Dipl.-Ing. Thorsten Pendzialek Dipl.-Ing. Matthias Mrosek · 2016-10-20 · Linde Material Handling...

Linde Material Handling


Dipl.-Ing. Thorsten PendzialekDipl.-Ing. Matthias Mrosek

Assistance Systems for Counterbalance Forklift Trucks

Model-Based Testing of Driver


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� Motivation for the Introduction of Model-Based Testing at Linde Material Handling

� Linde Safety Pilot Driver Assistance System

� Modeling Requirements for Testing the Linde Safety Pilot Driver Assistance System

� Model Validation

� Model-Based Testing Framework

Outline


Evolution of Software-Testing at LMH

Functions & Complexity

Manual Testing

Reporting -

Time -

Quality -

Flexibility -

Partly Automated Testing

Reporting +

Time +

Quality +

Flexibility –

Fully Automated Testing

Reporting +

Time ++

Quality ++

Flexibility +

Electronic Control Unit (ECU) Testing

Vehicle-Based Model-Based

Vehicle in the loop

„Tessy“ systemECU in the loop

HiL system

Plain testing

1990 1995 2000 2005 2010 2015

BR335-02BR350 BR39x BR386 BR387

BR1120

LSP

BR387

LSP

BR39xBR336-03 BR39x

update

BR1120

DMC

??

Main Drivers to Introduce Model-Based Testing

� More projects

� More variants

� Higher function complexity

� Shorter development cycles

� Stricter regulations e.g. functional safety

� Increased test effort to validate future assistance systems e.g. LSP


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Outline

Linde Material HandlingAccidents with Counterbalance Forklift Trucks Happen– And Often the Drivers are not Aware Why

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Who is Responsible?

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BGV D27-§§§§8 Stability Against Collapse:„Counterbalance trucks have to be operated in a way,that stability against collapse is preserved. “

Responsibility of the Forklift Driver� Load?� Load center of gravity?� Maximal allowed lifting height?

Producers are liableto indicate thestationary carryingcapacity in eachtruck.

Operator

Driver

Producer


Stationary Carrying Capacity

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Stationary Carrying Capacity is Often Hard to Determine

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Linde Safety Pilot - ActiveMeasured Quantities and Sensors

Lifting Height

Load Force

Rear-Axle Force

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Pressure Sensor

Wire-ActuatedEncoder

Axle-Force Sensor


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Video LSP-WOM


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Outline


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HIL Design


HIL Design – Modeling WorldModeling, Data Acquisition

8/22/2014 13

- Mast+Attachment Data

- Working Hydraulics Model

- Sensor Characteristics

- Steering Model

- Brake Model

- CAN Restbus

- Powertrain Models

-electric

-hydraulic

- Powersource Models

-Battery

-ICE

DUT

Road Environment

Chassis

Tires

Vehicle dynamics

+ Mast dynamics

Responsibility Linde Responsibility IPG


10.01.2012 | Team 387/388 DOC00015050

Huge Truck VarietyActual Series BR387/388

Capacity E20 E25 E30 E35 E40 E45 E50

Truck height flat high flat high flat high flat high flat high flat high flat high

387

CompactStandard

OHG 440 Ah 560 Ah 440 Ah 560 Ah 440 Ah 560 Ah

CompactComfort OHG 440 Ah 560 Ah 440 Ah 560 Ah 440 Ah 560 Ah

LongStandard


LongComfort OHG 550 Ah 700 Ah 550 Ah 700 Ah 550 Ah 700 Ah

388

CompactStandard

OHG 700 Ah 700 Ah 700 Ah

LongContainer

OHG 840 Ah 840 Ah 840 Ah

LongComfort OHG 840 Ah 840 Ah 840 Ah 840 Ah

LSP500 LSP600

Trucks: 34

Masts: 4

Height Range: 3-7m


10.01.2012 | Team 387/388 DOC00015050

Huge Truck VarietyActual Series BR387/388

Capacity E20 E25 E30 E35 E40 E45 E50

Truck height flat high flat high flat high flat high flat high flat high flat high

387

CompactStandard


CompactComfort OHG 440 Ah 560 Ah 440 Ah 560 Ah 440 Ah 560 Ah

LongStandard


LongComfort OHG 550 Ah 700 Ah 550 Ah 700 Ah 550 Ah 700 Ah

388

CompactStandard

OHG 700 Ah 700 Ah 700 Ah

LongContainer

OHG 840 Ah 840 Ah 840 Ah

LongComfort OHG 840 Ah 840 Ah 840 Ah 840 Ah

LSP500 LSP600

Trucks: 34

Masts: 4

Height Range: 3-7m

Reference Vehicles


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Outline

Linde Material HandlingHardware In The Loop – HILValidation Process

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Bild HIL

Schublade

DataAcquisition

SystemModeling

TestExecution

Setup HILEnvironment

ModelValidation

Discussionof Results

DiscussionOf ResultsApprovedModel

Linde Material HandlingVehicle Dynamics ValidationTest Execution - Validation Driving Maneuvers

Quelle: Schyr, Fa IPG 18

Linde Material HandlingVehicle Dynamics Validationx,y Coordinates

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Real Input

Real vs Simulated Results

Steering wheel

Pedal

speed

axay


13.7.2012 Fußzeile 20

Lifting Dynamics ValidationForklift z Coordinate

Mast Stage Transition


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Outline

Linde Material HandlingHardware In The Loop – HILDriving & Lifting Maneuver Testing

• Define maneuver• Define various conditions in which to test:

• Loads• Load center of gravity• Mast type + attachment• Vehicle variant• Environment (Road inclination, surface…)

• Program test script• Decide on which physical quantities to focus

for automated test case evaluation �Criteria!

1. Requirement 2. Setup Model

3. Test case generation

• Execute test scripts + store results • Check if specified boundaries have been violated• Automated protocol with highlighted deviations

including illustrations• No user interaction required• Remote usage of analyzing tools (e.g. Matlab)

4. Test case execution on Hil

„Drive speed shall be reduced smoothly when forklift condition is potentially dangerous e.g. lifted load while driving…“

Physically:• Inertia of Vehicle• Center of Gravity• Mast type and data• Mast attachment• Geometries• Powertrain• Hydraulics• Tires

Electrically:• Additional sensors• Additional control units• Additional data and

teaching effort for ECUoperability

Linde Material HandlingHardware In The Loop – HILState Diagram & Electrical Failure Testing

• Collect test cases A, B, …• Specify expected behavior• Review previously generated

result files and re-specify behavior

1. Requirement 2. Test case

3. Test case schedule

• Load schedule + execute test cases A, B, …• Store results• Compare to expected behavior given by test

case schedule(automated/interactively)• Highlight deviations

4. Test case execution on Hil with test manager software

+

• Straightforward• Mouse click programming• Predefined macros• Configurable macros

Linde Material HandlingVielen Dank für Ihre Aufmerksamkeit

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Dipl.-Ing. Thorsten Pendzialek Dipl.-Ing. Matthias Mrosek · 2016-10-20 · Linde Material Handling...

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