Dr.

Mihai Nica
DVP&R Florian Klück M.Sc.

DVP&R Methodology @ AVL AVL List GmbH

(Headquarters)
Validation of Electrified Powertrain Systems

Confidential
DVP&R

The AVL-PTE Design Verification Plan & Reporting (DVP&R)

unifies in one Workproduct (Master-Document) the Validation
and Verification (V&V) test procedures that are to be
performed in the context of development projects of
mechatronic systems or its subsystems.
Additionally it enables progress monitoring and
documentation of the execution of the V&V activities within
the project development.

In this context the DVP&R combines the validation and

verification principles of DVP&R: Unified test program for all skill areas
 mechanics,
 electric & electronics,
 and software development (including calibration)

to generate a simpler, more economical and reliable validation

and verification process.

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 2

AGENDA

• DVP challenge and AVL solution

• AVL DVP methodology
• TARGETS and LOAD PROFILING
• Test Program
• Evaluation & Optimization
• Summary & Conclusion

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 3

 DVP CHALLENGE & AVL SOLUTION

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 4

DVP CHALLENGES

New/ modified systems New markets/ applications

Verification “Are we testing the right things?”
tasks? “Do we have the right targets?”
Failure
modes?

Traditional development process & test programs

Specification & Requirements & Milestones 

Workflow  Test targets  Responsibilities  Testing approaches 

Modified responsibilities Economic boundaries

“Are the “Are we testing Timeline
New Worksplit New Worksplit responsibilities at the right
between Supplier & Budget
departments OEM
aligned?” time?”
Capacity

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 5

 AVL DVP&R PROCESS & LOAD MATRIX INTERACTION

Design Verification
Design Verification
and Validation
& Validation
Plan &
Plan
Reporting
(DVP) (DVP&R)
Testing
Testing Testing
Testing
requirements
requirements

Test
Testprogram
program Functional
Functional
• Basic DVP Function
Function Functional
functional
functional
issues development
development
• FMEA Verification development
development
and
and
• FP -Database
reliability
reliability
Reliability
Reliability
• Technical LOAD
LOADMATRIX
MATRIX TM
& &
Reliability
Reliability Durability FP
FP-- Analysis
specifications Durability
Durability durability
durability
and
and Initial
& DVP
durability Mission Profile
Targets
• Others durability
durability reliability testing
testing
Validation test program Load
LoadAnalysis
Analysis
issues
issues test program
Evaluation
Optimization

Results, failures, measurement, data, new procedures

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 6

 AVL DVP METHODOLOGY

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 7

DVP&R LIFE CYCLE

① DVP&R
② DVP&R
Target
Planning
System
Definition
Application & Test Evaluation and System Application & Test Evaluation and
Analysis Targets Program Optimization Analysis Targets Program Optimization

③ DVP&R
Monitoring
System Application & Test Evaluation and
Analysis Targets Program Optimization

System Application & Test Evaluation and

Analysis Targets Program Optimization

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 8

 DVP&R PROCESS FLOW

 For each project, the DVP&R Work product (i.e. Deliverable) will be planned and monitor on a level - based approach
(similar to the requirement engineering process)

… …

HW
Parts
EHW SWS S+A …
Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 9
IDENTIFY VERIFICATION TASKS
FROM VEHICLE LEVEL DOWN TO COMPONENT LEVEL
Electric Powertrain
Example Topology Motor, Inverter
Electric Powertrain System:
(+ HV Harness)
- Motor
- Inverter
Reduction Gear Unit
- HV Harness

Shafts (Inverter -> Motor)

• Cardan shaft
- Transmissions
• Drive shaft
• Rigid axle - Cardan and Drive Shafts
• Transmission
- Axle/Differential Gear Unit
DIFF
- (Rigid) Axle
Axle/Differential Gear Unit
(Rigid) Axle

System Generate a common understanding of the covered technical elements

analysis and their interfaces
Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 10
 VISUALIZE VERIFICATION TASKS & FAILURE MODES
EXAMPLE

Component failure mode combinations Verification tasks

Failure modes with unknown impact
Inverter Tasks with unknown impact
Motor

Failure modes relevant HV-Harness

for verification
Transmission
Tasks to be executed
(Rigid) Axle

Failure modes relevant Cardan & drive shafts

for verification & validation
Differential Gear Unit

System Generate an overview what needs to be covered by the DVP

analysis Define countermeasures to clarify unknown impacts
Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 11
 AVL DVP METHODOLOGY
TARGETS and LOAD PROFILING

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 12

LOAD PROFILING – USAGE SPACE ANALYSIS
Analyze customer driving Analyze ambient Analyze target market
and vehicle usage conditions
patterns
Analysis regarding: Analysis regarding:
 Different regions  Geography
 Develop representative  Different seasons /
customer vehicle usage  Driving behavior
months
cycles  Road characteristics
 Representative
 Profiles which include  Market segments
distributions
velocity and gradient  Population

Field driving ExtraUrban

Highway
cycles Offroad
Dynamics

Urban
Dynamics

Load
Load

Example: Ambient
Example: Reference Highway
temperature distributions in
different areas
Velocity

Example: Population of China

Time

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 13

LOAD PROFILING – USAGE SPACE ANALYSIS
Lifetime distribution Generate larger data Reduction step
matrix base
 Set up weighting tables
 No pre-existing data  Design of experiments  Calculate lifetime mileage
 Market researches  Variations included proportion
 Varying boundaries  Consider variations which
(vehicle loading, vehicle Example: fulfill target
gradients, ambient
conditions, vehicle modes)
profile slope weight
Hilly urban flat 15.0%
%(lifetime km / lifetime hours) TOTAL Urban Rural Highway Offroad urban hilly 5.0%
rural flat 55.0%
Overall 100.0% 20.0% 60.0% 18.0% 2.0% rural hilly 5.0%
highway flat 15.0%
Vehicle loading: empty 10.0% 50.0% 11.0% 1.0%
highway hilly 3.0%
100.00%
offroad flat 0.0%
Vehicle loading: full 10.0% 10.0% 7.0% 1.0% ambient weight
offroad hilly 2.0%
very low 13.0%
Vehicle Gradient: flat 15.0% 55.0% 15.0% 0.0% Flat standard 78.0%
100.0% very hot 9.0%
Vehicle Gradient: hilly 5.0% 5.0% 3.0% 2.0%

Ambient Temperatur (very low) 4.0% 5.0% 4.0% 0.0%

profile slope loading ambient mode weight

Ambient Temperatur (standard) 100.0% 14.0% 50.0% 12.0% 2.0%
urban flat empty very low auto 0.585%
rural flat empty very low auto 3.575%
Ambient Temperatur (very hot) 2.0% 5.0% 2.0% 0.0%
highway flat empty very low auto 0.715%
Full variation of cycles & offroad
urban
flat
hilly
empty
empty
very low
very low
auto
auto
0.000%
0.195%
(% of time) TOTAL Auto Power Pure 4WD Save

Vehicle Modes 100% 60% 5% 10% 20% 5%

parameters would lead to a rural hilly empty very low auto 0.325%

high number of cycles Example: Reduction step

Example: Lifetime distribution
matrix

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 14

 DEFINITION OF COMPONENT LOAD PROFILES
DERIVED FROM REAL WORLD VEHICLE DATA

Damage modeling &

Usage space analysis Simulation model
statistical analysis

Failure
parameter
sheet
Fleet data Reference cycle(s)

Results: Results Results

• Reference cycles based on actual end • Time based component load data • Lifetime load profiles
customer usage • Parameter variation covering different • Lifetime load collectives for
• Market related analysis report ambient conditions or control components
strategies

Targets & Utilize customer fleet data efficiently

responsibilities to generate load profiles for new systems and components
Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 15
 AVL DVP METHODOLOGY

TEST PROGRAM

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 16

DVP&R: GENERATION OF V&V PLANS
Customer Wants
System
Quality History
Software
Design Requirements
…
Quality Gates
Changes

Milestones,
Boundary
Design

Diagrams
Tests
Interface Analysis

FMEA

FP-Sheet

RCL

DVP&R

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 17

DVP&R
MAIN TEST CATEGORIES
10 Functional System Development and Integration
• Performance and range
• Core Functions (e.g. external Charging)
• Emission and Consumption System
• On-Board Diagnostics

20 Geometrical Integration
• Geometrical Targets (Digital Mock-Up)
• Weight monitoring
• Center of gravity and inertia
• Assembly (e.g. accessibility)
• Serviceability

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 18

DVP&R
MAIN TEST CATEGORIES
30 Mechanical System Development and Integration
• Durability
• Mechanical Functional Testing (e.g. Efficiency)
• NVH Functional Testing (e.g. NVH Analysis of
e-Machine)
• Robustness and Misuse
• Vibration, Stiffness, Strength
• Shock, Crash, Crush

40 Thermal System Development and Integration

• Condensation and pressure handling
• Cooling system performance
• Tightness and vacuum test
• Filling and Degassing of cooling circuit
• Wind Tunnel Testing
• Street testing (e.g. uphill towing)

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 19

DVP&R
MAIN TEST CATEGORIES
50 Electrical System Development and Integration
• HV Architecture
• Energy Management
• Load Balance
• EMC (e.g. Immunity, Emission, ESD)

60 System Safety
• HV Safety (ISO 26262)
• Functional Safety
• Vehicle Safety (active and
functional passive safety)
• Safety of components

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 20

 ADAS V&V

Develop ADAS functions, control units and vehicle integration

ADAS validation (MIL cloud, MIL office, HIL,VIL, proving ground, public street)
ADAS Center

ADAS test and validation tools

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 21

 AVL DVP METHODOLOGY

EVALUATION & OPTIMIZATION

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 22

VISUALIZE STATUS AND RISKS OF ACTUAL DVP

Required tasks from system analysis Correlation with planned test program

Tasks with unknown impact Inverter

Motor

HV-Harness

Transmission

Tasks to be executed (Rigid) Axle

Cardan & drive shafts

Differential Gear Unit

Connect verification tasks and failure mode with the planned program
Test program
Visualize risks and guide team to close gaps
Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 23
 DEFINITION AND VISUALIZATION OF
DVP IMPROVEMENTS

Status DVP-Result Main request Applied improvements

Targets & timeline

“Clarify
 Specify targets
First analysis responsibilities
 Improve timing of testing
results And
Responsibilities
targets”
 Align responsibilities

Test program
 Modify procedures
“Achieve
1st update of  Define new procedures
best possible
analysis Risk based task coverage
task coverage”
 Decide risk based on tasks in development
team

Management and project team

Final update “Visualize effects of
 Agree on changes
of analysis changes”
 Highlight & agree on remaining risks

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 24

 SUMMARY & CONCLUSION

Confidential Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 25

 AVL DVP
BENEFITS
AVL DVP
 Increased technical and
economical efficiency of
verification and validation
test program
 Minimized risk of verification
& validation gaps
 Consideration of individual
program targets, boundaries
and customer processes.
Confidential
 Identification of verification tasks from vehicle level
System down to component level
analysis  Identification of components and failure modes to be
covered by testing in one document
 Clear definition of project specific verification &
Targets
and 
validation targets
Alignment of responsibilities for complete test program
Responsibilities  Highlight needed missing information
Collection of all required testing activities in one

document
Test Program
 Correlation of verification tasks and failure modes with
planned testing program
 Clear visibility of the verification & validation risks for
Evaluation and all relevant components
optimization  Structured approach to make progress & improvements
visible
Dr. Nica Mihai, Florian Klück M.Sc. | | 05 Juli 2017 | 26
THANK YOU

www.avl.com

Contact:
mihai.nica@avl.com