change. The
problem was solved with a small modification to build
up the linear pressure with small steps (where the step
size is pmax change and the pmain is the unmodified brake
pressure for the wheel) (Fig. 10).
Figure 10: The calculation of the pmain start(n) and
pmain changed(n) parameters
The cycle interval calculation module gives values
of the current cycle interval, where the tstep is the
simulation step length (Fig. 11).
Figure 11: The calculation of the t(n) and t’(n)
parameters
The target pressure calculation part selects the target
pressure (Fig. 12).
Figure 12: The calculation of the ptarget(n)
The pressure difference calculation part calculates
the difference between the current and the target brake
pressure (Fig. 13).
Figure 13: The calculation of the pdiff(n)
The pressure calculation part calculates the modified
brake pressure (Fig. 14).
Figure 14: The calculation of the p(n)
61
After the modification of the veDyna model the next
step was the creation of Veristand project. The compiled
model is compatible with the Veristand so the input and
output signals can be connected to the devices inputs
and outputs. The conversion of wheel speed signals is
necessary because the model provides the wheel speeds
in km/h but the ABS ECU expect it frequency
modulated pulses (Eq. 2) (switch on and off the voltage
with a frequency).
teethnk
v
f 6.3= , (2)
where:
v – The vehicle velocity
k – The circumference of the wheel
nteeth – The numbers of the teeth of the speed
measure disc
Another important setting is the emulation of the
ECU starter CAN frames.
The final step was to create a Veristand user interface
for the simulation to observe and change the parameters
(Fig. 15).
Figure 15: The speeds and pressure page of the
user interface
Results
Based on the developments a real-time vehicle simulator
was realized to create an integrated hardware in the loop
(HIL) simulation environment in which new theoretical
research results can be easily validated.
Figure 16: The vehicle velocity (km/h) and wheel
speeds (km/h) without the ABS ECU
(emergency braking from 115 km/h)
Figure 17: The brake pressures (Pa) without
the ABS ECU (emergency braking from 115 km/h)
Figure 18: The vehicle velocity (km/h) and wheel
speeds (km/h) with the ABS ECU
(emergency braking from 115 km/h)
Figure 19: The brake pressures (Pa) with
the ABS ECU (emergency braking from 115 km/h)
The behavior of the ABS ECU based test system
was in concordance with expectations (Fig. 16., Fig. 17.,
Fig. 18. and Fig. 19.) but some small further development
needed to refining the simulation. Another improvement
should be on the pressure model taking into consideration
of the motor state of the ABS.
ACKNOWLEDGMENT
We acknowledge the financial support of this work by
the Hungarian State and the European Union under the
TAMOP-4.2.1/B-09/1/KONV-2010-0003 project and
the intensive technical support of Continental Teves
Veszprem and National Instruments Budapest.
62
REFERENCES
1. P. E. RIETH, S. A. DRUMM, M. HARNISHFEGER:
Electronic Stability Program: The brake that steers,
Verlag Moderne Industrie, 2002, 16–26
2. F. GUSTAFSSON: Automotive Safety Systems,
Replacing costly sensors with software algorithms,
IEEE Signal Processing Magazine, 26(4), 2009, 32–47
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/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken die zijn geoptimaliseerd voor prepress-afdrukken van hoge kwaliteit. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)
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/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
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(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
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/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
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/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
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/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
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/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice