ID 020C: Hardware-in-Loop: System Testing Without the System

ID 020C: Hardware-in-Loop: System Testing Without the System Applied Dynamics International Marcella Haghgooie Sr. Field Applications Engineer 13 October 2010 Version: 1.2

Marcella Haghgooie Sr. Field Applications Engineer, Applied Dynamics International Over 30 years experience in Systems Engineering for applied physics applications of real-time hardware-in-loop simulation supplying robust development and test facility tools to aerospace, automotive, power, and medical industries. MSEE from Northeastern University, BS Physics from Brandeis University 2

Renesas Technology and Solution Portfolio Microcontrollers & Microprocessors #1 Market share worldwide * ASIC, ASSP & Memory Advanced and proven technologies Solutions for Innovation Analog and Power Devices #1 Market share in low-voltage MOSFET** * MCU: 31% revenue basis from Gartner "Semiconductor Applications Worldwide Annual Market Share: Database" 25 March 2010 ** Power MOSFET: 17.1% on unit basis from Marketing Eye 2009 (17.1% on unit basis). 3

Microcontroller and Microprocessor Line-up Superscalar, MMU, Multimedia Up to 1200 DMIPS, 45, 65 & 90nm process Video and audio processing on Linux Server, Industrial & Automotive High Performance CPU, Low Power Up to 500 DMIPS, 150 & 90nm process 600uA/MHz, 1.5 ua standby Medical, Automotive & Industrial High Performance CPU, FPU, DSC Up to 165 DMIPS, 90nm process 500uA/MHz, 2.5 ua standby Ethernet, CAN, USB, Motor Control, TFT Display Legacy Cores Next-generation migration to RX General Purpose Up to 10 DMIPS, 130nm process 350 ua/mhz, 1uA standby Capacitive touch Ultra Low Power Up to 25 DMIPS, 150nm process 190 ua/mhz, 0.3uA standby Application-specific integration Embedded Security Up to 25 DMIPS, 180, 90nm process 1mA/MHz, 100uA standby Crypto engine, Hardware security 5

Innovation Embedded Control Systems need Hardware-in-Loop Simulation 7

Innovation using HIL Simulation Simulation Architecture must include real-time simulation components pseudo real-time environments and displays global time stamping for synchronization Improved hardware capabilities compute power communication bandwidth 8

Hardware-In-Loop with Renesas and ADI Applied Dynamics International (ADI) has over 50 years experience supplying tools for Hardware- In-Loop (HIL) Systems. Renesas provides the MCU families to integrate easily into your products and your Hardware-In- Loop (HIL) test facilities. 9

The Need Renesas MCU ADI s HIL Simulators 10

Agenda What is HIL? Virtual Systems integrated with HIL Simulation Systems Process Improvements using HIL Real-time HIL as Risk Reduction Platform From Model-based Development to HIL-based System Testing Q&A 11

Key Takeaways Understand how Hardware-in-Loop (HIL) simulation and testing can be useful in your product development process Identify systems development where HIL is beneficial List tool characteristics that enable HIL integration and test Highlights of the HIL demo in Lab Session: 020L SH2A Model Based Design (MBD), Virtualization & Hardware in the Loop (HIL) Lab 12

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 13

Real-time HIL Simulation Applications: Test and Rapid-Prototyping Closed-loop Testing Stimulate Monitor Response Real-time Simulator Open-loop Testing Stimulate Monitor Response Real-time Simulator Rapid Prototyping Stimulate Monitor Response Real-time Simulator 14

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 15

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 16

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 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 17

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. 18

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 19

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 testing span life cycle Early fault detection minimizes late process high-cost changes 20

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 21

Boeing Satellite Development Center 100% Successful 1 ST Missions Standard Validation Platform Fly Spacecraft on the Ground Satellite Emulator 22

Gulfstream Aerospace 75% Test Time Reduction ITF and ARDL 23

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). 25

HIL Modular Simulation 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 26

HIL Modular Simulation Real-time simulation models and tools for device emulation Requirements for real-time simulation plant models Emulated embedded processor transitions to actual processor in the loop Example: SimuQuest Engine model, Renesas Control Processor 27

HIL Modular Simulation Signal conditioning for actuators and sensors Easy integration of the embedded processor toolset Integrated data acquisition and performance estimates HIL is safe, low cost platform to perform experiments 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. 29

I/O Considerations ADI s PCI-Engine is a specialized PCI solution providing engine signal emulation including the hall effect sensors 30

HIL Demonstration Emulated Engine Closed-loop loop with ECU ADI Emul8 PCI-Engine Installed in HIL System ECU Simulink Model Engine Emulation Breakout Panel 31

HIL Demonstration rtx HIL System 32

ECU Testing with Emulated Engine Open-Loop Stimulate Monitor Test ECU s 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 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 34

HIL Modular Simulation - PCI-Engine PCI-Engine was integrated with the Renesas Controller and the SimuQuest Engine Model for HIL automated testing 35

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 36

Innovation Embedded Control Systems need Hardware-in-Loop Simulation 37

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