Combined real and virtual domain product validation using top-down strategies

Transcription

1 Combined real and virtual domain product validation using top-down strategies Martin Geier Steffen Jäger Christian Stier Albert Albers IPEK Institute of Product Engineering 1 KIT University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association

2 My presentation will show who we are and what we do explain our powertrain validation approach focus on modeling for validation purposes in opposite to modeling for design purposes give examples of current applications outline challenges and solutions we are working on

3 O u t l i n e IPEK at a glance validation in product engineering X-in-the-loop validation approach top-down modeling strategies examples of combined real & virtual validation methods

4 Karlsruhe Institute of Technology One Institution. Two Missions. Staff Professors Students 732 Million Euros Budget

5 IPEK Institute of Product Engineering Karlsruhe Facts 2 professors 7 research groups 3 senior engineers 54 scientists 20 technical staff education since Ph.D. 14 lectures over 300 student assistants ~1900 coached students equipment automotive test labs high performance computing test vehicles mech. & elec. workshops

6 IPEK research approach systems methods process models systems drives automotive powertrains, robotics humanoid robot, micro systems micro planetary gear, power tools direct fastening tool, methods validation methods virtual and real testing, Contact & Channel-Model development methods knowledge management,.. optimization methods topology optimization, process models holistic development processes integrated product engineering model ipem validation management optimization processes

7 O u t l i n e IPEK at a glance validation in product engineering X-in-the-loop validation approach top-down modeling strategies examples of combined real & virtual validation methods

8 IPEK model of product engineering a systemic approach

9 O u t l i n e IPEK at a glance validation in product engineering X-in-the-loop validation approach top-down modeling strategies examples of combined real & virtual validation methods

10 powertrain system interactions phenomena & manuevers Note: system borders and varables are driven by the design of topology and attributes

11 X-in-the-loop basic concept What is the X? How can we run it in the Loop? How can we use/model it?

12 O u t l i n e IPEK at a glance validation in product engineering X-in-the-loop validation approach top-down modeling strategies examples of combined real & virtual validation methods

13 top-down modeling approach define model purpose in our case the phenomena for specific maneuvers consider object system to be validated decide on unit under test and remaining system find subsystem interactions, model common interfaces important for causality, try to allow model reusability define essential model features basis for implementation implement and execute

14 top-down modeling generic example model purpose We want to check if driving a specific maneuver with our product is satisfying No uncomfortable phenomena should be perceived

15 top-down modeling full modeling space generic example

16 O u t l i n e IPEK at a glance validation in product engineering X-in-the-loop validation approach top-down modeling strategies examples of combined real & virtual validation methods powertrain in the loop

17 top-down modeling model partition plane

18 Example powertrain validation partitioning and setup domain Purpose: verify gear rattle phenomena for real driving cycle

19 top-down modeling model maturity and fidelity plane

20 Example powertrain validation model fidelity and underlying product maturity

21 Example - test bench PLP powertrain validation at IPEK - generation

22 O u t l i n e IPEK at a glance validation in product engineering X-in-the-loop validation approach top-down modeling strategies examples of combined real & virtual validation methods subsystem in the loop

23 Example subsystem validation partitioning and setup domain Purpose: verify gearbox damping & loss

24 Example subsystem validation model fidelity and underlying product maturity

25 Example - test bench PPP (Power Pack) virtual unit under test real-time controller + automatization driver ECU ICE UUT TCU gearbox driveline, chassis environment power (each) 209 kw max. rev. speed /min peak torque 700 Nm inertia 0,029 kgm² rot. freq. excitation > 300Hz

26 Example subsystem validation model fidelity and underlying product maturity Purpose: verify gearbox rattle

27 Outlook extension of IPEK XiL-equipment and methods battery simulator for electrical powertrains high-speed electrical motors to load vehicle traction motors apply more DOF excitation on test rigs (axial, radial) implement distributed EtherCAT realtime simulation network systems engineering approaches to support XiL modeling

28 Thank You! Enjoy some impressions from the lab. nice Porsche at dyno with force mount

29 Thank You! Enjoy some impressions from the lab. laser scanning of hybrid on roller dyno

30 Thank You! Enjoy some impressions from the lab. cockpit box for real driver at roller dyno

31 Thank You! Enjoy some impressions from the lab. powertrain in the loop test rig, generation

32 Thank You! Enjoy some impressions from the lab. powertrain in the loop test rig, generation

33 Thank You! Enjoy some impressions from the lab. old powerpack test rig with hybrid system

34 Thank You! Enjoy some impressions from the lab. power pack test rig component in the loop

35 Thank You! Enjoy some impressions from the lab. dry clutch system test rig

36 Thank You! Enjoy some impressions from the lab. Mini-HiL test rig development platfm

37 Thank You! Enjoy some impressions from the lab. squeeze film damper test rig

38 Thank You! Enjoy some impressions from the lab. modal analysis with big shakers modal analysis with laser scanner