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www.kit.edu
Karlsruhe Institute of Technology (KIT) / Institute of Control Systems (IRS)
KIT – University of the state of Baden-Württemberg and
National Laboratory of the Helmholtz Association
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for Design and Evaluation of
Haptic Driver Assistance SystemsIPG apply & innovate 2014, September 23/24
Simon Rothfuss, Michael Flad, Sören Hohmann
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Research Fields of the IRS
2 09/24/2014
Automation
SolutionsCooperative
Assistance Systems
Alternative Energy
Storage Solutions
Haptic Cooperative
Advanced Driving Assistance System (ADAS)
Sources: http://people.tuke.sk/ivo.petras/RLD.gif
cdn.redmondpie.com/wp-content/uploads/2012/11/iOS-battery-logo.png
bosch-kraftfahrzeugtechnik.de/media/ubk_europe/db_application/stage_funktion/bilder/ESP_Function_w982.jpg
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Haptic Cooperative ADAS
Direct Perception
Direct Integration
Instant Communication
Intuitive Cooperative
System
3 09/24/2014
Source: http://commons.wikimedia.org/wiki/File:American_shepherd3.jpg
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Cooperative ADAS Development
Cooperative ADAS development requires test environment
4 09/24/2014
HW-in-the-loop HumanVirtual Car
Simulation
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Overview
5 09/24/2014
Brake Simulator
Mechanics
Electronics
Control
HiL Integration
Validation
Overview
Components
Overview
Concepts
Driving Simulator
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Advanced Driving Simulator
6 09/24/2014
Steering
Wheel
Brake
Screen
Realtime
System
Sound
Sources: pk-soundandmusic.com/imagebase/7-1417505.gif
sensodrive.de/__we_thumbs__/1035_5_s-pr-wheelHT-1.jpg
autosieger.de/images/articles/continental_gaspedal_3.jpg
bosch-automotivetechnology.com/media/en/ubk_europe/db_application/...
...downloads/pdf/antrieb/de_5/gs_datenbl_apm_de.pdf
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..._refl_dp_300dpi_200x250mm_cmyk_081218.jpg
Throttle
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Overview
7 09/24/2014
Mechanics
Electronics
Control
HiL IntegrationDriving Simulator
Validation
Overview
Components
Overview
Concepts
Brake Simulator
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Hybrid car characteristic
Requirements
Conventional pedal force characteristic
8 09/24/2014
Accuracy according perception
Short response time
Human perception
Nonlinear force characteristic
Nonlinear dynamic
Recuperation
only
Recuperation
&
Conventional
Brake
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
New Concept
Accuracy according perception
Short response time
9 09/24/2014
Basic concepts for pedal force simulator
Passive Active
New Concept:
Brake Feedback Force Generation by Electric Drive
Nonlinear force characteristic
Nonlinear dynamic
Requirements
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Brake Pedal Simulator - Mechanics
10 09/24/2014
Synchronous
Motor
GearboxConnector
Torque SensorPedal
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Brake Pedal Simulator - Mechanics
11 09/24/2014
Incremental
Encoder
SpringLimit
Stops
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Electrical System
12 09/24/2014
CANInterface
DSP
Incremental
EncoderQEI
Torque
Sensor
CAN
BusPWM
Drive Control Unit
SM µCGateUnit
Converter QEI
Pedal Control Unit
/A D
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Software Architecture
13 09/24/2014
Sensor
Input
Reference
Calculation
Control Algorithm
Failure
Detection
SystemSupervision
System State
Estimation
OutputEnable & Limit
Filtering
PWM SignalField-Oriented
ControlGate Signals
EmergencyStop
Pedal Control Unit (DSP)
Drive Control Unit (μC)
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
System Model – Mechanics
14 09/24/2014
MM Motor Torque
MF Spring Torque
MP Pedal Torque
MG Pedal Mass Torque
MRi Friction Torque
i Gear Ratio
φi Shaft Angle left/right side
JM/G Inertia of Motor/Gearbox
J1‘ Inertia of connecting elements left
J2 Inertia right
kDK Spring Constant of Torque Sensor & Connector
dDK Damping Rate
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
System Equations
Coupled nonlinear differential equations
with
Constraints
15 09/24/2014
1 1 1 2 1 2 1 1
2 1 2 1 2 2 2
2
2
2
( ) ( ) ( ) ( ) ( ) ( ) ( )
(
( )
( ) ( ) ( ) ( ) ( ) ( ) ( ) ...
( ( ))
)
) ( )(
DK DK M R
DK DK p R
G F
J t k t t d t t i M t M
J t k t t d t t M t M
M t
t
M
t
t
20 ( ) : Angle of Limit Stops
-120 ( ) 120 M
t
Nm i M t Nm
2
1 1' ( )M GJ J i J J
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Software Architecture
16 09/24/2014
Sensor
Input
Reference
Calculation
Control Algorithm
Failure
Detection
SystemSupervision
System State
Estimation
OutputEnable & Limit
Filtering
PWM SignalField-Oriented
ControlGate Signals
EmergencyStop
Pedal Control Unit
Drive Control Unit
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
PI-State Feedback Control
17 09/24/2014
MP Pedal torque
MS Reference torque
x System states
u Command input torque to motor
z Disturbances
V
System
Kx
u
--
z
x
MPMS
Kp
Kiʃ
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
System State Estimation
Measurement equation
Problem: Not all system states x and pedal torque MP can be measured
Use of Extended Kalmanfilter for estimation
Estimated quantities
System states
Pedal torque
18 09/24/2014
1 1 2 2ˆ ˆ ˆ ˆ( ) ( ) ( ) ( )
T
t t t t
1
2
1
2
2
2
( )( ) 0 0 1 0
( )( ) 0 0 0 1
( )( ) 0 0
( )Mes DK DK
tt
tt
tM t k k
t
PM̂
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
V
System
Kx
u
--
z
MS
Kp
Kiʃ
Kalman-
filter zk
y
PI-State Feedback Control
19 09/24/2014
Pedal torque, estimated
MS Command input torque
System states, estimated
zk Disturbances, known, used in Kalmanfilter
x̂
PM̂
PM̂
x̂
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Deviations below human perception
Measurement Results
20 09/24/2014
Root-Mean-Square-Error < 12N
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Summary – Brake Pedal Simulator
System control and state estimation designed
Simulator emulates arbitrary nonlinear force characteristics
Required accuracy of pedal force achieved
21 09/24/2014
Control AlgorithmSystem Model
V
System
Kx
u
-
y
-
z
Kalman-
filter
x'
MP'
MS
zk
Kp
Kiʃ
1 11
1 1 1 11 1
2 2
2 22 2
2 2 2 2
1
0 1 0 0
( ) ( )
( ) ( )...
( ) ( )0 0 0 1
( ) ( )( )
0 0 00
1
( )
0
0
DK DK DK DK
DK S FDK DK DK
M
t tk d d k d
J J J Jt td
t tdt
t tk g kk d d d
J J J J
J t
iJ
M
1 10
1
2 20
0 2 0 2
2 2
0 0 ( )
( )0 0 0
( ) ( ) ( )1 1
0
R
R
P g F
sign M
sign M
M t M M
J J
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Overview
22 09/24/2014
Mechanics
Electronics
Control
Driving Simulator
Validation
Overview
Components
Overview
Concepts
Brake Simulator HiL Integration
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Brake Pedal Simulator Integration
23 09/24/2014
CAN
Source: duden.de/_media_/small/P/PC-201100281327.jpg
dspace.com/files/jpg2/px4_px10_px20-de-002_desktopversion_schraeg...
..._refl_dp_300dpi_200x250mm_cmyk_081218.jpg
Brake Pedal
Simulator CarMaker
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Integration Concepts
Concept 1
Brake pedal simulation in CarMaker
Feedback force command to
brake simulator
Pedal position used in
CarMaker
Complex brake pedal simulation
possible
Concept 2
Brake pedal characteristic
implemented on brake pedal
simulator
CarMaker selects characteristic
Pedal position returned to
CarMaker
Higher torque / time resolution
24 09/24/2014
Brake Pedal
Simulator
CAN
CarMaker
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Conclusion
25 09/24/2014
Advanced Driving Simulator presented
Haptic interfaces available
Test bench for cooperative ADAS
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Result
26 09/24/2014
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
27 09/24/2014
Thank you for your attention
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Appendix
28 09/24/2014
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Pedal Feedback Force Characteristic
29 09/24/2014
Real brake pedal force introduced
by braking system
Modelling with pedal force
characteristic
( ( ), ( )) ( ( ))
( ( ), ( ))
( ( ), ( ))
Pedal Static
Hysteresis
Damping
F s t s t F s t
F s t s t
F s t s t
( ): Pedal Travels t
( ( ))StaticF s t
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Pedal Feedback Force Characteristic
30 09/24/2014
( ( )) ( ( ), ( ))Static HysteresisF s t F s t s t ( ( ))d s t
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Pedal Feedback Force Characteristic
Idealized pedal force characteristic for 2 different pedal velocities
31 09/24/2014
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Software Architecture
32 09/24/2014
CAN Signal
Internal Signal
Sensor
Input
Reference
Calculation
Control
Algorithm
PWM
Signal
Emergency
Stop
Failure
Detection
System
Supervision
System State
Estimation
Output
Enable
& Limit
Field-
Oriented
Control
Gate
Signals
Filtering
Pedal Control Unit
Drive
Control
Unit
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
System Equations
Coupled differential equations
Friction model
33 09/24/2014
1 1 1 2 1 2 1 1
2 1 2 1 2 2 2
2 2
2
( )
( )
( ) ( ) ( ) ( ) ( ) ( ) ( )
( ) ( ) ( ) ( ) ( ) ( ) ( ) ...
( ( ()) ( ))
DK DK M R
DK DK p R
G F
J t k t t d t t i M t M
J t k
t
t t d t t M t M t
t M tM
0( ) ( )Ri i i Ri Ri iM sign M d
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
System Equations
34 09/24/2014
Coupled differnetial equations
Non-Linearities
Linearization through
2 2( ) ( )2
G P
lM m g sin t
2 2
2
( ) ( )2
( )
G P
O S
sinlM m g sin t
g g t
2 20 and
1 1 1 2 1 2 1 1
2 1 2 1 22 2 222
( ) ( ) ( ) ( ) ( ) ( ) ( )
( ) ( ) ( ) ( ) ( ) ( ( ( ))) ( )
DK DK M R
DK DK p GR F
J t k t t d t t iM t M
J t k t t d M t M MMt t
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
System Equations
35 09/24/2014
1 1 1 2 1 2 1 1
2 1 2 1 22 22 2 2
( ) ( ) ( ) ( ) ( ) ( ) ( )
( ) ( ) ( ) ( ) ( ) ( ( ( )) ( ) )
DK DK M R
DK DK p R G F
J t k t t d t t iM t M
J t k t t d M M Mt t t M
Coupled differnetial equations
Non-Linearities
Linearization through
2 2 2( ) ( ) ( )FM k a sin t cos t
2 2
0 2 2 2
( ) · · ( )
( ) ( )· ( )
F
F F
sin cosM k a t
M k t
2 2 and
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Control Concepts Overview
36 09/24/2014
Compensator
DeadbeatController
SISO - Control H - Control
PI – State Feedback
Constant State Feedback
State Feedback Control
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Control Implementation with additional Spring
37 09/24/2014
V
System
Kx
u
--
z
MS-MF
Kp
Kiʃ
Kalman-
filter zk
y
-MF
x̂
PM̂
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Identification
38 09/24/2014
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
State Space Model for Kalmanfilter
39 09/24/2014
System equation
39
1 11
1 11 1 1 1
2 2
2 22 2
2 2 2 2 2
0 1 0 0 0
ˆ ˆ( ) ( )0
ˆ ˆ( ) ( )
ˆ ˆ( ) ( )0 0 0 1 0
( ) 1ˆ ˆ( ) ( )
ˆ ˆ( ) ( )
0 0 0 0 0
DK DK DK DK
DK S FDK DK DK
P P
t tk d d k d
t tJ J J J
t t
k g kk d d dt t
J J J J JM t M t
1
1 10
0 0 2 2 20
2
...
0 0
10
( ) ( )0 0
( ) ( )1
0
0 0
M R
g F R
Ji M t sign M
M M sign M
J
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
State Space Model for Kalmanfilter
40 09/24/2014
Measurement equation
1
12
22
2
ˆ ( )
ˆ ( )( ) 0 0 1 0 0
ˆ ( )( ) 0 0 0 1 0
( ) 0 0 0 ˆ ( )
ˆ ( )
Mes DK DK
P
t
tt
tt
M t k k t
M t
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Kalmanfilter - Simulation
41 09/24/2014
Time [s]
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Kalmanfilter - Simulation
42 09/24/2014
Time [s]
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Kalmanfilter - Measurement
43 09/24/2014
Simon Rothfuss, Michael Flad, Sören Hohmann:
Integration of an Active Brake Pedal Simulator in the CarMaker Environment for
Design and Evaluation of Haptic Driver Assistance Systems
Quelle:
http://www.kistler.co
m/medias/sys_mast
er/
celum_assets/88247
08071454_934-
073_web_6407_png
.jpg?2
Measurement Setup
44 09/24/2014
Pedal force sensor attached to pedal
Actuation via human foot
Hence, no possibility to apply velocity profiles
Record command input torque
Used pedal characteristics: