Hardware-in-the-Loop and Real-Time Testing Techniques

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2 Hardware-in-the-Loop and Real-Time Testing Techniques Fanie Coetzer Application Engineer

3 The Challenge of Complexity BMW 7 Series: 70 ECUs Lexus 460: 100 ECUs

4 Embedded Control Systems Navigation Control Flight Control Steam Turbine Control Dryer Cycle Control Print Head Control Medical Device Control

5 Impact Risk Damage Reputation Recall Time to Market Certification Multiple Software Systems Increased Cost

6 Embedded Control System Testing Challenges Increasing application complexity Increasing reliability requirements Decreasing time to market Decreasing development cost Test Challenges Test Resources

7 Embedded Software Development K c K p Design Physical Testing Prototyping HIL Validation K c K p K c K p Deployment

8 Real-Time Testing of Embedded Software K c K p Design Physical Testing Prototyping HIL Validation K c K p K c K p Deployment

9 Test Cell Stimulus and Monitoring Test System Logging / Analysis Stimulus Test Cell UUT Test Cell Controller

10 Test Systems With Closed-Loop Control Test System Logging / Analysis Stimulus Pressure Chamber UUT Closed-Loop Control Pressure Sensors and Actuators Alarming

11 Hardware-in-the-Loop Test Systems HIL Test System Wind Turbine Controller Logging/Analysis Stimulus Wind Speed and Angle Rotor Speed Pitch Angle Wind Turbine Model

12 Real-Time Testing Software Functionality Application Architecture Stimulus Generation Data Logging Single-Point I/O Alarming Calculated Channels Run-Time Editable User Interface User Management Multichassis Synchronization Closed-Loop Control Deterministic Model Execution

13 Application Architecture Real-Time Testing and Simulation Software Stimulus Generation Data Logging Single-Point I/O Alarming Calculated Channels Run-Time Editable User Interface User Management Multi-Chassis Synchronization Closed-Loop Control Deterministic Model Execution RT PXI RT PC Industrial Controller NI CompactRIO NI Single-Board RIO

14 What Is HIL Simulation?

15 Embedded Control Systems Actuator Commands Sensor Feedback Electronic Control Unit Closed-Loop Interactions

16 Embedded Control Systems Disturbance (load) Desired Speed Motor Controller Motor Command DC Motor Motor Speed

17 Testing Embedded Control Systems System-Level Testing Test System Stimulus Logging/ Analysis UU T Disturbance Desired Speed Motor Controller Motor Command DC Motor Measured Speed

18 Testing Embedded Control Systems System-Level Testing What if the DC Motor is not available yet? What if test failures could damage the DC Motor? What if the DC Motor is very expensive (capital, maintenance, operation, facilities)? What if the DC Motor conditions are not repeatable? Disturbance What if there are numerous variations of the DC Motor? Motor Command DC Motor Measured Speed

19 Testing Embedded Control Systems Component-Level Testing Test System Stimulus Logging/ Analysis UU T Desired Speed Motor Controller Motor Command Disturbance Measured Speed

20 Virtual Reality for Your UUT What does your UUT know about the world around it? UU T Voltage Desired Speed Motor Motor Command Current TCP Controller PWM Impedance ENCODER Measured Speed Timing

21 Testing Embedded Control Systems Virtual System-Level Testing Test System Stimulus Logging/ Analysis MODEL UU T Desired Speed Motor Controller Motor Command Measured Speed Stimulus = MODEL(test profile, UUT response)

22 Testing Embedded Control Systems Virtual System-Level Testing Test System Stimulus Logging/ Analysis MODEL UU T Desired Speed Motor Controller Motor Command Measured Speed

23 What Is a Model? m k c

24 System Modeling Tools NI LabVIEW ITI SimulationX Maplesoft MapleSim C/C++ MathWorks, Inc. Simulink Software Esterel SCADE LMS AMESim NI MATRIXx SystemBuild Simulink is a registered trademark of MathWorks, Inc. All other trademarks are the property of their respective owners.

25 MathWorks, Inc. Simulink software SimulationX from ITI Supported Modeling MapleSim from Maplesoft GT-POWER from Gamma Technologies Inc. TESIS DYNAware models Esterel SCADE Suite NI MATRIXx SystemBuild NI LabVIEW FORTRAN/C/C++ Environments AVL BOOST RT AVL CRUISE Dymola from Dassault 3KEYMASTER In Work AMESim models from LMS VI Grade models CarSim/TruckSim/BikeSim from Mechanical Simulation Corp. Simulink is a registered trademark of MathWorks, Inc. All other trademarks are the property of their respective owners.

26 Reduce Cost and Risk With HIL Testing Increase reliability and quality Achieve better test coverage Take advantage of test repeatability Develop more efficiently Shorten validation process Identify design issues earlier Lower cost to innovate

27 Process Automation Creates HIL Test System for Aircraft Arrestor Control System Using NI VeriStand Field testing (per day) $50k Previous validation program (20 days) Current validation plan with HIL testing (10 days) $1,000k $500k HIL test system cost $50k Total savings using HIL testing with field testing $450k NI VeriStand s out-of-the-box capabilities made it practical for us to develop an HIL test system, reducing our total testing cost. Greg Sussman, Process Automation

28 Staying Competitive in a Rapidly Evolving Market To keep quality and budgets under control amidst growing product and market complexities, engineering teams should view the software and hardware test components as a common DNA that persists throughout the entire development process, from requirements definition to production test. ni.com/ato

29 Traditional View of the Development Process Design Physical Testing Prototyping HIL Validation C Code Generation

30 Testing Throughout the Process Model-inthe-Loop Testing Physical Testing Lab or Field Evaluation HIL Validation Software-inthe-Loop Testing

31 Test Components User Interfaces Stimulus Requirements Models Analysis Reports

32 Test Continuity Through Component Reuse

33 Add System Model NI VeriStand Real-Time Engine Syste m Model Data Table fuel spark position load UI Communication User Interface, Analysis, Reports

34 Add ECU Model and Connect NI VeriStand Real-Time Engine ECU Model Syste m Model Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

35 Configure Stimulus Profiles NI VeriStand Real-Time Engine ECU Model Syste m Stimul Model us Profile Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

36 Configure Data Logging NI VeriStand Real-Time Engine ECU Model Syste m Stimul Model us Profile Data Loggin g Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

37 Select UI Channels NI VeriStand Real-Time Engine ECU Model Syste m Stimul Model us Profile Data Loggin g Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

38 Model-in-the-Loop Test System NI VeriStand Real-Time Engine ECU Model Syste m Stimul Model us Profile Data Loggin g Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

39 Convert to Control Prototyping System NI VeriStand Real-Time Engine Syste m ECU Model DAQ Hardw Stimul are us Profile Data Loggin g Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

40 Convert to HIL Test System NI VeriStand Real-Time Engine ECU DAQ Hardw Syste are m Stimul Model us Profile Data Loggin g Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

41 Convert to Physical Test System (Test Cell) NI VeriStand Real-Time Engine ECU Syste m DAQ Hardw are Stimul us Profile Data Loggin g Data Table fuel spark position speed load UI Communication User Interface, Analysis, Reports

42 Consistency and Efficiency Throughout the Process Test components are automatically reusable across all testing applications. Requirements Design Physical Testing Data Loggin g Stimulus Profile Prototyping HIL Validation Data Loggin g Stimulus Profile Data Loggin g Stimulus Profile C Code Generation Data Loggin g Stimulus Profile

43 Test Component Reuse Benefits Reuse provides correlation of test procedures and results across all development phases Continuity of test components reduces test application development and maintenance costs Common test components and interfaces create operational efficiency throughout the process

44 Learn More About HIL and Real-Time Testing ni.com/hil HIL architectures HIL reference systems Online tutorials Coming Soon: ni.com/testcell Learn about real-time test cells Dynamometers Servo-hydraulic testers Environmental temperature chambers