Extensive Test of Heavy-Machinery ECU on a NI VeriStand HiL using TestWeaver

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1 Extensive Test of Heavy-Machinery ECU on a NI VeriStand HiL using TestWeaver Dr. Thomas Neubert, Hydrive Engineering GmbH Dr. Mugur Tatar, QTronic GmbH

2 1 Introduction 2 Software Test Strategies 3 New Test Generation Strategy 4 Test Application 5 Summary Page 2

3 1 Introduction 2 Software Test Strategies 3 New Test Generation Strategy 4 Test Application 5 Summary Page 3

Transmission, Hydraulic Tracking Systems Dampening Systems Ground Surface System Fleet Management

4 Software Complexity in Heavy Machinery Single Solutions - yesterday - Integration of Single Systems - today - Networking of Data and Functions to Assistance Systems - tomorrow - Complexity of Software Engine, Transmission, Hydraulic Tracking Systems Dampening Systems Ground Surface System Fleet Management Anti-Roll-Over- System Error Detection, Diagnosis Telemetric Teach-In- Systems Workspace Monitoring Virtual Tow Bar Time Seite 4

Cause and Consequence of a Software Failures 14.09.1993: Accident of flight LH 2904, Airbus A320-211 in Warsaw after landing!

5 Cause and Consequence of a Software Failures : Accident of flight LH 2904, Airbus A in Warsaw after landing! Runway ground touch right landing gear non-effective brake because of aquaplaning delayed ground touch of both landing gears because of hard crosswind software releases braking flaps and thrust reversing just now (Condition: both landing gears >12 t load && both wheels turning) Runway distance too short for overshooting or braking Consequence: 2 dead persons, 54 injured persons Source: Seite 5

Causes and Consequences of a Software Failures Environmental

(soft, hard) Summer / winter conditions Driver - Use Cases

sequences Interaction with other systems Systematic Failures Concept

Hardware faults Tolerances Aging Faults happen.

6 Causes and Consequences of a Software Failures Environmental Conditions Ground type (street, sand) Street (dry, wet, ice) Sand (soft, hard) Summer / winter conditions Driver - Use Cases Non-predictable use cases and applications Non-logical operating sequences Interaction with other systems Systematic Failures Concept faults rounding faults, division by zero, data type conversions Hardware faults Tolerances Aging Faults happen... Important: Find all faults in due time... Machine Software Test and validation must be done in a large space of situations Seite 6

7 1 Introduction 2 Software Test Strategies 3 New Test Generation Strategy 4 Test Application 5 Summary Page 7

8 V-Model for Software Development System Design Test Cases Vehicle Test Debugging System Spezification Software Design Test Cases Test Cases System Integration Test Software Module Test Debugging Debugging T E S T Software Implementing Page 8

Test Automation Today Manually written test scripts Test

9 Test Automation Today Manually written test scripts Test #31 start_car(); shift_lever Test Test #31 #31 = D; while(gear<2) call call init(); a=...; accelpedal = 20; if(time>2) if(b<0.5) error( no... shift )... Control SW Machine Model Co-Simulation Problems HiL Test High costs for development and maintenance of scripts Low coverage of tests SiL Test

10 TestWeaver Idea Intelligent generation of s of differing test scenarios Active attempt to: - maximize state coverage - drive the system in difficult situations Testing = playing against (simulated) system Benefit High coverage Low efforts for test specification

11 1 Introduction 2 Software Test Strategies 3 New Test Generation Strategy 4 Test Application 5 Summary Page 11

TestWeaver Test Generation Strategy controllable input component fault inputs u vehicle model ECU controller quality observers MiL/SiL/HiL simulation state alarm outputs y 1.

12 TestWeaver Test Generation Strategy controllable input component fault inputs u vehicle model ECU controller quality observers MiL/SiL/HiL simulation state alarm outputs y 1. Change suboptimal scenarios to generate worst-cases 2. Drive the system in states that were not covered before y TestWeaver Reactive scenario generation each scenario depends on history of generated scenarios All cases can be reproduced reached state alarm state state space u state DB test report

13 TestWeaver Test Generation Strategy fault 1 alarm! root time t0

14 1 Introduction 2 Software Test Strategies 3 New Test Generation Strategy 4 Test Application 5 Summary Page 14

15 Test Application - Excavator Excavator Control Software - developed and approved 5 years ago - undesirable error messages in field - not reproducible - high warranty costs - customers dissatisfied Software should be driven into situations where undesirable errors will be detected. Page 15

16 HiL Test Bench test bench frame ECU signal conditioning host PC real-time PC RT Model control Page 16

Test Bench Architecture Hand Coded Tests Test Cases Test Automation -

net API Realtime Simulation Error codes reading and clearing ECU

PressureReliefValveA pump40cc motor45cc tank2 engine supply

17 Test Bench Architecture Hand Coded Tests Test Cases Test Automation - manually created test cases Test Reports Driver signals.net API Realtime Simulation Error codes reading and clearing ECU Control Software Realtime Machine Model V_A CheckValveA PressureReliefValveA pump40cc motor45cc tank2 engine supply pressurereliefvalvea tank1 CheckValveB V_B Signal Conditioning Failure Insertion Unit Sensor Signals Valve Currents Page 17

18 Results of Hand Coded Tests 1 st step: - 50 manually created test cases - different load types (fixed, shuttling) - different load and load positions 2 nd step: - more than 200 further test cases manually created - sensor tolerances test effort: 3 month No error reproduced. Page 18

19 Test Bench Architecture Generated Tests Test Space TestWeaver Test Reports Coverage Goals Automatic Generated Test Scenarios Driver signals VeriStand.net connector API Error codes reading and clearing.net API Realtime Simulation ECU Control Software Realtime Machine Model V_A CheckValveA PressureReliefValveA pump40cc motor45cc tank2 engine supply pressurereliefvalvea tank1 CheckValveB V_B Signal Conditioning Failure Insertion Unit Sensor Signals Valve Currents Page 19

20 Results of Generated Tests Implementing of TestWeaver Set-up: 3 days test effort: 7 days - more than 2700 test scenarios automatically created - slope - load at bucket - attachment position - speed After 2700 test scenarios error has been reproduced! Page 20

21 Summary 1 Introduction 2 Software Test Strategies 3 New Test Generation Strategy 4 Test Application 5 Summary Page 21

Summary Hand Coded Software Tests Definition of test cases and quality criterias Generated Software Tests Definition of input space and not allowed system states automatic generation of test

22 Summary Hand Coded Software Tests Definition of test cases and quality criterias Generated Software Tests Definition of input space and not allowed system states automatic generation of test scenarios Verification of software functionality (functions, electrical faults, safety) Limited test coverage ( test cases) High test effort Verification of software robustness High test coverage ( ) Low test effort Seite 22

23 THANK YOU FOR ATTENTION Page 23

Silver + TestWeaver Tools for Simulation-Based Design System Test and Validation

Silver + TestWeaver Tools for Simulation-Based Design System Test and Validation Mugur Tatar QTronic GmbH, Berlin SESP 2008, Noordwijk Company Profile QTronic: Tools & Engineering for Simulation-Based