R2R – Model Based Testing for E-Mobility Applications

Authors

Dr. M. Wipfler, Dr. W. Rossegger, Dipl.-Ing. B. Pressl, Dr. T. Haidinger, Dr. R. Bauer, Kristl, Seibt & Co GesmbH, Graz

Year

2020

Print Info

Fortschritt-Berichte VDI, Reihe 12, Nr. 813

Summary

Current advances in the electrification of vehicles and the associated increase in complexity are leading to a continuous rise in the development effort involved. Putting vehicles into service which have a large number of networked control units represents a growing challenge due to the mutually interrelated influences of the different functions and the large number of iteration loops this requires.
This paper presents a test methodology for model-based road-realistic testing on the test bed. The modular model toolbox and the flexible integration of the submodels into the test bed automation system make it possible to test all vehicle components as well as the entire vehicle under fully realistic road conditions using KS Road to Rig (R2R) technology.
Components of the device under test not present on the test bed are replaced by corresponding models. Reproducible conditions simulating the respective environmental conditions are created on the test bed using hardware and software modules that can be combined flexibly. These include the temperature (such as -30 °C to 50 °C in the entire test cell), humidity, road surface and course of the roadway as well as the geographical location of the vehicle simulated by means of GPS spoofing. The sensor signals for acceleration, cameras, radar and LIDAR are also made available to the vehicle. The test beds used are ready to go after a very short set-up time and can be flexibly adapted to changing test sample types and testing tasks.
The integrative development and optimization of the functional modules and their networking is carried out simultaneously on the same vehicle by the respective teams responsible for the different functional areas. This way, the various operating modes of the vehicle are tested and proven at an early stage, while software versions that are not yet fully mature do not impair the safety of personnel in any way. In modern powertrain topologies, the interaction of the various components involved in the mapping of the required functions always entails a consideration of the overall system (Function in the Loop) in order to verify the functionality. With its significant savings in the number of test vehicles required and the substantial reduction in development time, the methodology presented here leads to a reduction in development costs and a shortening of the time to market, while at the same time improving product quality.