ABS/ESP ECU Testing with Sophisticated HIL Simulation Methods

Taking ABS/ESP as an example, the paper will show different configurations of Hardware-in-the-Loop (HIL) test systems, namely the ABS/ESP ECU HIL and the brake system HIL. The HIL simulation will be demonstrated with the vehicle dynamics simulation environment CarMaker. CarMaker maps realistically all subcomponents of the vehicle like suspension, steering, braking, tires, masses and aerodynamics. Using it, longitudinal, lateral and vertical dynamic scenarios can be simulated with sophisticated driver, traffic and 3D road models in a full test automation process. Functions, failures, failsafe methods, security functions and the performance of the control systems can be analyzed and evaluated comprehensively. This will be illustrated with concrete simulation examples with different vehicle/engine options, equipment levels, tire conditions and changing environmental conditions (road conditions, cross wind).