Transcript RT-LAB Introduction

ELECTRONIC PLATFORMS AND ON-BOARD
SYSTEMS ON SMART VEHICLES:
DEALING WITH INFORMATION IN "REAL TIME"
Next-Generation HIL Design Tools
for Next-Generation Vehicles
Jean Bélanger , CEO
Opal-RT Technologies Inc
Montréal, Québec, Canada
www.opal-rt.com
June 2005
www.opal-rt.com
Opal-RT in Brief
• Established in 1997
• RT-LAB: Real-Time Simulation Platform for
Simulink™ and SystemBuild™
– Hardware in the Loop for Demanding Simulations
– Distributed, Parallel Processing using Off-the-Shelf
Technologies – PC, FireWire, QNX, NI, FPGA etc
– Scalable Power for the most complex dynamic models
– Comprehensive API for on-line tools for visualization and
interaction, eg LabVIEW™
• 50 Employees
• Over 200 Customers Worldwide…
www.opal-rt.com
Core Markets & Main Customers
Automotive
• GM, Ford, Toyota, Hyundai, Peugeot, Audi/VW
• Tier 1: Delphi Delco, Bosch, Visteon, Allison
Transmission
Electrical & Power Electronic Systems
• GE, ABB, Hydro-Quebec, Mitsubishi Electric etc
Academic Research and Education
• US: MIT, Berkeley, Michigan, Ohio State, Texas (UT
and A&M) etc etc.
• Canada: Windsor, Waterloo, Alberta, UQ (AM, TR, AC),
Ecole Polytechnique, ETS, McGill etc etc.
www.opal-rt.com
Outline
•
Technology Convergence in the Automotive Industry
•
Modularization of Electro/Hydraulic/Mechanical Systems
•
The Challenges arising from increased in-vehicle
electronics
•
Simulation, Testing and Validation Process and the Tool
Chain to support it
•
Challenges and Opportunities for the Canadian
Automotive Industry
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Technology and Market Convergence
“Electronics represent more than 20% of an average
vehicle's value. Since the majority of new
automotive technologies being developed are
electronic, this percentage is projected to double by
the year 2010.”
Delphi Electronics, 2003
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Technology and Market Convergence
Electronics Share of a Vehicle's Value: 2001-2010
Source: ABI Research
40%
3 5%
36%
3 7%
39%
30%
34%
3 1%
24%
20%
2 1%
22%
20%
10%
0%
2009 2010
2008
2007
2006
2005
2004
2003
2002
2001
Year
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Penetration Rate
50%
Technology and Market Convergence
“The global automotive semiconductor market will grow from
a value of $12.3 billion in 2002, to just over $17 billion by
2007. The largest target application for automotive silicon is
body and chassis control, which includes electronic traction,
suspension and stability control systems. This segment
commands approximately 26% of the automotive
semiconductor market and will be worth $4.4 billion in
2007.”
ABI Research, 2002
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Technology and Market Convergence
50% = $8.5bn
2002 Total: $12.3 billion
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2007 Total: $17 billion
Automotive System Modularization
•Engine Control
•Transmission Control
•Active Suspension
•Active Camber
•Traction Control
•Stability Control
•Power Steering
•ABS
•“X-by-Wire”
•Electric Drives
•Energy Generation
•Energy Storage
System Modularization drives the need for standard dynamic components
and control systems across vehicle platforms. Software determines
system behavior and how the components interact with each other
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Motorola (paraphrased from AEI Magazine)
Example: Electric Power Steering
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More Electronics = More Software!
Power Steering Error
CONTROLLER.exe has caused a fatal error. If the
problem continues, please contact your vendor.
Press Ctrl, Alt, Del to restart
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Challenges
How do we develop testing strategies to assess the reliability and
safety of complex electro/mechanical/hydraulic systems while
maintaining, or even reducing, costs?
System complexity will dramatically increase with
–
The number of interconnected controllers
–
software functionality
–
Number of engineering teams
Complexity will increase even more with the introduction of fuel-cell and
hybrid-electric vehicles
Safety margin will decrease
“Our ability to design
The total cost of failure will increase dramatically
complex systems currently
User tolerance to failure will decrease
exceeds our ability to test
System will need to be designed for testability
these systems…”
Opal-RT Customer, GM
www.opal-rt.com
Solutions
“Virtual” Prototyping through simulation will play an increasingly key
role in system design, commissioning and test.
Automotive and electrical system manufacturers will increase the use of
simulation

to reduce time-to-market and R&D cost

and to increase end-user functionality, quality, safety and reliability
Connection to real components through Hardware-in-the-Loop (HIL)
Testing is critical to this strategy
Validation of controller before integrating into the prototype vehicle reduces
errors and costs
Validation of model against the real thing improves the whole process,
dramatically reducing development cycles and time-to-market
This process is now well
defined and widely adopted…
www.opal-rt.com
THE ‘V’ DEVELOPMENT PROCESS
Design
Highly
iterative
process
Structural (CAD)
Dynamics
Validate
FEA
Off-line Simulation
Plant commissioning
Deploy (Production)
Test track
in-vehicle
calibration
(commissioning)
Virtual Prototype
HIL, Real-Time Simulation
Visualization
Lab Testing
Test cells
Control Prototype
Physical Components
RT Simulation
+ HIL
With actual controller
Implementation
Production Code
Prototype Component
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Maintenance
THE ‘V’ DEVELOPMENT PROCESS
Complete Vehicle
Multiple
Concurrent
Development
Teams
Transmission
Engine
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Power Steering
Braking
Control System Design Tool Chain
RT-LAB
MULTI-ECU
SIMULATION
CLUSTER
Design & Development
Design
Specification
& Requirements
Definition
RT-LAB Simulation Server
RT-LAB Engineering Simulator
Hardware
in the
Plant
Simulation
“Virtual
Prototype”
Loop
RT-LAB Rapid Prototyping Controllers
PC/104
Controller
3rd-Party I/O
Prototyping
FPGA I/O
Signal Conditioning
Specialized Interfaces (CAN, Flexwire, MOST etc)
Hand-Coding or
Automatic Code Generation…
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Production
& Quality
Control
Controller
Integration,
Tuning,
Calibration
ECU Memory Interface
mSTACK
In-vehicle processor
Controller
Unit (ECU)
Test
Production
Code
RT-LAB TestDrive
Validation & Integration
HILBOX:
RT-LAB™ Engineering Simulators
Vehicle Dynamics
Body Electronics
Transmission
Engine
Hardware in the Loop
From subsystem simulation…
Each engineer with his/her own simulator
www.opal-rt.com
RT-LAB™ Engineering Simulators
Vehicle Dynamics
Body Electronics
Transmission
Engine
Hardware in the Loop
…to virtual system integration
Subsystem simulations come together into one simulator
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Challenge for Canada
• Strategists must not lose sight of the growing trend
towards the use of in-vehicle electronics, particularly
for vehicle control – a $8.5bn US market by 2007
• It will be critical to develop an automotive industry
strategy that includes the ability to design and test
advanced embedded car electronics for this market
• If Canada doesn’t act now, emerging countries like
India and China will soon compete through their lowcost, highly educated workforce, and rapidly
developing R&D capability
Can we afford to be
left out of this market?
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Recommendation
Increase our expertise in all aspects of
automotive software development, testing and
implementation by
1) collaborating with major OEMs and Tier 1 suppliers
on new product development and testing
2) attracting major OEMs and Tier 1 suppliers to carry
out some of their R&D in world-class Canadian facilities
3) developing our own expertise through special
projects, funded by Canadian partners, independently of
OEMs, if necessary
For Example…
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Example: Virtual Vehicle Test Cell Facility
Facility allows manufacturers to
“road-test” new or modified vehicle
components without a specialized
test vehicle.
The World’s First Virtual Vehicle Test Cell opened in
September 2002 at SwRI, San Antonio, Texas
Dramatically reduces costs (at least
$500k per test vehicle eliminated)
It is now fully booked for the next three years and
work has begun on a second facility
Automated, repeatable tests
Other automotive research organizations are now
planning their own facilities around our technologies
Climatic extremes without driving to
the Arctic or Arizona
www.opal-rt.com
Photos courtesy Southwest Research Institute
Virtual Vehicle Test Cell Facility: How it Works
Using a Model-based approach means that component models that were
developed at the design stage by different groups or suppliers can now be
incorporated into an RT-LAB Engineering Simulator in the Test Cell
Virtual components
Driver/Road Course
Road
Load
(Test Track)
Driveline
(Tires, suspension,
driveshaft)
Transmission
Engine
ECU
Real components
Photos courtesy Southwest Research Institute
www.opal-rt.com
Virtual Vehicle Test Cell Facility: How it Works
As the test component becomes available from the manufacturer, it can be readily
connected to the simulator via low-inertia dynamometers, bypassing the virtual component.
This provides extremely high-fidelity simulation of the engine and test-track loads on the
component, and allows the test program to commence with minimal delay
Virtual components
Driver/Road Course
Road
Load
(Test Track)
Driveline
(Tires, suspension,
driveshaft)
Transmission
Dynamometer
Engine
ECU
Electric
Motor
Transmission
Real components
Photos courtesy Southwest Research Institute
www.opal-rt.com
Virtual Vehicle Test Cell Facility: How it Works
As the test component becomes available from the manufacturer, it can be readily
connected to the simulator via low-inertia dynamometers, bypassing the virtual component.
This provides extremely high-fidelity simulation of the engine and test-track loads on the
component, and allows the test program to commence with minimal delay
Virtual components
Driver/Road Course
Road
Load
(Test Track)
Driveline
(Tires, suspension,
driveshaft)
Transmission
Dynamometer
Engine
ECU
Electric
Motor
Transmission
Real components
Photos courtesy Southwest Research Institute
www.opal-rt.com
Summary
• Vehicular electronics is a rapidly growing market,
particularly in Body & Chassis, and Powertrain
Control
• Demand for active electro/mechanical/hydraulic
systems will drive the demand for more research
into control development and integration
• An $8.5bn market cannot be ignored and we
need to plan for success in this market now
• As an industrial region with all the right skills,
Canada is well placed to become a leader in
research in this area
www.opal-rt.com
Final Message
Don’t build the hammer,
build the house!
• Professional-grade tools for ECU development
and testing are already available and are being
used by the major automotive players
• Canada has a ready supplier of the right tools
to facilitate the development process and help
build the required R&D facilities to service this
market
Thank you
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