SimulationX at Krauss-Maffei Wegmann

ITI’s simulation solutions helped KMW reduce testing efforts by up to 85 % compared to non-HiL-based tests.

Learn more about Krauss-Maffei Wegmann and how they develop cutting-edge heavily armored yet lightweight vehicles on a HiL test bench consisting of individual hardware and software components that are standard throughout the industry.

The task at hand

Optimized operator-machine interface

Krauss-Maffei Wegmann GmbH & Co. KG leads the European market for armoured wheeled and tracked vehicles with locations in Germany, Greece, the Netherlands and the USA. The armed forces of over 30 nations worldwide rely on tactical systems made by KMW including innovative protected leading and functional vehicles such as the new Armoured Multi-Purpose Vehicles (AMPV). Together with TraceTronic and ITI, Krauss-Maffei Wegmann a holistic validation strategy for the embedded systems has been designed. These innovative command and multi-purpose vehicles are characterized by a high mobility, providing a maximum protection at the same time.

The self-supporting safety cell made from armored steel and the composite armor set new benchmarks for this class of vehicles. Through them, the current protection standards are exceeded while at the same time significant weight optimizations are achieved. Simple vehicle handling and optimized human-machine interfaces inside the vehicle further contribute to the high protection level, as driver and crew need to focus on their mission-related tasks. The simpler it is to drive the AMPV, the higher is the eventual safety for vehicle occupants and equipment. The novel validation framework for the embedded systems in the AMPV developed by the project partners ensures a consistent quality of the AMPV and keeps a high cost efficiency as well as a maximum flexibility at the same time.

The solution

Innovative HiL-based test bench

The implementation of this tasks ranges from modeling of physical components, functional testing and real-time and Hardware-in-the-Loop simulation. The project started with the implementation of the HiL test bench based on National Instruments components whereby the customer requirements and the electronic control units (ECU) to be integrated were analyzed. All physical components interacting with vehicle controllers have been modeled in a second step in SimulationX. The modeling made use of the SimulationX libraries for Mechanics and Transmission Elements, Hydraulics and Pneumatics.

SimulationX offers a number of functions that the model adjustment to real-time requirements in a natural way. These models allows to quickly transferring a complex model used in component development into a simplified model for the real-time application. In order to fully exploit the advantages of the HiL test bench, a flexible test automation environment has been used. Core of the implemented test automation environment is the TraceTronic software ECU-TEST. This solution controls the overall test environment, including simulation, malfunction generation, bus access and diagnostics.

The benefits

Testing control units in the loop to produce vehicles right first time

The engineers of KMW, TraceTronic and ITI have succeeded in developing a novel combination-HiL test bench, consisting of a unique combination of internationally established standard hardware and software components, for the development of state-of-the-art, highly-protected and at the same time comparably lightweight multi-purpose vehicles. The vehicle manufacturer bears the responsibility for the overall system, which consists of the vehicle, ECUs developed in-house and ECUs obtained from external suppliers. In order to fully master this responsibility, all ECUs must be integrated and tested in combination such that they can be installed to the vehicle right-first-time afterwards.

With the validation framework the customer receives an optimally-priced, highly scalable validation framework, which is composed of the combination-HiL test bench, tailored real-time models and a highly automated test environment. This combination allows the manufacturer to integrate the different vehicle ECUs in an optimal and cost efficient way. Thus they can fully exploit the resulting advantages in scalability and I/O flexibility. With real-time models in the loop, the AMPV’s ECU network can be validated in an automated and time-efficient way, providing an integrated approach for the optimization of the whole system. In this project, the test effort has been reduced by 85% compared to non-HiL testing, at the same time achieving a significantly higher test depth.

Simulation in the automotive industry

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