Open, Scalable Real-Time Solutions Introducing TestDrive ECU-in-the-Loop Testing Q & A Alan Soltis Applications Engineer <Insert Date>
TestDrive Simulator An Overview Compact, robust chassis Pentium 4 processor and PC core I/O modules with integrated signal conditioning and protection TestDrive graphical user interface TestDrive test automation Cost-effective replacement of static simulators Scalable from static / open-loop to dynamic / closed-loop Powered by a mature RT-LAB and QNX real-time platform Modeling done using Simulink
TestDrive A Walkthrough Slots Slots for for I/O I/O modules modules with with signal signal conditioning conditioning and and monitoring monitoring Real-time PC Inside: Pentium 4, 3GHz 25A 25A power power moding moding lines lines and and connections connections including including battery battery voltage, voltage, ignition, ignition, accessories, accessories, radio. radio. 10U 10U desktop desktop simulator, simulator, external external dimension: dimension: 17 17 (w) (w) x 16 16 (h) (h) x 12 12 (d) (d) Rear Rear high-density high-density 56-way 56-way ELCO ELCO connectors connectors for for direct direct ECU ECU connection connection PCI PCI slots slots for for optional optional modules, modules, such such as as CAN CAN bus, bus, GPIB, GPIB, and and IEEE IEEE 1394 1394
Interfacing with the ECU In-the-Loop Crank Synchronous I/O Crank and other reference pulses (11) Variable cam (4) Software selectable output stage open drain, +/- 12v, 0-Vbatt, 0-5v Spark and injector capture (24) Knock simulation Sensor Simulation Digital outputs (43 per module) Configurable power rails Ratiometric analog outputs (16) PWM outputs with analog mode (24) Programmable resistors (12) Current monitoring and feedback 0.5 ohm to 200 kilo-ohm range Actuator Capture - One I/O module that measures analog & discrete states plus pulse width on each channel - 39 channels per module - Resistive loads on all channels
Typical Configurations Engine Simulator Typical Configuration Crank, cam, and other reference pulses (15) Spark and injector capture (24) Digital outputs (43) Ratio-metric analog outputs (32) PWM outputs with analog mode (24) Programmable resistors (12) Actuator capture (39 + 10) CANbus (2) 200+ I/O Channels Transmission Simulator Typical Configuration Digital outputs (43) Ratio-metric analog outputs (16) PWM outputs with analog mode (24) Actuator capture (10) CANbus (2) 95 I/O Channels Vehicle Simulator Sample Configuration For body ECU testing Digital outputs (86) Ratio-metric analog outputs (16) PWM outputs with analog mode (24) Actuator capture (78 + 10) CANbus (2) 216 I/O Channels
Modeling with TestDrive I/O channels are defined in Simulink TestDrive uses Simulink models for both open-loop and closed-loop testing Comes with a compiled model for open-loop testing No need for model development until closed-loop simulation No need to learn Simulink to run TestDrive Simulink is needed only for development system Lowers deployment cost
Interacting with Simulator The TestDrive GUI runs on a laptop or desktop host or directly on a tactile interface module The TestDrive interface animates and monitors a graphical panel (included or user-designed) with signals to/from the real-time system Signals can be assigned to graphical elements in real-time and the configuration is saved for each project New panels are created and edited from LabVIEW, but no wiring is needed, just the graphical layout
Deployment Example Ethernet Direct Connection Test Engineer (running tests) Ethernet LAN Connection Simulator Engineer (building models) Ethernet Remote Connection
Deployment Example Europe Program specific panels and scripts Program 1 Compiled model Template GUI panels Template scripts US Program specific panels and scripts shared within the team Simulator Team Program 2 India (remote access)
Automating Simulations with TestDrive TestDrive GUI uses python based scripting for test automation Python scripts can be run asynchronously (from Windows host machine), or in realtime (on the simulator, time based) Signals can be referenced via unique Alias, referenced to the Simulink signal tree
RT-LAB TestDrive Software Packages Included (base) with each simulator: TestDrive GUI (for interactive use) RT-LAB Run-time Python scripting language (for test automation) Open-loop model (precompiled) For model development (closed-loop), add: Matlab/Simulink/RTW to create or modify your simulated model (engine, vehicle, ) RT-LAB development license to compile and run your model in real-time For custom GUI development, add: LabVIEW base to develop your own virtual instrument (VI) panels
RT-LAB TestDrive Hardware Highlights Software configurable I/O hardware Software selectable rail voltages for ECU inputs No jumpers, no DIP switches Initialization script for one ECU allowing one simulator to be shared among multiple projects Software configurable power moding Software selectable engine crank/cam patterns Each pattern is specified as a MAT file Robust design I/O channels have built in over current protection in case of an incorrect connection or faults
Fully Programmable Powertrain and Vehicle Simulation for ECU-in in-the-loop Testing Compact and robust platform Comprehensive modular I/O set Fully software configurable Built-in signal conditioning and protection Open-loop ready with zero set up time Upgradeable from open-loop to closed-loop Automated testing Easy to use Affordable Tactile interface No auxiliary software cost for open-loop 2005 Opal-RT Technologies Inc