EtherCAT with MORPHEE 2, D2T s Automation System A fast and reliable communication with the test bed

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1 EtherCAT with MORPHEE 2, D2T s Automation System A fast and reliable communication with the test bed Ing Jérémie EFFLAME (1) ; Ing Stéphane PELLETIER (2) 1) Product department, 11 rue Denis Papin, Trappes, France *2) Sales deparmtent, 11 rue Denis Papin, Trappes, France Abstract : During many years, 100 Hz was the typical control frequency required by test bed automation systems. The increasing complexity of modern IC engine mapping has leaded the standard towards 1 khz, and often more. D2T s MORPHEE 2 advanced ( i ) automation system offers today a solution which can reach up to 1 0 khz ( ii ), using the unmatchable performances of the Ethercat field bus. Todate, Ethercat is considered as the future standard for communication between test bed equipments. Many peripherals with an Ethercat link are already available on the market, such as controllers, I/O systems, CAN modules As an Ethercat master, MORPHEE 2 is fully compatible with all Ethercat slave devices, and many acquisition systems are already interfaced with D2T s solution: GANTNER, HBM, BECKOFF Moreover, the Ethercat D2T solution also provides the fast ECU access function, required for rapid measurement purposes or transient engine calibration tasks. In addition to the fast speed communication, the D2T solution has many other advantages, compared with other field buses. An Ethercat network is easy to implement and the commissioning cost is being reduced. I/O conditioners can be kept as close as possible to the unit under test. Ethercat works with Ethernet, a standard for PC hardware and wiring. Thanks to Ethercat redundancy system, the reliability of the control and acquisition system is getting improved: even though a connection breaking of the network occurs, the system remains secured and goes on running. MORPHEE 2 Ethercat is now a fully proven solution which has been running on many test benche s of a major OEM. ( i ) MORPHEE 2 is a unique real time system for automation, simulation and calibration. ( ii ) Depending on the PC and acquisition system performance 1. INTRODUCTION As the new Powertrains become more complex, there is an increasing need for new methodologies and new tools, especially for testing and calibration tasks. In the development of a new engine, more parameters and constraints need to be considered: for example, for engine diesel, only one injection by cycle, with ten ECU labels, was required in 1995 against often five injections today, and more than labels. In the same time, the goals of the automotive manufacturers remain to decrease the development time of their vehicles, and to decrease their cost. How to manage this contradiction, with on the one hand more complexity, and on the other hand less time and cost? How to improve the productivity of a testing procedure or a calibration methodology? For calibration, it is called transient calibration. Today, 1

2 many publications present the last progress and the last methodologies in that field. However, they will be widely used only if they are integrated in standard and robust tools, considering the evolutions of PC technologies. In this document, our goal is to present a solution for faster control and acquisition on a test bed, which is required for the future dynamic test beds and transient calibration methodologies. This solution combines the automation system controlling the test bed with the use of a standard and open protocol, so-called EtherCAT. 2. The Automation System The MORPHEE 2 Automation System, designed by D2T, is a unique system for test bed automation, engine calibration tests implementation and model integration into the test bed. MORPHEE 2 has been developed to meet the future requirements for test bed automation over the next 10 coming years. The main characteristics of MORPHEE 2 are the following: A real time kernel with a maximum kernel frequency up to 10 khz. This kernel has been designed by the company IntervalZero (formerly Ardence) and is fully compatible with future operating systems and hardware developments. A system which is able to be interfaced in any kind of environment, with a high level of scalability and versatility. It enables to upgrade easily a test bed, which is an expensive mean with many high-technological devices such as emission benches. The flexibility of this system is also its opening to any communication standards, such as EtherCAT. A system designed for calibration tasks: an unlimited number of look-up tables, with a size up to 512 x 512, an unlimited number of channels, parameters and ECU; a system opened to any calibration tools. Fig. 1 MORPHEE 2 in its environment MORPHEE 2 is based on the Real time of IntervalZero RTX kernel. Here are the general characteristics with a dual core processor: - 1 core dedicated to RTX, 1 core dedicated to Windows XP - Very low latency time (< 1 µs) => cycle rate up to 10 khz - RTX processes real-time interrupts while running real-time tasks Thanks to a specific HAL extension, RTX has priority on XP: RTX preempts Windows XP anywhere, at least outside critical Windows XP interrupt-processing code. RTX defers Windows XP interrupts and faults while running real-time tasks makes it possible real time TCP-IP (IPv4 and IPv6), RS232C, or USB 1.1/2.0 communication with devices 2

3 Master EtherCAT MORPHEE 2 EtherCAT Wiring redundancy Slave EtherCAT Slave EtherCAT Slave EtherCAT Fig 2 IntervalZero (Ardence) RTX architecture 3. The EtherCAT protocol (Ethernet for Control Automation Technology) EtherCAT is an open high performance Ethernet-based field bus system. This protocol is now used by about 900 member companies. D2T was the first company to validate a testing application with the EtherCAT technology at an automotive customer site. As a matter of fact, EtherCAT enables to support higher frequency, up to 10 khz as MORPHEE 2, required for future calibration applications. Fig. 4 Master / slave architecture As said, the first advantage of EtherCAT is its high speed capabilities. It has very good transfer rates, bandwith and transfer speed, and is fully real-time. The clock rates show performance greater than 10 khz. The topology is not only the classic one and expensive - switch-based Ethernet star topology. Line or tree network can also be chosen. The system is also redundant. Due to that, the reliability of the control and acquisition system is getting improved: even though a connection breaking of the network occurs, the system remains secured and goes on running. EtherCAT has been defined following four main goals: - To define an Ethernet protocol dedicated to automation applications - To have shorter data update times (called also cycle times) - To have low communication jitter, for synchronization purposes - Without increasing hardware costs EtherCAT implements a master/slave architecture over standard Ethernet wiring: in our case, MORPHEE 2 is the master, while the slaves are the devices controlled by MORPHEE2. EtherCAT provides wiring redundancy (ring LAN). EtherCAT enables to decrease wiring costs. It uses standard Ethernet wire. Another advantage for EtherCAT is that it does not require specific boards: standard Ethernet boards can be used for the EtherCAT Master. 4. Integration of the EtherCAT protocol in a test bed The solution which has been implemented is based on: The MORPHEE 2 Automation System The KOENING RTX master (EtherCAT master real-time, designed by the company KOENING) The KOENING Studio, for the configuration of the system An EtherCAT driver developed for MORPHEE 2 3

4 In the following scheme, it is possible to see the test bed architecture: Fig. 3 Test bed architecture for data acquisition and fast ECU Access The following scheme presents the integration of EtherCAT in MORPHEE 2, with the EtherCAT driver and the RTX master. Fig. 6: Procedure for creating a new slave on MORPHEE 2 Automation System 5. Applications in a test bed: data acquisition and fast ECU Access MORPHEE 2 with EtherCAT provides a wide access to many hardware for many applications, such as data acquisition, fast ECU access, drive, actuators and measuring devices. The acquisition is truly real time, with no buffering. 5-1 Data acquisition with EtherCAT Fig. 5 EtherCAT integration in the Automation System To interface the data acquisition with the automation system, through MORPHEE 2, is then very easy: adding an EtherCAT slave in MORPHEE 2 is a simple operation. The sample rate can reach up to 10 khz The usual measurements made with classical acquisition hardware in a test bed are possible: Voltage, Current, Resistance, Temperature TC PT100, PT1000 Digital I/O Bridge, LVDT Frequency, PWM 5-2 Fast ECU Access With increasing complexity of engines, the calibration effort is rising up which is reflected in the number of 4

5 calibration labels in an ECU. The goals of the new calibration methods are: Performance increase to reduce calibration times, Moving from steady state experiments to transient calibration, Better reproducibility of test runs D2T has developed a solution for fast ECU access with ETAS. In the following figure, a common architecture used today is described: In this architecture, the communication to the ECU is done trough a direct EtherCAT link. The configuration remains done by INCA. The cycle time is now less than 1 ms. In such a configuration, the rapid calibration access allows to increase the number of intermediate calibration steps and to reduce the required set time. The increased number of intermediate calibration steps leads to a faster stabilization time. The overall calibration task can be reduced by ~30%. Here under the decrease of number of calibration steps and the faster stabilization time are described: Fig. 7 Today s architecture for the access to the Engine Calibration Unit (ECU) Fig. 9 Number of steps and stabilization time in the previous architecture In this figure, the communication to the ECU is done through ETAS s calibration tool INCA, via the MCD3 protocol. The configuration is done by INCA, via MCD3. The usual cycle time is 100 ms in this architecture. In the following figure, the new architecture proposed by D2T and ETAS is described: Fig Number of steps and stabilization time in the new architecture 6. CONCLUSION Fig. 8 New architecture for Fast ECU access In the coming years, EtherCAT will become the leading communication protocol in the automotive testing applications. EtherCAT enables to support higher frequency (up to 10 khz) and to distribute a larger flow of information compared to previous used fieldbus. It means high dynamic performances in the engine or powertrain test bed, and the management of more measuring devices. It also simplifies 5

6 the communication inside the test bed, with only one communication protocol. And with EtherCAT, the integration becomes much more simple: less wiring, only one communication board for all devices. Linked to MORPHEE 2, the new D2T test bench automation system, it is today the most performing system of the market. This EtherCAT technology based on Ethernet technology allows to: - Use standard network interface cards (Ethernet board) - Add or remove devices during test (hotplug) - Manage invalid measurement channels (disconnected channels) - Manage error on the bus - Transmit local area network through EtherCAT (Ethernet over EtherCAT) The next step for the development of solutions with EtherCAT will be its implementation in combustion analysis systems such as D2T s OSIRIS. 6

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