Automotive System and Software Engineering with Model Based Design

Agenda 1 Ansys Model Based System and Software Engineering Solution 2 Model Based Systems Engineering 3 Model-Based Software Engineering 4 Virtual Systems Prototyping

What is a System? A system is a construct or collection of different elements that together produce results not obtainable by the elements alone. - INCOSE The Environment Actuators Disturbances Uncertainty Variability Extremes Failures Software Energy Storage Power Generation Sensors Temperature Pressure Humidity

Major Automotive Systems & Software Engineering Challenges Managing System Design Complexity Optimizing Overall System Performance Reducing Physical Hardware, Electronics and Embedded Software Component Costs

A focus on Embedded Systems and Software Challenges Managing Systems Design Complexity Manage Requirements & Traceability Manage Functional and Architectural Design Produce Interface Control Documents (ICDs) Reducing Embedded Software Costs Reduce costs of producing Embedded Code Reduce costs of testing Embedded Code Reduce costs of certifying safety-critical applications under ISO 26262 Optimizing Overall System Performance Enable Virtual Prototyping of complete systems Optimize systems performance Eliminate late stage integration failures Reduce physical and hardware-in-the loop testing

State-of-the-Art Engineering Practices Managing Systems Design Complexity Model-Based Systems Engineering Reducing Embedded Software Costs Model-Based Software Development Optimizing Performance & Eliminating System Integration Failures Virtual System Prototyping

Lifecycle V-model of ISO 26262 (Part 6)

Ansys SBU Product Family Embedded System Design Control Software Design HMI Software Design Test Environment

Ansys Model Based System and Software Engineering Solution User Requirement System Concept Verification Full Virtual Prototype Simulation System V&V System Analysis&Design Verification for Different Physics Auto Sync Detail Design for Different Physics Software&Hardware Integration Software Auto Code Generation Lifecycle Management Code Generated

Agenda 1 Ansys Model Based System and Software Engineering Solution 2 Model Based Systems Engineering 3 Model-Based Software Engineering 4 Virtual Systems Prototyping

Systems Engineering Objective Design the right product/system from user needs Means Successive levels of requirement and design details, from customer high level needs to real product Guidance: Systems V-cycle, INCOSE Challenges Coexistence and collaboration of multiple engineering disciplines and teams Management of complexity, consistency and ambiguity at all levels of details Enablement of product line, variant and change management

Model-Based Systems Engineering Typical Upper V Workflow 1 Requirements Analysis Manage textual requirements (Doors, Word, Excel ) 2 Operational Analysis Modelling of operational scenarios 3 Functional and Architectural Analysis Modelling of functions and Architecture 4 Detailed Design Embedded Software, Electronics, Physical Hardware

Ansys SCADE System Diagrams Use Case Sequence State Machine Activity Block Definition Internal Block Tables

ANSYS SCADE System Model-Based Embedded Systems Engineering Complete Systems Engineering environment for Embedded Systems and Software Requirements Analysis, Functional and Architectural Design Supports industry and customer specific systems engineering configurability Embedded System/Software Synchronization Modular system design and verification, automatic I/O definition synchronization, Interface Control Documents (ICD) production and team collaboration support

ANSYS SCADE LifeCycle Requirements Traceability Direct traceability between System and Software requirements (in DOORS, Word, Excel, etc..) and SCADE System, SCADE Suite & SCADE Display models and SCADE Test suites Automatic Documentation Generation Ensures that System, Software, Tests & Code documentation are automatically produced and up to date with the design Multi-Vendor ALM/PLM Support Seamless integration with Application & Product Lifecycle Management, version and configuration management tools, and automated production of design metrics

Agenda 1 Ansys Model Based System and Software Engineering Solution 2 Model Based Systems Engineering 3 Model-Based Software Engineering 4 Virtual Systems Prototyping

System Software Collaboration System Software Models Synchronization Avoid duplication of efforts and inconsistencies between system structural models and software behavioral models System design and Software components evolve independently On-demand re-synchronization of interfaces Interfaces described in SCADE System model Software designs

ANSYS SCADE Suite Embedded Control Software Design Efficient modeling of controls, logic and algorithm designs within a single environment Integrated Suite for Prototyping, Modeling, Simulation, Verification, and Optimization Efficient debugging and optimization of software models and code size, speed and performance Certified Code Generation Automatic C and Ada certified code generators (ISO 26262, IEC 61508, DO-178B/C, EN 50128) Enables 80% embedded code production and testing cost reduction [ ] void Button_ABC_N(inC_Button_ABC_N *inc, outc_button_abc_n *outc) { /* ABC_N::Button::SM1::SSM_SM1_dispatch_sel */ SSM_Button_SM1_ST SSM_SM1_dispatch_sel; if (outc->init) { outc->init = kcg_false; SSM_SM1_dispatch_sel = SSM_SM1_Unselected ABC_N; } else { SSM_SM1_dispatch_sel = outc->m_pre_; } switch (SSM_SM1_dispatch_sel) { case SSM_SM1_Locked ABC_N : outc->foreground = white_abc_n; outc->background = green_abc_n; if (inc->unlock) { outc->m_pre_ = SSM_SM1_Preselected ABC_N; } else { outc->m_pre_ = SSM_SM1_Locked ABC_N; } break; case SSM_SM1_WaitUnlock ABC_N : outc->foreground = black_abc_n; outc->background = grey_abc_n; if (inc->unlock) { outc->m_pre_ = SSM_SM1_Unselected ABC_N; } else { outc->m_pre_ = SSM_SM1_WaitUnlock ABC_N; } break; [ ]

Software Unit Design with SCADE Suite SCADE Suite formally defined input allows for: Unambiguous model description Semantics checks of the model

TÜV SÜD ISO 26262 Qualification TÜV SÜD has qualified SCADE Suite Code Generator for ISO 26262 for use up to the highest safety level (ASIL D) This enables to eliminate the software low level testing to verify that the code is correct relative to the model

SCADE AUTOSAR Capabilities 17.2 AUTOSAR ARXML Architecture File Import/Export System Design Refinement & Model Verification Control Software design Synchro Generation SCADE Suite generated code AUTOSAR RTE Wrapper Code integration Any AUTOSAR operating system

ASAP2 Code Generation The SCADE Suite ASAP2 Extension generates: The proper ASAP2 file defining the characteristics A header for sensors declarations A C file for the values

ANSYS SCADE Suite @ Subaru Program/Application Electric Vehicle Engine Controls Vehicle dynamics Engine functions Vehicle energy consumption (Heating & air conditioning, Breaking, Body controls) Battery load management Key Results Subaru was able to describe consistent readable models ranging from safe architecture design to detailed designs Thanks to SCADE Suite s KCG IEC 61508 certified code generator, the verification time at code level was significantly reduced By using SCADE, SUBARU engineers completed a large and very complex application while significantly reducing software development and testing time. Masaru KURIHARA Deputy General Manager, Electronics Engineering Department, Fuji Heavy Industries Ltd.

ANSYS SCADE Display HMI Software Design Efficient modeling of HMI designs featuring an integrated environment with logic design Complete GUI Prototyping, Modeling, Simulation, Verification, and Optimization Rapid prototyping, model checking and debugging, simulation, integration with graphics platforms and human factors optimization Certified Code Generation Automatic certified code generator (DO-178B/C, EN 50128, ISO 26262, IEC 61508) Enables 80% embedded code production and testing cost reduction PC, Android, Apple ios and critical/rugged embedded graphics platforms

SCADE Display for Tactile Automotive Infotainment Automotive tactile/interactive infotainment HMI demo model developed with SCADE Display, for Android & ios

SCADE Display @ DLR Automotive Program/Application Traffic Information System Simulator Simulation environment for interactive driving Haptic components with force feedback (steering, pedals, side stick) Several interfaces for integration of real electronic control units (e.g. CAN) Interfaces for psychological evaluation methods Key Results Flexible HMI design by the use of free configurable displays Ideal environment for rapid prototyping Easy creation of typical automotive elements (e.g. scales) Bitmap import from Photoshop

HMI/ Behavioral Integration at Any Levels SCADE Suite Simulator (execution of generated code) SCADE Display Model(s) (execution of generated code) Integrated Co-simulation and Debug capabilities Simulate Control and Display parts at the same time, with step-by-step, scenario management, etc Use same code generators as for production reliability Integrated Production Code Generation Tight integration of generated code ensures optimal performance Benefit from SCADE Suite Simulator capabilities (step-by-step / continuous modes, scenario management, graphical debugging, etc.) Relies on generated code for both SCADE Suite & SCADE Display Simulate / Debug SCADE Suite & SCADE Display models at the same time Tight integration of generated code ensures optimal simulation performance

ANSYS SCADE Test Interactive Test Creation and Rapid Prototyping Efficient environment to create requirements-based test suites and run interactive software simulation Automated Tests Execution of Software Models on development platform with Automated Model Coverage acquisition Ensures 100% confidence in software test suites Automated Tests Execution of Generated Software Code on any Hardware Target Fully automated reuse of validated software test suites on processor target (includes drivers for LDRA, RTRT & VectorCAST)

Agenda 1 Ansys Model Based System and Software Engineering Solution 2 Model Based Systems Engineering 3 Model-Based Software Engineering 4 Virtual Systems Prototyping

ANSYS Simplorer A Comprehensive platform for modeling, simulating, and analyzing virtual system prototypes Spans electrical, electronics, mechanical, thermo-fluids, and embedded software systems Open Integration of existing tools Full VHDL AMS, Spice and FMI compliance enables embracing and extending existing tools and libraries (Modelica and other FMI-compliant tools) 3-D Precision When You Need It Cosimulation with 3-D solvers and reduced-order modeling (ROM) captures complex multi-physics interactions when precise system verification is required Leader in simulation for power electronics and electrical systems Rich modeling libraries and design automation designed especially for high-performance power electronics and electromechanical simulation

When is System Simulation Useful? At the start of the design process Early Architectural Tradeoffs Simulation-in-the-loop for predictive studies Pre-Sales / Collaboration tool During the design process Embedded Control Algorithm Design / Tuning System Verification / Validation Virtual Integration Platform At the end of the design process System Performance Optimization Robust Design After the design process has been completed Maintenance (predictive maintenance) Simulation Model embedded with controls (adaptive controls)

Electric Vehicle Powertrain example Key Business Drivers System Cost Reliability / Warranty Package Size Energy Efficiency Safety Integrity Drive Quality

Electric Vehicle Powertrain Key Components Power Electronics (Inverter) Traction Motor Power Source Mechanical Dynamics & Loads Embedded Control Power Cables

Electric Vehicle Powertrain As a System Model Power Source R3 L1 AM4 A SIMPARAM1 OFF Time >= Tsw ON V E1 0 C1 C2 R1 R2 VM1 + V Power Electronics: Inverter P N U1 ~ - V1 V2 V3 V4 V5 V6 U V W L1 L2 L3 SET: S1:=0 S_Motor CTRL=S1 N1 N2 N3 SET: S1:=1 Power Cables L1 L2 L3 I1 I_Motor I3 N1 N2 N3 Traction Motor (PMSM) n1 n2 n3 PMSM_DQ m1 F_ROTB1 T MASS_ROTB1 Load_Torque A B C U_UMR N A B C U_MOT N + SM_ROTB1 F TDELAY=t_load AMPL=trq_load TRISE=20ms OFF=0 FPGA 0 0 0 PWM_3PH1 Udc DC-Link Voltage n_ref u1 u2 u3 phi_el u1 u2 u3 phi_el PWM Modulator V1 V2 V3 V4 V5 V6 Mechanical Dynamics & Loads w_ref TDELAY=5ms AMPL=n_ref-n0 TRISE=300ms OFF=n0 i1f i3f w_el I1f I3f w_el Integrating Current Sampling Mechanical Angle Input I_1 I_3 phi_m Embedded Control

Modeling the EV System Power Source Detail Equivalent Circuit Model + CFD ROM VHDL-AMS Behavioral Model Basic Equivalent Circuit Fidelity

Modeling the EV System Power Electronics: Inverter Detail 3-phase Inverter with Dynamic Thermal IGBTs 3-phase Inverter with Ideal IGBTs State-Averaged Controller Fidelity

Modeling the EV System Traction Motor Detail Co-simulation with 2D/3D FEM Electric Circuit Equivalent ROM VHDL-AMS Behavioral Model Fidelity

Modeling the EV System Power Cables Detail S-Parameter ROM for Distributed Tx Lines Lumped Element Lossless Model Ideal Connections Fidelity

Modeling the EV System Embedded Control Detail Ideal Control Blocks Generated Control Application Code Fidelity

Modeling the EV System Mechanical Dynamics Detail Mechanical ROM of Flexible Shaft Lumped Element Mechanical Effects Fidelity

Assembling & Analyzing the System Goal: Evaluate System Architecture, Size Key Components Power Source R3 L1 AM4 A SIMPARAM1 OFF Time >= Tsw ON V E1 Fidelity 0 C1 C2 R1 R2 VM1 + V Power Electronics: Inverter P N U1 ~ - V1 V2 V3 V4 V5 V6 U V W L1 L2 L3 SET: S1:=0 S_Motor CTRL=S1 N1 N2 N3 SET: S1:=1 Power Cables L1 L2 L3 I1 I_Motor I3 Permanent Magnet Synchronous Motor N1 N2 N3 n1 n2 n3 PMSM_DQ m1 F_ROTB1 T MASS_ROTB1 Load_Torque VHDL-AMS Behavioral Model FPGA A B C U_UMR N A B C U_MOT N + SM_ROTB1 F 0 0 0 TDELAY=t_load AMPL=trq_load TRISE=20ms OFF=0 PWM_3PH1 Udc DC-Link Voltage n_ref u1 u2 u3 phi_el u1 u2 u3 phi_el PWM Modulator V1 V2 V3 V4 V5 V6 Mechanical Dynamics & Loads w_ref TDELAY=5ms AMPL=n_ref-n0 TRISE=300ms OFF=n0 i1f i3f w_el I1f I3f w_el Integrating Current Sampling Mechanical Angle Input I_1 I_3 phi_m Embedded Control

Assembling & Analyzing the System Goal: Characterize Motor Losses Power Source R3 L1 AM4 V E1 0 C1 C2 R1 R2 VM1 + V A P N SIMPARAM1 Power Electronics: Inverter U1 ~ - V1 V2 V3 V4 V5 V6 U V W CTRL=S1 I1 I3 A B C Co-simulation A B C U_UMR U_MOT N L1 L2 L3 OFF SET: S1:=0 S_Motor Time >= Tsw N1 N2 N3 N ON SET: S1:=1 Power Cables L1 L2 L3 I_Motor with 2D/3D FEM N1 N2 N3 n1 n2 n3 PMSM_DQ m1 Fidelity Permanent Magnet Synchronous Motor + SM_ROTB1 F F_ROTB1 T MASS_ROTB1 Load_Torque TDELAY=t_load AMPL=trq_load TRISE=20ms OFF=0 FPGA 0 0 0 PWM_3PH1 n_ref u1 u2 u3 phi_el Udc u1 u2 u3 phi_el DC-Link Voltage PWM Modulator V1 V2 V3 V4 V5 V6 Mechanical Dynamics & Loads TDELAY=5ms AMPL=n_ref-n0 TRISE=300ms OFF=n0 w_ref i1f i3f w_el I1f I3f w_el Integrating Current Sampling Mechanical Angle Input I_1 I_3 phi_m Embedded Control

Assembling & Analyzing the System Goal: EMC Prediction R3 Power Source L1 AM4 A SIMPARAM1 OFF Time >= Tsw ON V E1 0 C1 C2 R1 R2 VM1 + V Fidelity P ~ 3-phase Inverter Nwith Power Electronics: Inverter Dynamic Thermal IGBTs U1 - V1 V2 V3 V4 V5 V6 U V W A B C U_UMR N L1 L2 L3 SET: S1:=0 S_Motor I_Motor N1 L1 N1 for Distributed Lines N2 L2 N2 CTRL=S1 N3 A B C U_MOT N SET: S1:=1 Power Cables Fidelity S-Parameter ROM L3 I1 I3 Permanent Magnet Synchronous Motor N3 n1 n2 n3 PMSM_DQ m1 + SM_ROTB1 F F_ROTB1 T MASS_ROTB1 Load_Torque TDELAY=t_load AMPL=trq_load TRISE=20ms OFF=0 FPGA 0 0 0 PWM_3PH1 n_ref u1 u2 u3 phi_el Udc u1 u2 u3 phi_el DC-Link Voltage PWM Modulator V1 V2 V3 V4 V5 V6 Mechanical Dynamics & Loads TDELAY=5ms AMPL=n_ref-n0 TRISE=300ms OFF=n0 w_ref i1f i3f w_el I1f I3f w_el Integrating Current Sampling Mechanical Angle Input I_1 I_3 phi_m Embedded Control

Assembling & Analyzing the System Goal: MiL, SiL Testing / Calibration & Tuning R3 Power Source L1 AM4 A SIMPARAM1 OFF Time >= Tsw ON V E1 0 C1 C2 R1 R2 VM1 + V Power Electronics: Inverter P N U1 ~ - V1 V2 V3 V4 V5 V6 U V W A B C U_UMR N L1 L2 L3 SET: S1:=0 S_Motor CTRL=S1 N1 N2 N3 A B C U_MOT N SET: S1:=1 Power Cables L1 L2 L3 I1 I_Motor I3 Permanent Magnet Synchronous Motor N1 N2 N3 n1 n2 n3 PMSM_DQ m1 + SM_ROTB1 F F_ROTB1 T MASS_ROTB1 Load_Torque TDELAY=t_load AMPL=trq_load TRISE=20ms OFF=0 FPGA 0 0 0 PWM_3PH1 n_ref Fidelity TDELAY=5ms AMPL=n_ref-n0 TRISE=300ms OFF=n0 w_ref u1 u2 u3 phi_el i1f i3f w_el Embedded Control Udc u1 u2 u3 phi_el I1f I3f w_el DC-Link Voltage PWM Modulator Integrating Current Sampling Mechanical Angle Input V1 V2 V3 V4 V5 V6 I_1 I_3 phi_m Generated Control Application Code Mechanical Dynamics & Loads

Our Vision: a Fully Virtual Automobile Prototype Efficiency Drive Cycle Electric Drivetrain and IC Engine Battery and Charging NVH EMI/EMC/Antenna Braking Thermal and Stress External Aero Brakes and Sensors Electric Powertrain ADAS Infotainment and Keyless Entry Infotainment Radar ECU and Embedded Software Suspension

Engineering Benefits Simplorer enables assembly of complete virtual system prototypes High level of interoperability with tools, model reuse, and support for standards (VHDL-AMS, Spice, Modelica, C, C++..) Unique connections to ANSYS 3D physics and embedded software Simplorer enables more comprehensive system testing Evaluate architectures, select components and tune parameters to achieve optimal system performance Identify problems between hardware and software components earlier Create virtual test rigs to evaluate system compliance with performance standards Simulate 1000s of virtual prototypes to analyze system robustness and reliability

Economical Benefits Simplorer Enables system prototyping and testing cost reductions Replaces physical prototyping/test equipment with virtual systems Model reuse and automation increase efficiency of system testing

谢谢!