Transcript RT-LAB TestDrive
Open, Scalable Real-Time Solutions
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Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th , 2005
Open, Scalable Real-Time Solutions
www.opal-rt.com
Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th , 2005
ECU Testing Challenges
Challenges: • Growing number of ECUs in new vehicles • Growing number of ECU variants • Growing amount of control software to test At the same time: • Static simulators are becoming inadequate • Dynamic simulators are powerful, but require more time (model development), training (operation) and money.
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Progression of ECU use in Vehicles
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50% 40%
3 5% 3 6 % 3 7% 3 9 %
30%
3 4 % 3 1%
20%
2 2 % 2 4 %
10%
2 0 % 2 1%
2001 2002 0% 2003 2004 2005 2006 2007 2008 2009 2010
Year
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Difficulties with Static Simulators
The current static simulators lack: • Automated I/O Configurability • Expansion for new I/O types and higher pin counts • Support for dynamically linked I/O channels such as VVT • Data bus simulation • Support for test automation • Support for plant models • Support for remote access . . .
Next Generation – Design Objectives
• • • • • Support users accustomed to static simulators and their simplicity – Easy and Intuitive LABVIEW GUI customizable by users – Tactile User Interface with digital potentiometers, switches and led indicators Provide a repeatable test environment – Software configurable I/O pull-up voltages and resistor – No internal jumper for I/O adaptation – Power moding on each IO boards to emulate in-vehicle conditions – Sophisticated test automation facilities Increase test efficiency and return on investment – Remote access over Ethernet for around-the-clock testing – Automated software and hardware configuration – Change of ECU type in less than 5 min.
– Automatic verification of ECU harness connection Decrease unit cost for open loop testing – Affordable price for large quantities of ECU testers – No MATLAB/SIMULINK/RTW/LABVIEW licenses required at run-time Scalable and upgradable to full-feature distributed HIL systems – Provide a model-based simulator to those who may not be familiar with real-time dynamic simulation – Large-scale multi-ECU integration tests using distributed simulation of vehicle subsystems www.opal-rt.com
Open, Scalable Real-Time Solutions
www.opal-rt.com
Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th , 2005
Introducing TestDrive
• Compact, robust chassis • Pentium 4 processor core • I/O modules with integrated signal conditioning and protection • TestDrive graphical user interface • TestDrive automation scripts • Optional tactile interface • 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 www.opal-rt.com
TestDrive is more than an HIL Simulator
Unlike a traditional HIL simulator, TestDrive is
: • Mainly for open-loop testing, can be used for closed loop • Primarily for functional test during ECU development • Inexpensive to buy and to operate • Does not requires model development • Requires minimal set up time • Does not require Matlab/Simulink/RTW to run • Can be used by software engineers with no modeling background (users of current static simulators) • Affordable - can be deployed in large numbers ….
But can be upgraded as a full-feature close-loop HIL simulator by adding software and processor modules
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Open, Scalable Real-Time Solutions
www.opal-rt.com
Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th , 2005
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 www.opal-rt.com
RT-LAB TestDrive – Hardware Highlights
Modular, compact and high channel count
– Over 200 IO channels using 7 slots, with 4 spare slots • Designed to meet testing challenges for the next generation ECUs.
– Multiple systems can be linked for additional capacity
Harness and connector ID
– 5 dedicated pins on each connector for connector Ids – 16 dedicated pins on each harness for harness Ids – Models and test script can check to make sure the proper ECU is connected using these IDs.
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RT-LAB TestDrive – Chassis
Slots for I/O modules with signal conditioning and monitoring Real-time target computer with Pentium 4 CPU TCP/IP connection to host PC 25A power moding lines and connections including battery voltage, ignition, accessories, radio. 10U desktop simulator, external dimension: 17” (w) x 16” (h) x 12” (d)
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Rear high-density 56-way ELCO connectors for direct ECU connection PCI slots for optional modules, such as CAN bus, GPIB, and IEEE 1394
RT-LAB TestDrive – Modules
Common to all modules: • FPGA-based daughter board: – Maximizes commonality between modules – Contains I/O logic for each module – Protected from the I/O stages to minimize replacement cost in case of failures • Prototyping area for custom circuitry www.opal-rt.com
RT-LAB TestDrive – BM & PDL
Base Module (BM) • Power moding (8) • Communication activity and general purpose measurement (10) Pulse Driven Load Module (PDL) • Measures analog & discrete states as well as pulse width (PWM) for each channel (39) • Resistive loads on all channels www.opal-rt.com
RT-LAB TestDrive – RPG & SM
Reference Pulse Generation (RPG) • Variable cam (4) • Crank and other reference pulses (11) • Cam and cranks have a selectable output stage: open drain, +/- 12v, 0 Vbatt, 0-5v • Spark and injector capture (24) • Knock simulation (2) Switch Module (SM) • Digital output board with configurable rails (43) www.opal-rt.com
RT-LAB TestDrive – ASM, POM & RSM
Analog Sensor Module (ASM) • Ratiometric analog outputs (16) Pulsetrain Output Module (POM) • Digital PWM outputs with analog mode • True 0% and 100% capability Resistive Sensor Module (RSM) • Programmable resistors (12) • Current monitoring and feedback • 0.5 ohm to 200 kilo-ohm range www.opal-rt.com
RT-LAB TestDrive – Tactile Interface
• Serves as the simulator’s host PC – Pentium M CPU, touch screen – Windows XP Professional • Touch screen with stylus • Detachable for remote operation • Maps real-time simulation signals to physical knobs, switches, and LEDs – “Tactile” objects are mapped to signals in real-time model through the GUI www.opal-rt.com
Open, Scalable Real-Time Solutions
www.opal-rt.com
Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th , 2005
RT-LAB TestDrive – Software Highlights
Designed for ECU software testing, TestDrive combines: • Static simulators’ ease-of-use – TestDrive GUI – Tactile Interface Module provides a unique combination between real-time simulation and touch-and-feel operation – Optimized for software or test engineers • No Matlab/Simulink and no modeling • Hardware configured in software • Automated testing: scripts can be reused and easily shared • Low cost for deployment in large numbers www.opal-rt.com
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 license to develop your own virtual instrument (VI) panels www.opal-rt.com
RT-LAB TestDrive and Simulink
• I/O channels are defined in Simulink • By running a model, TestDrive takes full advantage of Simulink, for both open-loop and closed-loop testing • Yet, the TestDrive GUI hides the model from the end users so they don’t need to learn Simulink • Simulink is needed only for development system, which helps lower the overall deployment cost www.opal-rt.com
RT-LAB TestDrive User Interface
• The TestDrive interface 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 www.opal-rt.com
RT-LAB TestDrive Configuration
Graphical User Interface Software
for test set up and simulation control running from Windows host PC.
System Configuration Panel Scripts and Macros Python Editor Real-Time Simulation RT-LAB RT-LAB TestDrive Interface Module Configuration Panels Model Design Matlab/Simulink
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Panel Design Interface LabVIEW and compiled LabVIEW Signal Mapping Interface
RT-LAB TestDrive Software Packages
• • • •
Simulator Engineers
Configuring simulator Customizing models Very few of these engineers Tools: – RT-LAB – Matlab/Simulink/RTW • • •
ECU Systems Engineers
Customizing panels Setting-up automated tests Tools: – TestDrive GUI – LabVIEW – Python
Number of Users
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• • • •
Software and Test Engineers
Performing interactive tests Customizing test cases Executing test cases Tools: – TestDrive GUI – Python
Where Does RT-LAB TestDrive Fit … in the design process
(TestDrive vs. Full Scale Dynamic HIL Simulators) Design Specification & Requirements Definition System Validation Plant Simulation Integration Testing Controller Algorithm Development Functional Checkout Signal Mapping and Power Moding Module Power Supply Coding and Unit Testing
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TestDrive Design Highlights - System Fast time to productivity with your simulator
1. Connect ECU to your simulator 2. Install GUI software on your host PC 3. Point GUI to the simulator, you are ready to configure I/O channels in GUI www.opal-rt.com
Uses of TestDrive at Delphi
Europe Program specific panels and scripts Program 1
TestDrive is now used by several companies and is being evaluated by DENSO
Compiled model Template GUI panels Template scripts Program specific panels and scripts shared within the team US Simulator Team Program 2 www.opal-rt.com
India
Fully Programmable Powertrain and Vehicle Simulation for ECU-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