Using Cost Effective Distributed HIL for Rapid Prototyping

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1 Using Cost Effective Distributed HIL for Rapid Prototyping Renesas Electronics America Inc.

2 Enabling Smart Solutions Embedded Control Systems need Hardware-in-Loop Simulation 2

3 Innovation using HIL Simulation Simulation Architecture must include real-time simulation components pseudo real-time environments and displays global time stamping for synchronization distributed components Smart hardware capabilities include compute power communication bandwidth 3

4 Hardware-In-Loop (HIL) with Renesas and ADI Applied Dynamics International (ADI) has been supplying HIL Real-time Systems and simulation tools for over 50 years. Renesas provides the MCU families to integrate easily into your smart products and your Hardware-In-Loop (HIL) test facilities. 4

5 Smart Technologies require Renesas MCU ADI s HIL Simulators 5

6 Agenda What is HIL, Distributed HIL and Rapid Prototyping? Using Virtual Systems integrated with HIL Simulation Systems Process Improvements using Distributed HIL for Rapid Prototyping Risk Reduction using Real-time HIL Platform Best Practices (Model-based Development, HIL Simulation) Q&A 6

7 Key Takeaways Understand how Hardware-in-Loop (HIL) simulation and testing can be useful in your smart product development process Identify product development where HIL is beneficial List tool characteristics that enable HIL integration and test Highlights of the HIL demo using Model Based Design (MBD), Virtualization & Hardware in the Loop (HIL) 7

8 What is HIL? Simulation uses technology to provide an experience within an environment that is representative of the real thing. Hardware-in-Loop (HIL) uses simulation and real hardware components to provide an identical experience to the real thing. NASA Ames Vertical Motion Simulator 8

9 Real-time HIL Simulation Applications: Test and Rapid-Prototyping Closed-loop Testing Scenarios Monitor Response Real-time Simulator Open-loop Testing Stimulate Monitor Response Real-time Simulator Rapid Prototyping Stimulate Monitor Response Real-time Simulator 9

10 System Test Bench System Testing without the System The system test bench starts with model-based simulation. Models can consist of: Physics-based plant models Control algorithms Experimental data Mathematical Function data Subsystem implementations Communication Databus Interface documents describe model I/O 10

11 System Test Bench System Testing without the System The system test bench includes the Embedded Control System: Emulated or virtual system (model-based) Actual software (hand-coded or auto-coded) Actual hardware (prototype or production) Supports Test case development Supports Revision Control 11

12 System Test Bench Benefits System Testing without the System The system test bench provides the platform for: Co-simulation of Models and Embedded Software Interface document verification (model I/O validation) Defining hardware interface requirements Designing the graphical tester and end-user interfaces Generating test cases and script for test automation And the benefits: Co-simulation assets flow through product life cycle Quick turn-around on design changes Managed product development and testing Early evaluation of end-user experience through simulation enables smart solutions 12

13 System Test Bench HIL System Testing without the System The virtual system test bench integrates with the HIL Simulation System by reusing the assets from the Modelbased development. 13

14 System Test Bench HIL System Testing without the System HIL brings process improvement by adding: Physical plant and/or human in the loop Embedded processor (or emulated processor) in the loop Prototypes and production controllers and subsystems in the loop 14

15 Process Improvements using HIL Simulation HIL Simulation provides the bottom-line process improvements to testing and life-cycle support: Faster development/deployment of embedded systems Validated and repeatable testcases that span product life cycles Early fault detection can eliminate high-cost recalls 15

16 Real-time HIL as Risk Reduction Platform Risk reduction facilities where software and hardware can be developed, integrated, tested and evaluated prior to being fielded Subsystem stand alone functionality Systems interoperability Supports highly coordinated systems integration Distributed HIL uses subsystems at varying stages to create an early system integration lab 16

17 Boeing Satellite Development Center 100% Successful 1 ST Missions Standard Validation Platform Fly Spacecraft on the Ground Satellite Emulator 17

18 Gulfstream Aerospace 75% Test Time Reduction ITF and ARDL 18

19 Real-time HIL as Risk Reduction Platform Proven cases where HIL Simulation provide industry with identifiable risk reduction: Safe Testing outside the box (what if requirements are exceeded?) Fault detection and insertion test cases are easy to do (without damaging costly equipment) Put your product through the paces without having to work in extreme environments (using simulated terrain and temperatures instead of extremes of desert or mountains) Distributed HIL lets you explore new technology for your product by easy insertion and connection into existing test configurations 19

20 The Automotive Research Center (ARC) University of Michigan ARC has current research and experiments using Internet-Distributed HIL (ID-HIL) Principal Investigator:Tulga Ersal, UofM, Goal: Evaluate a novel hybrid power management strategy by integrating the engine and battery testing facilities at the University of Michigan Case Study Team includes: University of Michigan TARDEC ADI 20

21 ID-HIL Hardware Resources Driver Interface Battery Testing Laboratory Engine Testing Laboratory Walter E. Lay Automotive Laboratory 21

22 ID-HIL Selecting Coupling Points Driver Interface Battery Testing Laboratory Engine Testing Laboratory Walter E. Lay Automotive Laboratory 22

23 ID-HIL Selecting Coupling Points Driver Interface Battery Testing Laboratory Engine Testing Laboratory 23

24 ID-HIL Selecting Coupling Points Driver Interface Battery Testing Laboratory Engine Testing Laboratory 24

25 HIL Modular Simulation Tools ADI delivers modern, open architecture, scalable tools for the development and test of embedded controls electronics that: Correctly match capability and cost with the development and testing task Allow a common tools approach throughout various stages of development Allow the tools to grow and expand as the user s requirements and capabilities change 25

26 HIL Modular Simulation supports Real-time simulation models and hardware for device emulation Real-time simulation plant models Easy transition from emulated embedded system to actual embedded processor and code in the loop Demonstration: ADI HIL, SimuQuest Engine model, Renesas Control Processor 26

27 HIL Modular Simulation includes Signal conditioning for actuators and sensors Integration of the embedded processor toolset Integrated data acquisition and performance estimates A safe, low cost platform to perform experiments 27

28 HIL Modular Simulation - PCI-Engine PCI-Engine is an innovative tool for the design, development and acceptance testing of engine control units (ECU). PCI-Engine emulates an 8- cylinder engine with signal measurement and generation that is crankbased and time-based. 28

29 I/O Considerations ADI s PCI-Engine is a specialized PCI solution providing engine signal emulation including the hall effect sensors 29

30 HIL Demonstration Emulated Engine Closed-loop with ECU ADI Emul8 PCI-Engine Installed in HIL System ECU Simulink Model Engine Emulation Breakout Panel 30

31 HIL Demonstration ADI rtx HIL System Real-Time Simulator 8-Cylinder Simulink Engine Model PCI-Engine PCI- Therm B r e a k o u t P a n e l 8 spark measurement 8 fuel measurement CAN throttle position sensor Hall effect cam emulation Hall effect crank emulation Thermistor emulation Battery voltage power moding Oxygen sensor Engine Controller Manifold absolute pressure Mass airflow 31

32 ECU Testing with Emulated Engine Open-Loop Stimulate Monitor Test ECU s recognition of an event and the appropriateness of the ECU response Simple as a set of potentiometers and switches ECU response is measured to determine that it is within tolerance Multiple input events to ECU may be generated simultaneously ECU Closed-Loop Real-Time Engine Model Test: ECU control algorithm effectiveness Response time and control stability Adaptive capability of controller ECU 32

33 HIL Modular Simulation - PCI-Engine ADI s sensor emulation technology developed for HIL applications includes sensors and emulated devices Ratiometric sensors, Thermistor and Thermocouple emulation, Encoder measurement/emulation PCI-Engine was integrated with the Renesas Controller and the SimuQuest Engine Model for HIL automated testing 33

34 HIL Summary Hardware-in-the-Loop Simulation Model-based development and testing of a single subsystem System Integration Model-based integration testing of stand-alone functionality and subsystem interoperability Rapid Prototyping Plant model with control algorithm development using a simulation centric process 34

35 Innovation Embedded Control Systems need Hardware-in-Loop Simulation 35

36 Questions? 36 Company Logo HERE

37 Renesas Electronics America Inc.

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