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Driving Performance and Safety Through Smarter Validation

A leading global automotive OEM partnered with ALTEN to validate its Brake System Management (BSM) ECU, covering critical safety features such as ABS, ESC, ARS, TCS, and Hill Hold Assist. ALTEN built a robust Hardware-in-the-Loop (HIL) validation framework, combining dSPACE benches, Vector CANoe, CAPL scripting, and Python automation, to simulate real-time vehicle dynamics, inject faults, and automate test cycles.

This approach enabled faster, repeatable, and early-stage validation, reducing dependency on physical vehicles while ensuring high coverage and compliance with ISO 26262 safety standards.

Challenge:

Validating complex braking features under real-time conditions was challenging due to limited physical testing, inconsistent manual analysis, and lack of automation. Key issues included:

  • ECU Communication Failures: ECU occasionally failed under fault injection (sensor open/short, freeze), requiring fine-tuning per ISO 26262.
  • Simulation Drift: High-frequency braking behaviors (ABS, ESC) sometimes caused drift/delays in HIL models under heavy loads, impacting signal fidelity.
  • Verdict Ambiguity: Edge cases like slippery or split-µ surfaces produced unclear outcomes due to fluctuating wheel speeds and torque feedback.
  • Signal Synchronization Issues: Misalignment between plant model outputs and CAN timestamps complicated analysis of fast-changing signals.
  • Diagnostic Gaps: Simultaneous feature activations (TCS + ESC) led to missed or false DTCs, needing better filtering and logic.
  • Toolchain Complexity: Coordinating CANoe, CAPL, dSPACE, AutomationDesk, and Python posed challenges in execution, logging, and results consolidation.
  • Harness/Mapping Mismatches: ECU harness or signal structure changes caused silent test failures and lengthy debugging.
  • Scalability Limits: Expanding BSM features required more scalable, parameterized test cases to support regression cycles efficiently.
  • Limited ECU State Visibility: Without XCP or access to internal variables, deeper validation (e.g., ESC stages, brake force distribution) relied only on CAN-level inference, adding debugging complexity.

Solutions: ALTEN built a comprehensive HIL-based automation framework to validate the BSM ECU across features like ABS, ESC, ARS, TCS, Hill Hold Assist, and Emergency Braking. Key elements included:

  • End-to-End HIL Automation: dSPACE benches with real-time plant models enabled closed-loop braking simulations.
  • Multi-Tool Integration: Vector CANoe, CAPL, dSPACE ControlDesk, AutomationDesk, and Python supported synchronized execution, fault simulation, and automation.
  • Fault Injection & Monitoring: Open/short circuits and invalid data were simulated with real-time detection to ensure ECU robustness.
  • Accurate Verdict Logic: Timestamp alignment and refined CAPL scripts improved results for edge cases (e.g., split-µ, icy roads).
  • Concurrent Feature Simulation: Overlapping scenarios (ESC + TCS) validated through layered state machines for clearer outcomes.
  • Enhanced Diagnostics: Stronger UDS services and CAN filtering improved DTC monitoring and traceability.
  • Data & Reporting Tools: JIRA-linked test repositories and DOORS-based requirement mapping ensured traceability; automated reports boosted efficiency.
  • Scalable Test Suites: Parameterized, modular test cases with Python generators supported regression and variant testing.
  • Signal Mapping Automation: Scripts cross-validated CAN DBC mappings and ECU pinouts, reducing human error and setup delays.

Benefits: The implemented HIL validation strategy delivered several tangible benefits that enhanced both testing efficiency and product quality:

  • Increased Test Coverage: Enabled automated validation across a wide range of braking scenarios including extreme edge cases.
  • Reduced Manual Effort: Automation reduced human intervention, saving significant time and effort during regression cycles.
  • Higher Accuracy & Traceability: Ensured accuracy in signal monitoring and failure diagnosis, backed by auto-generated logs and trace files.
  • Faster Issue Identification: Enabled early detection of issues via real-time fault injection and simulation.
  • Audit-Ready Reporting: Standardized logs, traceability reports, and defect linkage provided structured documentation for OEM/Client audits
  • Improved Compliance & Quality Assurance: Strengthened validation rigor for compliance with safety standards like ISO 26262.

Knowledge Where It Counts

The validation strategy was built using advanced closed-loop real-time simulation and model-based development principles. A robust HIL system was created by integrating dSPACE real-time hardware, MATLAB/Simulink vehicle dynamics models, and Vector tool chains. To ensure accuracy, fault tolerance, and seamless interaction between virtual and physical components, the following technologies were utilized:

  • Model-Based Simulation: MATLAB/Simulink was used to create dynamic plant models representing vehicle behavior, wheel dynamics, hydraulic systems, and brake mechanisms.
  • Real-Time HIL Platforms: dSPACE MicroAutoBox / SCALEXIO or NI PXI platforms used to execute plant models with millisecond resolution.
  • CAN Communication and Diagnostics: ECU communicates via CAN bus. Testing includes DBC decoding, UDS diagnostics, and service-based validation.
  • Automation & Scripting: Vector CANoe with CAPL scripting for test sequencing, signal monitoring, verdict generation, and fault simulation.
  • Functional Safety: Adheres to ISO 26262 guidelines to ensure safe operation of safety-critical systems during simulated faults and normal driving.
  • Real-Time Plant Models: Simulated tire-road interaction, vehicle mass distribution, brake hydraulic delay, and wheel dynamics behavior for high-fidelity results.

Tools & Technologies Used

The BSM project leveraged industry-standard platforms to ensure robust validation, traceability, and test coverage across the development lifecycle:

  • Requirement Management: IBM DOORS, Excel for requirement traceability.
  • Model Development: MATLAB/Simulink for plant models, control logic, and vehicle dynamics.
  • HIL Platforms: dSPACE SCALEXIO/MicroAutoBox and NI PXI for real-time Hardware-in-the-Loop simulation.
  • Signal & Diagnostics: CAN DBC, ODX/PDX for communication and UDS-based diagnostics.
  • Test Automation: Vector CANoe with CAPL scripting for automated test execution and fault simulation.
  • Reporting & Logging: Automated reports via CANoe, custom parsers, and Excel macros for efficient analysis.
  • Defect Tracking: JIRA and OEM tools for structured issue tracking and resolution.