MORPHEE 2, EtherCAT and Fast ECU Access. D2T s automation system : A fast and reliable communication with test bed

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Homer Walton
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1 MORPHEE 2, EtherCAT and Fast ECU Access D2T s automation system : A fast and reliable communication with test bed 1

2 Contents MORPHEE 2 Overview EtherCAT Overview EtherCAT Advantages EtherCAT in MORPHEE 2 Data Acquisition with EtherCAT Fast ECU access with EtherCAT and ETAS Road map 2

3 MORPHEE 2 overview MORPHEE 2 is a unique system for test bed automation, engine calibration tests implementation & model integration into the test bed (simulation). A real time system working with the real time RTX kernel which guarantees full compatibility with future OS and Hardware 3

4 Contents MORPHEE 2 Overview EtherCAT Overview EtherCAT Advantages EtherCAT in MORPHEE 2 Data Acquisition with EtherCAT Fast ECU access with EtherCAT and ETAS Road map 4

5 EtherCAT overview EtherCAT (Ethernet for Control Automation Technology) An open high performance Ethernet-based field bus system. EtherCAT goals Ethernet for automation short data update times (also called cycle times) low communication jitter (for synchronization purposes) low hardware costs. 5

EtherCAT provides wiring redundancy (ring LAN) Master

6 EtherCAT overview EtherCAT implements a master/slave architecture over standard Ethernet cabling. EtherCAT provides wiring redundancy (ring LAN) Master EtherCAT MORPHEE 2 EtherCAT Wiring redundancy Slave EtherCAT Slave EtherCAT Slave EtherCAT 6

7 Contents MORPHEE 2 Overview EtherCAT Overview EtherCAT Advantages EtherCAT in MORPHEE 2 Data Acquisition with EtherCAT Fast ECU access with EtherCAT and ETAS Road map 7

8 EtherCAT advantages High speed Very good transfer rates, bandwidth and transfer speed. Real-time capability Clock rates greater than 10 khz. Flexible topology Line network Tree network Star network Redundancy Wiring fault management 8

9 EtherCAT advantages Reduced wiring costs Uses standard Ethernet cable. Longer distances via digital signal transfer Shorter analogue signal paths. Reduced hardware costs Uses standard Ethernet board for the EtherCAT Master. 9

10 Contents MORPHEE 2 Overview EtherCAT Overview EtherCAT Advantages EtherCAT in MORPHEE 2 Data Acquisition with EtherCAT Fast ECU access with EtherCAT and ETAS Road map 10

11 EtherCAT in MORPHEE 2 D2T EtherCAT solution is based on: MORPHEE 2 automation system KOENING RTX master (EtherCAT master real-time) KOENING Studio (Configuration) EtherCAT Driver for MORPHEE 2 11

12 EtherCAT in MORPHEE 2 Test bed architecture: 12

13 EtherCAT in MORPHEE 2 MORPHEE 2 integration: 13

14 EtherCAT in MORPHEE 2 Adding a slave EtherCAT in MORPHEE 2 is very easy. Sample rate up to 10khz 14

15 Contents MORPHEE 2 Overview EtherCAT Overview EtherCAT Advantages EtherCAT in MORPHEE 2 Data Acquisition with EtherCAT Fast ECU access with EtherCAT and ETAS Road map 15

16 Data Acquisition with EtherCAT Automation system MORPHEE 2 A wide EtherCAT device range for multi application (Data acquisition, fast ECU access, drive, actuators, measuring devices ) True real time fast acquisition (no buffering) 16

17 Data Acquisition with EtherCAT A wide range of device Acquisition for physical measurements: Voltage Current Resistance Temperature TC PT100,PT1000 Digital I/O Bridge, LVDT Frequency, PWM 17

18 Contents MORPHEE 2 Overview EtherCAT Overview EtherCAT Advantages EtherCAT in MORPHEE 2 Data Acquisition with EtherCAT Fast ECU access with EtherCAT and ETAS Road map 18

19 Fast ECU access With increasing complexity of engines, calibration effort is increasing which is reflected in the number of 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 19

20 Fast ECU access A common architecture used today Communication to ECU is done through INCA (MCD3) Configuration is done by INCA (MCD3) Cycle time 100 ms 20

21 Fast ECU access A new architecture with Fast ECU access Communication to ECU is done through a direct EtherCAT link Configuration done by INCA (MCD3 - COM) Cycle time <1 ms 21

22 Fast ECU access A common architecture used today A new architecture with Fast ECU access 22

23 Fast ECU access The rapid calibration access enables us to increase the number of intermediate calibration steps, thus reducing 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% 23

24 Contents MORPHEE 2 Overview EtherCAT Overview EtherCAT Advantages EtherCAT in MORPHEE 2 Data Acquisition with EtherCAT Fast ECU access with EtherCAT and ETAS Road map 24

25 Road Map OSIRIS control and data exchange over EtherCAT A common architecture used today Fast access solution Increase data transfer speed between MORPHEE 2 and OSIRIS (Combustion Analysis) 25

26 Road Map DCU 3000: Dynamometer torque and speed servo-controlling 2 khz fast PID controllers Measurement filtering algorithms dedicated to engine applications 26

27 Powertrain Engineering Thank you for your attention You are welcome on our stand for a demonstration..

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

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, 78190