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Synopsis: The validation effort for power-electronics develops contrary to the development time. A correct test method using a highly efficient test system helps to reduce test costs and test time by increasing test coverage simultaneously. AVL Software & Functions presents the test methodology on an e-machine emulator that is used generally as a power electronics test bench. The presentation will cover inverter testing using the PHiL concept (principle, basic structure (setup), benefits); test categories and execution; test automation; additional test and measurement equipment

Synopsis: Electronic control units (ECU) and sensor systems are used in every automobile. Therefore, these components have to fulfill a variety of requirements. This includes leak tightness against dirt and moisture, because the penetration of liquids or humidity can cause serious malfunction of the ECU and the associated electronics. Leak testing of the ECUs as an end-of-line test integrated in the production line is of particular importance. The basics of leak testing and important practical aspects of the leak test of ECUs using the test medium of compressed air are discussed.

Synopsis: Data generated by professional driving simulators in terms of suspension loads/spring displacements/sprung and unsprung mass accelerations can feed a poster rig as a track replay file. This connection allows manufacturers to evaluate suspension performance for beyond-the-reality scenarios.

Synopsis: The paper presents a method to reproduce ride comfort missions on dynamic driving simulators. Offline simulation models were validated against track data, then the simulation outputs were used to reproduce the vibrations on the simulator cockpit, measuring accelerations on defined control points. The comparison showed a good correlation on smooth and rough asphalt although it is still not perfect on the obstacle. Some simulation model variants were then tested on the driving simulator by professional drivers in a blind test. The subjective ranking was in line with the characteristics of the variants, showing the potential of the method.

Synopsis: In this presentation, the potential of semantic data capture in the cloud in combination with the latest automated machine learning (autoML) approaches will be demonstrated. This will be achieved by using the example of the evaluation of road test data for generating generic load profiles for test benches using Markov chains. To present the broad application scope, further use cases from the field of testing will be briefly introduced, pointing out the specific benefits in each case.

Synopsis: Off-road is a performance nowadays much more requested by customers on modern cars. Current innovation and technology on AWD and traction permit further degrees of freedom, increasing vehicle capabilities. Has today testing to be different? The presentation shows a synthesis of criteria used in the development of a former FCA’s off-road vehicle. From requirements and constrains of the off-road intended car, correlated to customer needs, it starts a journey through available and past technologies, objective/subjective testing and simulation with the aim to find the right trade-off between a strong off-road and a safe, comfortable, premium on-road performance.

Synopsis: Digital transformation and the Industrial Internet of Things (IIoT) can provide insights into the way products are actually used in service. This presentation will describe the practical use of descriptive and predictive analytics, where an automotive component is monitored. This requires the collection of usage data from the vehicle such as digital bus data, vibration, temperature, strain, etc to gain knowledge about the health of the equipment and predictive maintenance. This case study will particularly illustrate how machine learning can help with predictive maintenance using CAN data to obtain a reliable estimate of the remaining useful life.

Synopsis: In the automotive industry, tools that enable early intervention in the development process are of great importance. With the help of an NVH driving simulator, engineers can detect possible problems in the early development phase. The immersion of the simulation with steering wheel and seat vibrations is further increased. It is even possible to selectively make individual transfer paths audible. Based on over 30 years' experience, Head Acoustics developed the new, scalable PreSense software, which is usable on a large variety of simulators: mobile while driving, within a mockup or even on the desk of the engineer.

Synopsis: The current WLTP and RDE legislation has been in force since September 2017. However, it is still subject to regular adjustments and extensions. We would like to take this opportunity to provide you with an overview of the current status of implementation. The presentation will also provide insights into the current development process of the Euro 7 legislation, showing the planned schedule, reporting on the focus areas figured out by the CLOVE consortium, giving an idea of the development of a new and improved series of tests and how this could lead to cleaner vehicles and better air quality.

Synopsis: The inevitable march toward post-Euro 6 emissions regulations incorporating Real Driving Emissions (RDE) will result in OEMs placing increased emphasis on frontloading vehicle and engine development using virtual tools to help shorten vehicle concept-to-production timescales and reduce costs. To meet these requirements, a road-to-rig (R2R) whole-vehicle development, calibration and verification approach known as RDE Plus (RDE+) is being developed at Horiba using road, chassis dynamometer, engine-in-the-loop (EiL) and virtual methodologies. Aspects of the RDE+ program are presented here.

Synopsis: The presentation will discuss life testing of ECUs, including a different type of testing. The High Accelerated Life Test (HALT) is intended to stimulate failure and improve design in comparison with the Service Life Test, which is intended to demonstrate a failure-free operation period. The Service Life Test can be realized as an Accelerated Life Test (ALT) demonstrating service life, or as a Reliability Demonstration Test (RDT) demonstrating survival probability. The presentation will cover the test characterization and information link to product development; stress type and level for test acceleration; physical model of test acceleration; test duration and sample size estimation.

Synopsis: Automotive end-of-line tests tend to focus on verifying key parameters/functions of the product, or may be determined based on previous production issues or known field failures. However, when a new product or technology is launched, the potential failure modes and related stresses or root causes may not be known. By utilizing the product’s DFMEA, a customized accelerated stress test regime may be developed to assist in determining potential field failures. Knowing these failure thresholds may help in developing meaningful end-of-line screening tests to detect related weaknesses during the entirety of production, and prevent field failures from occurring.

Synopsis: A hardware-in-the-loop system simulates real-time vehicle environments with the aid of a plant model and associated hardware to which an electronic control unit will be interfaced, making it perceive real vehicle operating conditions. The pivotal role of HILS in automotive vehicle development requires clear definitions and guidelines for the development and maintenance of a HIL framework to achieve remarkable improvements in testing and test work products. This paper talks about establishing CARM (Capture, Analyze, Realize, Maintain) guidelines, a workflow integrated with change management and filter guarded flag points to allow smooth operation and usability, which also ensures HIL rig efficiency and improved quality in the artifacts.

Synopsis: As Ethernet celebrates its 40th anniversary we will discuss how it has been deployed for automotive applications, plus the standards related to the implementation. The presentation will outline the role of IEEE, Open Alliance and Ethernet Alliance in the development of automotive Ethernet, and determine the relevant Automotive Ethernet specifications for PHY developers, OEMs and Tier 1 companies. It will also review the role of Automotive Ethernet relative to other emerging high-speed digital automotive standards.

Synopsis: This presentation will focus on practical test considerations and system validation for radiated emission measurement techniques. It will be aimed at EMC professionals and system and product designers from the automotive industry and any other related industries who need to comply to the CISPR25 standard. Functional system validation within the frequency range 100kHz-6GHz will be demonstrated. This range can be sub-divided into four different sub-ranges. The measurement setup of each sub-range will be exemplified and described in combination with the relevant automation software that is essential for the accurate execution of such tests.

Synopsis: For vibration tests, head expanders are used to enlarge the fixture clamping surface of electrodynamic shakers. Particularly for sinusoidal tests, this requires a multipoint control. Knowledge of the structural behavior of the head expander helps in selecting suitable control points. The analysis of operational deflection shapes (ODS) provides additional insights by visualizing the structural vibration. In contrast to modal analysis, which provides similar insights, ODS are extracted from measurement data collected during vibration tests. By means of an example, this presentation shows how the ODS analysis is performed and how the shape visualization can help in the selection of suitable control points.

Synopsis: With the complexity of functionalities and software in modern vehicles constantly growing, ECU testing is becoming increasingly demanding. In the majority of development projects, it is already unthinkable to complete all test requirements by means of manual testing only. Intelligent test automation solutions ensure that the high number of test runs as well as the required test depth is achieved. In this presentation you will learn how to how to plan and set up the project structure, as well as a sensible test automation toolchain to generate the maximum test coverage from your resources.

Synopsis: With the complexity of functionalities and software in modern vehicles constantly growing, ECU testing is becoming increasingly demanding. In the majority of development projects, it is already unthinkable to complete all test requirements by means of manual testing only. Intelligent test automation solutions ensure that the high number of test runs as well as the required test depth is achieved. In this presentation you will learn how to how to plan and set up the project structure, as well as a sensible test automation toolchain to generate the maximum test coverage from your resources.

Synopsis: The design of power electronics modules is heavily influenced by thermal concerns. Their reliability is critical, particularly when it comes to the automotive sector, where electrification pushes the limits of currently available devices, demanding higher power together with lower losses and dimensions. The lifetime, normally expressed as the number of power cycles the system can withstand, makes more sense if linked to the foreseen lifetime of the application in which the power module is used. Here, we will see how active power cycling can help designers predict the reliability of their modules, considering how parts will be used.

Synopsis: The presentation will provide an understanding of ripple voltage in BEV and PHEV high-voltage (HV) power net, covering its cause, effects and the challenges in measuring and testing it. It will cover the importance of testing HV components with artificial network circuitry to provide near vehicle test conditions, resulting in measurements and tests equivalent to real-world results. It will also introduce the Mercedes-Benz internally developed Ripple Generator, which is designed especially for testing HV components (including battery and power electronics) to simulate actual driving conditions, analyze specific frequencies and carry out ISO 21498 and MBN-LV123 Immunity Ripple Test. The presentation will be illustrated with measurements and findings taken from vehicles, testbeds and batteries.

Synopsis: The automotive community is chasing zeros: zero emissions, zero fatalities and zero traffic congestion. The hope is that autonomous vehicles will get us closer to these goals. Today’s cars use isolated sensors for specific safety tasks, but autonomous vehicles will require more sensors working together for accurate perception and safe planning. This requires a more sophisticated testing strategy stretching from simulation to hardware-in-the-loop testing to road testing. The need to increase testing in the simulated world is becoming incredibly important to cover the millions of miles driven. In this session, discover how the automotive community is building test systems that are future-proof to adapt to changes in vehicle design as we pursue autonomy.

Synopsis: This session discusses the challenges facing test system architecture for EV/HEV batteries and inverters. The use of scalable architecture can help engineers cover more test cases in less time, leading to faster time-to-market and cost optimization for these applications. For a fast-growing market like EV, a flexible and open test architecture can help meet the frequently changing technical requirements and government regulations. National Instruments has been making large investments in this space, and will discuss them in this session.

Synopsis: This talk will present some results of fault detection and isolation as well as fault-tolerant control for electric vehicles. First, an introduction to health monitoring and fault analysis, as well as sliding mode control techniques, will be presented; then, some results of model-based fault-tolerant control using sliding mode control techniques will be provided in the case of speed sensor faults. Finally, some concluding remarks, as well as theoretical and experimental results, will be given.

Synopsis: Close the gap between driver feel and objective metrics. We will provide insight on how to ensure the vehicle has precisely the desired requirements by translating brand identity in specific driving feel with increased efficiency and at reduced cost. Simulation models can be used to expand testing capabilities to access additional and more localized data that explains minor performance changes that are only perceived subjectively; maximize test accuracy and stability for critical test conditions (e.g. on-center performance); augment sensor output to reduce instrumentation time and cost; virtually evaluate chassis design modifications with XiL benches.

Synopsis: NVH aspects of electric motors in xEV create new powertrain testing needs in instrumentation and data processing. Testing needs to be combined with simulation models; for instance, to get virtual signals of hard-to-measure quantities. Methods that enable the prediction of powertrain NVH performance prior to integration in physical vehicle prototypes are also key. Even combustion engine NVH testing comes with challenges, as downsizing has resulted in more efficient engines but has negatively impacted NVH. Efficiently finding the optimal balance between NVH, power and efficiency requires changes in test instrumentation and methodology.

Synopsis: The speed of in-vehicle network standards is growing rapidly. Beyond compliance, system-level scenario-based testing is critical to meet reliability and safety standards requirements. In this presentation, Tektronix will present some system-level tests such as the system performance with noise, electromagnetic susceptibility test, system integrity test and protocol timing measurement at the system level. Automotive Ethernet is the most difficult standard to perform these tests as its full-duplex signal. In this paper, Tektronix will demonstrate a unique (patent pending) solution of software-based signal separation, which allows users to perform the aforementioned system-level tests.

Synopsis: As Ethernet celebrates its 40th anniversary we will discuss how it has been deployed for automotive applications, plus the standards related to the implementation. The presentation will outline the role of IEEE, Open Alliance and Ethernet Alliance in the development of automotive Ethernet, and determine the relevant Automotive Ethernet specifications for PHY developers, OEMs and Tier 1 companies. It will also review the role of Automotive Ethernet relative to other emerging high-speed digital automotive standards.

Synopsis: To validate the correct functioning of an automotive ECU, its analog and digital interfaces are generally stimulated with a set of system-level tests. When expected behavior is shown, the tests pass. But when is an ECU sufficiently tested? One metric that answers this question is code coverage – the degree to which the ECU’s software has been exercised during the tests. This workshop will discuss the importance of code coverage in system testing, and different coverage measures. A demo will show how coverage can be determined in day-to-day development and test.

Synopsis: To validate the correct functioning of an automotive ECU, its analog and digital interfaces are generally stimulated with a set of system-level tests. When expected behavior is shown, the tests pass. But when is an ECU sufficiently tested? One metric that answers this question is code coverage – the degree to which the ECU’s software has been exercised during the tests. This workshop will discuss the importance of code coverage in system testing, and different coverage measures. A demo will show how coverage can be determined in day-to-day development and test.

Synopsis: The presentation begins by defining kurtosis as a measure of the ‘peakiness’ of a random vibration response signal, illustrating it with graphs and relating it to the crest factor of shaker test data. The next consideration is the value of using kurtosis control to add kurtosis to a test signal. Adding kurtosis is an effective way to accelerate a random vibration test, but it is not foolproof because resonances can damp out the kurtosis effect if the transition frequency is not set properly. This introduces a discussion of a real-world method for selecting a transition frequency and implementing effective kurtosis control.