Efficient testing processes at Suzuki, featuring component testing
and virtual vehicle testing
Virtual Vehicle
Test Drives
Since 2000, Suzuki Motor Corporation has been
efficiently intensifying their use of dSPACE
simula-tors for the safe development of electronic control
units (ECUs). So far, Suzuki uses several simulators
for individual ECUs, including body and
air-condi-tioning, as well as engine, transmission and
all-wheel drive ECUs. But for the models Kizashi
and Swift, a dSPACE virtual vehicle simulator
takes over the efficient verification of all vehicle
control functions.
Electronic control technology is evolving with features such as adaptive cruise control (ACC), elec-tronic stability programs (ESP), and pre-crash safety systems. At the same time, more functions are inte-grated into a single ECU to reduce the overall number of ECUs per vehicle. Complex functions are distributed on several networked ECUs. Across-the-board validation of distributed functions is not pos-sible with component simulators for individual ECUs, and real test drives are not safe for testing such complex systems with all the connections and dependencies between functions.
A virtual vehicle simulator is required to test the whole ECU network.
Requirements for the Virtual Vehicle
To efficiently validate all of a vehicle’s distributed control functions the dSPACE virtual vehicle simulator has to meet the following precon-ditions:
n Information on each ECU and its
functions has to be shared across the whole hardware-in-the-loop (HIL) system.
n Network tests must be possible,
even if not all ECUs are available yet.
Virtual Vehicle
Test Drives
n Real loads must be includable
and switching between load and model must be automated.
n Test execution must be easy, so
that Suzuki’s engineers can focus on function design, not test creation.
n Variant handling by switching
between vehicle models or parameter sets must be easy to reduce HIL system downtime.
n Suzuki’s inhouse tools, e.g., for
diagnostics and RAM monitoring, have to be connected to the dSPACE virtual vehicle.
Virtual Vehicle Setup
The simulator consists of five inte-grated racks that are each configured for certain vehicle components, like engine, body electronics, driver assistance systems, etc. The con-trolled system models are all taken from dSPACE Automotive Simulation Models (ASM). Besides drivetrain and vehicle dynamics models, this setup also features models for the electrical system and the surround-ing traffic to test ACC functionality. Test automation is performed by
dSPACE AutomationDesk® together
with the Real-Time Testing (RTT) extension. This virtual vehicle simu-lator can be configured and param-eterized for the different variants of Suzuki Kizashi and Swift.
Flexibility of the Virtual Vehicle
The virtual vehicle simulator was designed to handle time-consuming tasks such as changing the target vehicle or vehicle configuration efficiently. For example, the test target engine can be switched from a gasoline engine ECU to a diesel engine ECU in just five minutes. The only manual tasks are releasing and attaching the ECU harnesses. Changing the optional vehicle fea-tures such as ACC or
air-condition-Component Simulator vs. Virtual Vehicle
To test a single ECU, e.g. for engine management, a component simulator is required. It comes with a dedicated setup for the ECU under test. To test multiple ECUs or a complete ECU network including all
commu-nication aspects, a virtual vehicle simulator is required. Several sim-ulators are closely integrated to represent a complete vehicle. A virtual vehicle can be config-ured for different vehicle variants.
ing, which vary according to the vehicle class, is simply a matter of changing settings in dSPACE
Control Desk®, the experiment
soft-ware.
Test Process
Any problem detected by the virtual vehicle can be verified thoroughly and in great detail on a component simulator. For example, a closed-loop problem detected by auto-matic tests overnight can be investi-gated and corrected the next day
Rack 1
ASM Engine Gasoline/Diesel
Rack 2
CAN B CAN B GW ASM Drivetrain Simple Body Model
Rack 3 0 1 2 3 DS911 Body, Power Window, Remote Starter CAN LIN1 LIN LIN3 Serial DS1006 DS4003 DS2211 slave_c DS1006_4
Simple Body Model ASM Electrical Components DS4330 DS4201-S
Rack 5
ASM Electrical Components
Rack 4 0 1 2 3 DS911 ACC,ESP, Air Conditioner, Airbag, Instrument Panel, Body Serial1 Serial2 Serial3 CAN DS1006 DS2004 DS2003
ASM Vehicle Dynamics + advanced BrakeHydraulics
ASM Traffic Simple Body Model DS2211 DS2202 DS4003 DS4502E DS4201-S Master DS1006 DS1006_5 slave_b DS1006_3
Dynamic model part ECU communications ECU‘s of this rack dSPACE I/O boards dSPACE processor + Gigalink Gigalink cable
Gigalink cable, synchronized swinging buffer for some signals
applied to ECUs that are only avail-able in virtual form and cannot participate in CAN communication. The CAN gateway functions simu-late abnormal states such as data corruption or wrong values on the bus to falsify and correct ECU messages if the available ECU was developed for a different vehicle platform. Combining these meth-ods allowed Suzuki to develop new functions even without a complete ECU network. If an ECU was miss-ing some functions, they were implemented using the two meth-ods. The whole implementation was optimized and the behavior of the other ECUs was tested in this way. Problems that might occur for new functions and ECUs that could have an impact on the whole ECU network were eliminated.
Use of dSPACE Products
Suzuki had been using dSPACE products for some years, so it was possible to transfer existing test
“ The biggest result of installing the dSPACE virtual vehicle simulator was
that it enabled us to easily perform important tests that we couldn’t
even run before.”
Katsuhiko Douhata, SUZUKI MOTOR CORPORATION
Yasuhiro Hayashi (on the left)
Yasuhiro Hayashi is General Manager of the automobile electric design depart-ment at Suzuki in Shizuoka, Japan.
Katsuhiko Douhata (on the right)
Katsuhiko Douhata is a technical expert for automobile electric design at Suzuki in Shizuoka, Japan.
on the component simulator. When the problem is solved the new, cor-rect function can be restored to the virtual vehicle for further automatic testing. Unlike the component sim-ulator, the virtual vehicle contains many parameters that are dynamic, which increases the depth of test-ing. As long as the tester uses the same test environment for the virtual vehicle simulator and the compo-nent simulator, it is possible to run common parameters, common environmental conditions, and com-mon tests. By adding test cases on a daily basis, testers can thoroughly verify control functions with large numbers of conditions.
The Advantages of Restbus Simulation
ECU functions that will be available on future ECUs and ECUs that are not yet available can be implemented by using restbus simulation and CAN gateway functions. Restbus simulation is a method normally
Knürr Miracel 37HE 800 mm 4HE
PX20 REAR
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1 2 T E4T E F 1 .6 A 2 4VDC Cont r ol Volt age 3HE 3HE 3HE 1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T !E L 0 5_ 0 6 _0 1 U 1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T !E L 0 5_ 0 6_ 0 2 U 1 8 T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T !E L 0 5 _0 6 _ 0 3 U R S IM - 1 _0 1 _ 0 1 4 T E 4 T E 4 T E 1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L 0 5_ 0 5 _0 1 V 4 T E1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L 0 5_ 0 5_ 0 2 V 4 T E1 8 T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L 0 5 _0 5 _ 0 3 V 4 T E1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L 0 5_ 0 5 _0 4 V 1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T !E L 0 5_ 0 6_ 0 4 U 1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L 0 5_ 0 4_ 0 1 W 1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L0 5 _ 0 4_ 0 2 W 4 T E 4 T E1 8 T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L 0 5_ 0 4 _0 3 W 4 T E1 8T E ELO AD M O DULE R E S E TO P E R A T IO N E R R O R ! CAUTI O N HO T ! ! CAUTI O N HO T ! E L 0 5_ 0 4_ 0 4 W 4HE 4HE PX20 REAR DS814Slot2Slot3DS1006 DS221 1_01/P3 DS221 1_01/P2 DS221 1_01/P1
DS5202EV1036DS5202EV1031Slot12Slot13Slot14Slot15Slot16Slot17Slot18Slot19Slot20 1HE 4HE 1HE dSPACE Simulator 4 T E 8 T E8 T E8 T E8 T E8 T E 8T E 1 0 3 3 0 2 1 0 3 2 9 1 1HE SC Supply 2x+15V I0 7 T E 1 0 3 3 0 2 1 0 0A2 1 1 0 0A2 1 1 0 0A2 1 1 0 32 9 1 6T E8 T E
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1 4 T E B 1 6 O NI B 1 6 O NI B 1 6 O NI Rack 1 Real loads Real loads Real loads
Rack 2 Rack 3 Rack 4 Rack 5
Auxilary Supply
RMST
dSPACE as a
Tool Supplier
Suzuki wanted to direct its efforts into developing the test target ECUs and network testing, but doing all the design work for the test equipment would have been very time-consuming. To save time, its virtual vehicle sim-ulator was built up in coopera-tion with dSPACE engineers. Suzuki’s engineers assembled the parameters and made the virtual vehicle compatible with Suzuki’s existing simulators. These efforts paid off, and as soon as the new simulator was completed, full ECU function testing and network testing started. High rates of operation have been maintained right up to the present. Suzuki’s workload was reduced because dSPACE is a one-stop supplier of simulator development tools, including
turnkey engineering. cases to the virtual vehicle. With
the test automation software AutomationDesk, it was easy to program and extend the test se-quences graphically, using high-level library functions. The test data
is read from Microsoft Excel® files
which were already used for test data handling. For time-critical operations, AutomationDesk also parameterizes and controls Python code, which runs in real time parallel
to the Simulink® models.
By combining powertrain, vehicle dynamics, electrical system and environment models from the ASMs, an entire vehicle simulation system was constructed for the virtual vehicle. The ASMs provide the con-ditions needed for vehicle drive control, to develop functions such as ESP, traction control, and adaptive cruise control. dSPACE ModelDesk
is the graphical user interface for intuitive parameterization and parameter set management for the ASMs. The many different variants involved can be handled fluently and easily by changing parameter sets in ModelDesk. Complete engine types, and parameters like engine displacement or distances for the ACC, were defined by graphical means and handled as parameter sets.
Suzuki’s entire test track was repli-cated in ModelDesk to run virtual vehicle dynamics tests and compare them with results from real test drives. This was done for conditions like summer and winter, and for different types of road surfaces. The state of the vehicle can be observed in 3-D animation Motion-Desk, making verification simple and clear.
“ Compared with a real-world vehicle, verification
on the dSPACE Simulator was easy and our
benefits of being able to run automated and
reproducible tests were huge.”
Katsuhiko Douhata, SUZUKI MOTOR CORPORATION Setup of the virtual vehicle simulator for testing the complete ECU networks of the new Suzuki models Kizashi and Swift.
Conclusion
By using the dSPACE virtual vehicle for a large number of ECUs, the functions and loads were tested very efficiently. The virtual vehicle was well designed, with the relays operated via the PC, the replaceable parts arranged on tables in front of the simula-tors, and the parameters able to be processed via a database. For example, the accuracy of ACC simulation was confirmed. The distance and attenuation were compared with the values for an actual vehicle and found to be correct.
“ We appreciate the convenient test creation
in AutomationDesk’s graphical user interface.”
Yasuhiro Hayashi, SUZUKI MOTOR CORPORATION
“ We were able to handle variants more easily than we had imagined by
changing virtual test tracks, engines, transmissions, and other
parameters fluently with dSPACE ModelDesk.”
Yasuhiro Hayashi, SUZUKI MOTOR CORPORATION
Future Development
To cope with the challenges of reducing fuel consumption, and electric current consumption, it’s important to simulate the behav-ior of the respective systems early on. In addition to the ASMs already installed, Suzuki will use the ASM Electric Components simulation model to accurately calculate the power consumption of the electric devices that are planned for future developments.
Suzuki is promoting partnerships using HIL with other divisions – not
only the electrical components division. The more tests that can be implemented across different divisions, the greater the data’s usefulness and the higher its
validity. n
Katsuhiko Douhata Yasuhiro Hayashi
SUZUKI MOTOR CORPORATION, Japan
