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CarMaker
Shift the Test Drive into Simulation!

CarMaker - Shift the test drive into simulation!

Complex interdependencies, a high degree of interactions and the desire for maximum safety and comfort are forcing engineers to rethink their traditional methods. CarMaker introduces a paradigm shift towards an integrated development of concepts, models, control systems and components.

Classic vehicle dynamics

Integrated systems

Chassis control

CarMaker

Fuel efficiency

Driver assistance systems

CarMaker is especially suited for the global vehicle dynamics simulation of passenger cars, race cars up to lightweight trucks, articulated lorries and buses. The seamless environment allows for a continuous development process: From office simulations on PC to hardware-in-the-loop (HIL) tests on single ECU and multi ECU test systems through to HIL tests on large system test rigs.

Key benefits:
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The easy reconstruction of test scenarios allows for a robust and productive test case implementation. Due to its unique software and model architecture CarMaker is extremely fast. The extraordinary performance saves time and hardware costs. The fully non-linear car and trailer models are very precise which guarantees high-quality simulation results. The sophisticated car driver model performs even the toughest driving maneuvers. CarMaker is a flexible and customizable development platform. You can easily integrate your own models and tools into this open integration platform. The high performance test management and test automation functions make your work efficient and time-saving. And last but not least: CarMaker covers a huge application range and can be seamlessly used for virtual test driving in office, lab and rig.

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Virtual test driving

The precise models of CarMaker are the basis for reliable simulation results. However, virtual test driving means much more than just running models. It means shifting the complete test drive from the road into the laboratory - with test maneuvers and processes as well as diagnostic and application tools. For this reason, the models of CarMaker are embedded into a sophisticated architecture of central services and online devices. This guarantees the highest performance, productivity, flexibility, interactivity and precision for your virtual test driving tasks.

CarMaker's architecture at a glance:

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Precise models realistically map the dynamic interactions of car, trailer, driver, road and traffic Central services empower the simulation for maneuver and eventbased testing Network services let you flexibly build up arbitrary MIL, SIL and HIL architectures Online devices give you interactive control over the simulation

Model platform
Car and trailer models
Central to the models for vehicle dynamics simulation are car and trailer models capable of real-time performance and which are valid up to the limits of driving dynamics. Their bodies are modeled as multi-body systems which are fully non-linear and extendable. The MBS models form the core model and integration platform for all other sub-components such as suspensions, steering systems, tires, brake system, drivetrain and aerodynamics. The models are arranged manageably in terms of the individual sub-assemblies and can be modified or exchanged for in-house models within Simulink and/or on a C code level. The parameterization can be done via a graphical user interface. Afterwards you can validate the parameters of single subsystems using the Model Check functionality.
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BodyRigid or BodyFlex (torsion, bending) with sprung mass, loads, engine, trim loads Suspension with linkage equation for all axles types with one model - selectable kinematics & compliance tables linear, non-linear and non-linear with up to 3D dempencies - single tunable components (damper, spring, buffer, stabilizer, external forces) Front Steering System (Detail 2DOF Steering Model as Option) Rear Axle Steering Detailed Hydraulic Model valid for ABS/ESP with Booster, master and brake cylinder, pump, valves, line volume, accumulator, attenuator Powertrain (front, rear, AWD, Electrical, wheel hub engines, ) with engine, clutch, gear box (MT, AT, and CVT as option), differentials 3D Tire Interface for IPGTIre, MF-5.2, MF-Swift etc. Axles are configurable with single or twin tires 3D Aerodynamics Body Sensors, Driver Assistance Sensors and Pre-View Road Sensor page 2

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Car and trailer combinations

Commercial vehicles are diverse - and CarMaker enables an effective model handling. You can flexibly combine car and trailer models to test your range of variants.

CarMaker pro
2-axle car &

lightweight truck

1-axle center-/ semi-trailer

2-axle center-/ semi-trailer

IPGDriver - the artificial intelligence

As on the test track, the crucial factor for virtual test driving is an intelligent driver model. CarMaker comes with IPGDriver, the most successful driver model for sophisticated closed-loop driving tasks. IPGDriver perfectly represents the actions and reactions of a real driver and has special capabilities for driving cars and lightweight trucks. No matter what you wish to simulate - a defensive driver or an aggressive driver, city courses or handling tracks, driving uphill or downhill, forward or backwards, stop&go or parking - IPGDriver is easy to configure and being now in his 6th generation has everything under control.
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Independent lane & speed choice based on - Road characteristics - driver characteristics - Lane usage with respect to the track borders incl. corner cutting - Vehicle characteristics - driving behavior Steering by steering-wheel angle or torque Driving at the limits with counter steering Identification of the optimal brake and acceleration points Gear shifting with or without clutching independent and via external access Turn off at junctions or exits Target braking & stop at traffic sign Stop & go, driving at walking pace and shunting at short distance (< 20 cm) Hill-starting with parking brake Driving backwards and parking Retrace of driving cycles such as NFEC, ECE, FTP etc. Self-Learning capabilities and knowledge memory

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IPGRoad - build up your individual test track!

You can arrange the 3D track with simple individual elements by stringing together straight lines, curves and clothoid curves. The particular track sections can further be defined with obstacles, friction coefficients, side wind and other track conditions. In addition, user defined trigger points can be assigned to road segments for velocity changes, stopping places or maneuver commands. Optionally you can also use measured road data as a three-dimensional track model, for example from test tracks or common tracks like the Nrburgring Nordschleife or mountain roads.
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3D road generator Creation of multi-lane roads, exits, junctions Road segment characteristics: slope, camber, bending, inclination, lines, areas, friction definitions Markers, pylons, traffic signs Obstacles e.g. wave, cone, cylinder, beam Road Environment: buildings, trees, guard rails, guide posts 3D road import: unlimited length, unlimited longitudinal resolution, ASCII or binary format TV 3D-Track grid data load (high resolution Curved Regular Grid)

IPGTraffic - create traffic volume

The traffic module simulates freely configurable traffic situations with an arbitrary number of moving objects (e.g. traffic, pedestrians) and stationary obstacles (e.g. parked cars, crash-barriers, traffic signs and buildings) surrounding a test vehicle equipped with a sophisticated sensor model. The module is optimally suited for the development of advanced driver assistance systems such as adaptive cruise control (ACC), lane keeping assistance, collision avoidance, intersection assistant, congestion assistant or pre-crash systems. Test scenarios can be easily configured. The type, dimensions and the starting conditions, paths, velocities and accelerations of the traffic objects can be defined dependent or independent on each other and on the test vehicle. There is no limit to the buildup of the scenarios - either in terms of the number of objects nor to the length of the single-lane or multi-lane tracks.
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Powerful traffic editor Moving and non-moving traffic objects e.g. vehicles, pedestrians, signs, traffic lights, road works, buildings Controlled by mini-maneuvers such as speed, longitudinal motion, lateral motion, ramp, sinus, etc. Mini-maneuvers triggered by time (relative, absolute), distance (relative, absolute), events, direct variable access (DVA) No limit on the number of mini-maneuvers or the number of traffic objects

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Maneuver and event-based testing: Interactive reconstruction of test scenarios

The maneuver-based testing method of CarMaker optimally supports virtual test driving. The interactive maneuver control allows you to easily reconstruct even the toughest use cases by combining open-loop and closedloop mini-maneuvers in the longitudinal and lateral direction. The driver model is optimally integrated and interacts with the maneuver control. As in the real test drive you assign actions to the mini-maneuvers such as driver activities, system interventions or failure insertions. Example: -split braking Mini-maneuver 0 1 2 3 4 5 Driving Action Speed up to 100 kph, approach -split area Marker Roll - Free Rolling Marker Brake - Braking, hold steering After 1sec - steer correction At 50kph - failure impact e.g. wheel sensor defect Brake up to stand still - diagnostic Longitudinal IPGDriver Open Loop Open Loop Open Loop Open Loop Open Loop Lateral IPGDriver IPGDriver Open Loop IPGDriver IPGDriver IPGDriver

Traffic Control
Due to the sophisticated central services of CarMaker comprehensive test scenarios consisting of specific constellations of traffic situation and driving maneuvers are reconstructed easily as well. Analogous to the maneuver control of the test vehicle, the user assigns a freely definable list of minimaneuvers to each object of the traffic control.

Triggering of maneuver actions

The maneuvers of the test vehicle and the traffic objects are controlled by a central control unit. It establishes a connection between the maneuvers of the traffic and the test vehicle which enables the triggering of the minimaneuvers of the traffic objects dependent on the maneuvers of the test vehicle. A further advantage is that the central control unit allows the user to set time, distance, route and event based triggers which can be used to start mini-maneuver sequences or mini-maneuver jumps. A central state observer monitors simulation variables selected by the user and evaluates them synchronously to the simulation program with regard to defined conditions. This allows the user to choose e.g. events such as the approaching of a route point, the distance between two vehicles or the difference velocity between the test vehicle and leading vehicle as a trigger for mini-maneuvers. www.ipg.de page 5

Online Devices
The online tools of CarMaker give you dynamic access to parameters, data and models. It thus establishes direct feedback between user and simulation. Control Center - access to all functions of CarMaker IPGMovie - realistic vision for online evaluation Instruments - total view for an interactive monitoring and control IPGControl - fast response for online signal analysis

Direct Variable Access

Online read and write access to all model quantities

Error Handling
Online control by the use of error conditions

Input from File

Measurements from real driving tests as inputs for maneuvers

TestManager - Productive test case management and automation

The TestManager allows for a smooth, robust and automated test process. It provides an organized platform to manage your project data. A powerful interface to requirements management tools such as DOORS let you import maneuver catalogs, variant matrices and evaluation criteria's into the TestManager of CarMaker. Within the TestManger the specification of test automation can be done without programming skills. If needed, user-defined start, end and simulation script procedures can be inserted as Tcl/Tk or MATLAB scripts. After test execution the results are automatically stored in test protocols and can be returned to the requirements management tool. Within the TestManager you can access all parameters of CarMaker. This enables the easy varying of parameters to conduct comprehensive parameter studies (e.g. DoE).
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Maneuver based test management and automation Easy implementation and application of test automation routines Access to all commands, models, parameters, variables and data of CarMaker Continuous use for MIL, SIL and HIL Reproducible, archiveable and modular test flow Exchange of models "on the fly" Automated generation of test protocols and reports Access to all parameters allows for comprehensive parameter studies

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Integration within MATLAB/Simulink

CarMaker is completely integrated into MATLAB/Simulink. The user can easily make modifications to the models by, for example, replacing certain components of the models with their own Simulink blocks. However, an easy and quick integration of control models and physical hardware components is also possible without Simulink.
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CarMaker models integrated as Simulink block sets Sub-segmented to all vehicle sub-systems for an easy customization Simple user modification, extension and replacement of blocks Same GUI, same models, same test runs, same parameters and same mechanisms as in CarMaker without Simulink Direct access to all variables

Online interfaces to Hardware-in-the-loop applications

The HIL package CarMaker/HIL contains the same functionality as CarMaker/Office plus additional functions for the real-time testing of ECUs and vehicle components. This real-time extension includes tools which allow you to control and monitor the HIL simulation out of the maneuver control during the test runs.

ECU diagnosis tools and flash utility

Different diagnosis interfaces (e.g. CAN, FlexRay, K-Line) to the failure memory of the ECUs are provided. You can read out, reset or delete the failure memory. Besides, you have read and write access to further areas of the ECU to read measurement values, modify application parameters or program the ECU flash.

Access to internal ECU data with CCP and XCP

Internal variables of ECUs that are connected to the HIL test bench by bus systems like CAN, Ethernet, FlexRay or LIN can be measured due to a direct CCP and XCP access from CarMaker to the ECU parameters.

FailSafeTester control
Electrical faults such as cable breakage, loose contacts, corrosion, short circuits and leakage current can be inserted interactively and in real-time.

Customize your development environment!

In addition to the standard tools in CarMaker, you can easily design and extend the simulation tools according to your individual needs. Generate arbitrary user interfaces, instruments or user panels - intuitive and adapted to your tasks! The library for the design of user defined displays contains e.g. tacho displays, number blocks, control lights, switches and buttons, bar displays and slices.

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Open Integration platform

CarMaker is an open integration platform to which customers and partners connect their own models and tools. This enables a wide spectrum of applications besides the classic vehicle dynamics simulation. These application fields are the testing and development of chassis control systems, driver assistance systems and system networks where the chassis control systems interact with further vehicle areas such as steering, drive train and electrical systems. In addition, CarMaker is the optimal environment for holistic consumption analyses and the further development of hybrid technology. With a global view on the vehicle as an overall system we continuously extend the application possibilities of the vehicle dynamics simulation in co-operation with our customers and partners. The versatility of CarMaker supports these efforts; and you stay at the cutting edge of the development!

Continuity with maximum performance

CarMaker is equally developed for office and HIL applications and perfectly meets the requirements of both. IPG's experience of building-up numerous HIL test benches is continuously introduced into the software. You profit from a seamless and optimally suited simulation platform: For concept design and testing, simulation on ECU and network HIL systems as well as virtual test driving on dynamic engine and powertrain test rigs. Regardless of the development phase, you work with the same tools, models, parameters and test scenarios using a robust, fast and productive development and testing process.

Contact IPG
Since it was founded in 1984 as a spin-off from Karlsruhe University, IPG has gone straight to the top. Today we are the leading supplier of simulation solutions, test systems and engineering services for virtual test driving from a single source. For global coverage, we are represented all over the world.

Headquarters in Germany
IPG Automotive GmbH Bannwaldallee 60 D-76185 Karlsruhe Phone: +49.721.98520.0 Fax: +49.721.98520.99 www.ipg.de

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