19.05.

2016

Virtual Validation
Methods, Use-Cases, and Tools

Carsten Schmidt
dSPACE GmbH Rathenaustr. 26 33102 Paderborn, Germany

Agenda

Introducing dSPACE - Company and Products

Introducing Myself - My work at dSPACE

Virtual Validation Methods and Tools

Benefits of Virtual Validation
Virtual Validation in Practice How Customers uses it

Tool Demonstration ACC Example

Summary

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Introducing dSPACE

Company Founder Dr. Herbert Hanselmann

Starts company in 1988 with a small group of
engineers
Spin-off from the University of Paderborn

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Today
President of dSPACE GmbH
2008 "Entrepreneur Of The Year
Member of University Council of Paderborn
University
dSPACE assumes social responsibility in
numerous projects

Headquater is in Paderborn (900 employees)

Additional offices near Munich, Stuttgart, and Wolfsburg (100 employees)

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dSPACE Worldwide
1000 employees in Germany
240 employees in other countries
1,240 in total (full-time)

dSPACE Inc. dSPACE Ltd. dSPACE SARL dSPACE Mechatronic dSPACE Japan K.K.
USA | Detroit United Kingdom | France | Paris Control Technology Co. Japan | Tokyo,
Cambridge China | Shanghai Nagoya, Utsunomiya

What Does dSPACE Do?

Develop tools (hardware and software) for developing control systems and electronic control units
dSPACE = digital Signal Processing And Control Engineering

Who Uses dSPACE Tools to Develop Control Systems?

80% of our customers: Automobile industry
20%: Aerospace, medical technique, . . .

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dSPACE Products in the Development Process

Software Real Testing

Architecture

HIL Testing
Control Design
Simulation

Virtual
Rapid Testing
Prototyping

ECU Software
Autocoding Unit Test

dSPACE Products in the Development Process

Software
Architecture System Desk
AUTOSAR Architecture Tool
HIL Testing
Control Design
Simulation

Virtual
Rapid Testing
Prototyping

ECU
Autocoding
Software
Unit Test

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dSPACE Products in the Development Process

RCP Hardware and Software
Software Easily experimenting with new control algorithms
HIL Testing
Architecture

Control Design
Simulation Virtual
Testing

Rapid
Prototyping

Software
ECU Unit Test
Autocoding

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dSPACE Products in the Development Process

Software
TargetLink
Architecture Generating production-quality
HIL Testing code
from Simulink models

Control Design
Simulation
Virtual
Testing

Rapid
Prototyping

ECU Software
Autocoding Unit Test

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dSPACE Products in the Development Process

Software Real Testing

Architecture
HIL Simulators
Test ECUs with simulated stimulus and simulated HIL Testing
feedback. Control Design
Simulation

Virtual
Rapid Testing
Prototyping

ECU Software
Autocoding Unit Test

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dSPACE Products in the Development Process

Software Real Testing

Architecture
Control Desk
Graphical frontend for measurement and HIL Testing
stimulation. Control Design
Simulation

Virtual
Testing

ECU Software
Autocoding Unit Test

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dSPACE Products in the Development Process

Software Real Testing

Architecture
MotionDesk
3D-Visualisation of car and environment
HIL Testing
Control Design
Simulation

Virtual
Rapid Testing
Prototyping

ECU Software
Autocoding Unit Test

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dSPACE Products in the Development Process

Software Real Testing

Architecture
ASM (Automotive Simulation Models)
+ ModelDesk Control Design
HIL Testing
Behavior models of engines, Simulation
power train,
vehicle dynamics, traffic etc.
Virtual
Rapid Testing
Prototyping

ECU Software
Autocoding Unit Test

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dSPACE Products in the Development Process

Software Real Testing

Architecture
VEOS (Virtual Ecu Offline Simulator)
Generates and simulates virtual ECUs together HIL Testing
Control Design
with an appropriate environment model
Simulation

Virtual
Rapid Testing
Prototyping

ECU Software
Autocoding Unit Test

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dSPACE Products in the Development Process

Software Real Testing

Architecture

HIL Testing
SYNECT Control Design
Simulation
Engineering Database for
development and testing artefacts
in all phases of development Virtual
Rapid Testing
Prototyping

ECU Software
Autocoding Unit Test

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About Me

Studies of Computer Science

dSPACE Employee since 2007
Department: Application Engineering
Working area: mostly TargetLink + SystemDesk

Typical engineering tasks:

Advising / supporting customers in using our products
Developing company-specific toolchains for customers

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Virtual Validation
Methods and Tools

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What is Virtual Validation? The goal is

to get a maximally realistic
software representation of a
real ECU at the earliest
possible stage of the
development process.
to allow system tests without
needing any hardware

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A Typical Automotive Development Workflow Problems:

- Variant 1: Classical Testing Testing requires a real car
Testing can be dangerous!
No test automation possible

OEM Supplier OEM

Develops functions Integrates SWCs Test in real car
Creates BSW
Delivers ECU

SWC 1 SWC 1 SWC 2

SWC 2 BSW

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A Typical Automotive Development Workflow Still problems:

- Variant 2: HIL Testing Long delay until new ECU version available
Hardware (ECU+HIL) is limited resource
Who is responsible, if ECU doesnt work?

OEM Supplier OEM

Develops functions Integrates SWCs Tests with HIL simulator
Creates BSW
Delivers ECU

SWC 1 SWC 1 SWC 2

SWC 2 BSW

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A Typical Automotive Development Workflow

- Variant 3: Virtual Validation

OEM OEM OEM

Develops functions Creates Virtual ECU(s) Tests with VEOS

SWC 1 SWC 2
SWC 1
Virtual BSW
SWC 2

VEOS
(Virtual ECU Offline Simulator)

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How does HIL Testing / Virtual Testing look like?

In case of HIL testing:

dSPACE Visualization and
Automotive animation
simulation models

Model and
environment
parameterization

Instrumentation Test automation

and simulation and reporting
control

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How does HIL Testing / Virtual Testing look like?

In case of Virtual Validation:

dSPACE Visualization and
Automotive animation
simulation models

Model and
environment
parameterization

VEOS
(Virtual ECU Offline Simulator)

Instrumentation Test automation

and simulation and reporting
control

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Different Roles and Sources of VPUs (Virtual Processing Units)

There are two different roles of VPUs:
Environment VPUs: Simulate the behavior of the environment
(car, traffic, etc). May also contain Soft-ECUs.
Virtual ECUs: Realistic counterparts of real ECUs
(i.e. support of A2L calibration etc.)

VPUs can be created from different sources

ASAM FMUs (Functional Mock-ups)
Simulink models
TargetLink models
VEOS
(Virtual ECU Offline Simulator) Handwritten C-Code
AUTOSAR ECU descriptions

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Understanding the Possible Abstraction Levels of VPUs (1)

V-ECU

SWC SWC SWC SWC Function Function

RTE

Com
IoHwAb EcuM

Os SchM EcuC PduR

CanIf
Dap MemMap

VPU-Ports / Connections

BUS (Frames, Pdus, Signals)

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Understanding the Possible Abstraction Levels of VPUs (2)

3 levels of communication:
Via RTE
Via VPU-Ports
Via Bus

VPUs can (but dont have to)

use BSW services
use bus communication

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Typical Abstraction Levels of VEOS Simulation Systems

Abstract Function AUTOSAR Architecture Muti-ECU System

on VFB Level with Bus Communication

Env. VPU Env. VPU Env. VPU

...

Simulation of pure One V-ECU for the whole ECU partitioning like in reality
function architecture Usage of BSW services
No AUTOSAR at all (no ECU partitioning) Bus communication like in reality
Usage of BSW services
No bus communication

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Creation Process of AUTOSAR V-ECUs

Import and mapping

Import or creation of bus communication
of architecture

SWC Import of SWC V-ECU V-ECU

SWC
SWC Gen.
implementations Implementation
Container VEOS

Auto-configuration available! Contains: Contains:

- SWC-Implementations - SWC-Implementations
- RTE-Implementation - RTE-Implementation
Import or creation - BSW-Implementations
- BSW-Descriptions
of BSW configuration (dedicated to Offline
Simulation)

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Visualization and
Summary: What is the Essence of VEOS? animation

Generation of VPUs from different sources, e.g.

Simulink
AUTOSAR Model and
environment
Implementation of AUTOSAR BSW services, e.g. parameterization

OS
NV-RAM manager
COM stack
Instrumentation
Calibration service and simulation
control
Management of virtual connections (VPU Ports)
Management of VPU execution
Simulation of bus communication (including bus timing)
Test automation
and reporting
Plus ... all the nice frontend tools

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Beyond VEOS - Virtual ECUs can also be used on Realtime Platforms!

Non- V-ECU

Implementation
Container
Non-

MicroAutoBox II VEOS SCALEXIO

Run production-intent code Simulate realistic ECU Connect Virtual ECU to
on a rapid prototyping on desktop environment physical signals for
platform without hardware Hardware-In-Loop testing

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Benefits

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Benefits of Virtual Validation

100%
Realism

Simulink Model + V-ECU + ECU + ECU +

Simulink Env. Model Env. VPUs HIL Simulation Real Hardware

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Compared with Simulink-

Benefits of Virtual Validation
based testing
More realistic / easier to provide
the required interfaces
100% Test environment (models, layouts,
Realism test automations) can be reused in
whole development process

Simulink Model + V-ECU + ECU + ECU +

Simulink Env. Model Env. VPUs HIL Simulation Real Hardware

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Compared with HIL testing

Benefits of Virtual Validation
Even possible, before real ECU
hardware is available
Faster testing cycles (no need to
100% wait until ECU supplier delivers
Realism new integration)
Easier debugging
No hardware resources (ECU+HIL)
required (which are limited and
expensive)
Virtual test bench is always
available
Simulink Model + V-ECU + ECU + ECU +
Simulink Env. Model Env. VPUs HIL Simulation Real Hardware Faster tests execution (simulation
faster than real-time)
Parallelization possible (since no
hardware is required)

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Compared with physical

Benefits of Virtual Validation
testing
No real hardware needed (also a
limited resource)
100% Tests can (better) be automated
Realism and thus be made reproducible
No risk of accidents or hardware
damage

Simulink Model + V-ECU + ECU + ECU +

Simulink Env. Model Env. VPUs HIL Simulation Real Hardware

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Benefits of Virtual Validation Comparison of Test Coverage

Maximal level of reality

Road Testing /
Bad scalability and variations
Vehicle-in-the-Loop
Extrem expensive

Good level of reality, test are reproducible

Hardware-in-the-Loop Moderate scalability and variations
Cheaper than Road Testing

Moderate level of reality, but test are very good

reproducible
Virtual Validation
Maximal level of scalability and variations
Cheaper than HIL-System

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Customer Use-Cases

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F-SIL Stations at BMW

Software-software integration before

software-hardware integration on
ECU prototype
Better quality of application software
before software-hardware integration
Less critical iterations with basic
software or hardware supplier

Source: Talk at SIMVEC 2014 conference in Baden-Baden

(Getos (BMW), Krgel (dSPACE))

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F-SIL Stations at BMW

Full automated V-ECU generation with

SystemDesk
Integration of HIL plant models
Reuse of layouts and tests of HIL
department

Source: Talk at SIMVEC 2014 conference in Baden-Baden

(Getos (BMW), Krgel (dSPACE))

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F-SIL Stations at BMW

Continuous integration approach

Function developer checks in his
function into the SVN database
After 10 minutes he gets back an
updated simulation system to test his
function

Source: Talk at SIMVEC 2014 conference in Baden-Baden

(Getos (BMW), Krgel (dSPACE))

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F-SIL Stations at BMW

Validate and test of the new function in

the updated simulation system with
ControlDesk Next Generation
Up to 60 function developers working
actual on F-SIL stations at BMW
F-SIL Stations are also used in the HIL
department for preparation and
frontloading of HIL tests

Source: Talk at SIMVEC 2014 conference in Baden-Baden

(Getos (BMW), Krgel (dSPACE))

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Google 5 Million Test Kilometers per Day

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Google 5 Million Test Kilometers per Day

Google
Road Testing 55 test vehicles
Vehicle-in-the-Loop ~ in total 3.9 Mio. km have been driven on streets
~ 10 k 15 k km are driven per week

Hardware-in-the-Loop

Google
Virtual Validation
~ 4.8 Mio km are driven virtual per day

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Demo

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Tool Demonstration: Developing and testing an ACC controler

(1) Define (2) Generate SWC

Frame Model (3) Develop
Architecture
Algorithm

(5) Define Task

Mapping + BSW (4) Generate and pass TargetLink
Configuration SWC Implementation

(6) Create V-ECU

(8) Configure Instrument Layout

(7) Create / configure

Environment VPU
(9) Simulate

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Summary

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Summary of Method V-ECUs can be created from a range of inputs

(Simulink models . . . AUTOSAR ECU descriptions)
Simulation Systems can have different abstraction levels
(Pure function . . . multi-ECU system with bus communication)
Realistic V-ECUs require AUTOSAR as enabling technology
Same testing tools usable for all development phases
(Virtual Validation . . . HIL testing)

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Summary of Benefits Early function testing BMW Use-Case 2

Function developers can do a virtual test drive whenever
needed
Early integration testing BMW Use-Case 1
SWC and ECU networks can be deeply validated before actual
hardware integration
Large test throughput Google Use-Case
Simulations can run faster than real-time
Tests can be executed in parallel without needing special
hardware
Test definitions can be reused
Layouts, test automations etc. can be reused from existing HIL
tests

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