Using models to scale agile mechatronics development in cars: case studies at Volvo car group

R&D at Volvo Car Group (VCG) has made great investments during the last decades in Model Based Development and Physical Modelling of the complex mechatronic systems associated with vehicles. Driven by the dramatic increase of electronics and software in competitive cars, enhanced also by the novel development of hybrid vehicles, the recent focus has been to scale agile mechatronic software development in the multi ECU system, utilizing the tools of and experience in modelling. VCG is currently developing ECU software using executable Simulink models with automated code generation and is currently in the phase of developing the essential automation frameworks for fast "continuous" integration and testing. Early integration and fast development loops are important but challenging in vehicle systems, while multiple suppliers as well as in-house developers are involved and where advanced control software development is conducted by domain experts, not software specialists. In parallel, much effort is spent in development of Plant models (usually physical models of dependent systems or mechanics). Plant models can be used both for development, which is usually equivalent with Understanding the system, and for various software regression tests. Case studies made at VCG shows that modelling should actually be considered as an enabler for agile development. The current challenges include efficient test environments for developers, fast and automated feedback from system or sub system integration (real and virtual), scaling of plant model architectures and finally the challenge of controlling the potentially diverging amount of variants, in mechatronics, software and models.