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Rapid Prototyping Automotive ECUs with CompactRIO (cRIO) and PXI
Carroll G. DasePresident, Drivven, Inc.
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cRIO and PXI ECU Prototyping Platforms
• CompactRIO (cRIO)– Compact, rugged features– 200 – 400 MHz CPUs– Up to 512 Mb Flash / 128 Mb RAM– 1M or 3M gate FPGA
• PXI– Multi GHz CPUs– Multi Gb memories, large hard drives– Many I/O card types, including FPGA
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Why a cRIO / PXI ECU?
• Full-authority engine, vehicle and test cell control within single system• Perform R&D or component testing with OEM engines• Rapidly prototype control and DAQ systems for concept engines• Using OEM ECUs for R&D or testing requires expensive / lengthy
original design team support and coordination
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Why a cRIO / PXI ECU?
• Develop experimental algorithms which OEM ECUs cannot execute• LabVIEW graphical programming environment is easy to use• Assemble unique combinations of I/O not possible with OEM ECUs• Sophisticated data acquisition synchronized with control within single
hardware / software platform
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How is a cRIO / PXI ECU Possible?
• National Instruments’ Open hardware/software architecture for cRIO I/O modules
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How is a cRIO / PXI ECU Possible?
• Drivven’s expertise with developing research and production engine control systems
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How is a cRIO / PXI ECU Possible?
• Drivven’s line of cRIO modules designed specifically for direct automotive sensor and actuator interface – available commercially-off-the-shelf
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Drivven Automotive cRIO Modules
• ADCombo Module Kit:– 21-Ch. automotive-style analog inputs, 12-bit, 4 kS/s per channel– 2-Ch. VR sensor inputs, 200mV – 150V– 2-Ch. Hall-effect sensor inputs
• VR/Hall Module Kit– 6-Ch. VR or Hall-effect sensor inputs– Individually software selectable as VR or Hall
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Drivven Automotive cRIO Modules
• Port Fuel Injector Driver Module Kit– 4-Ch. Low/high impedance port fuel injector drivers– 4-Ch. General purpose solenoid drivers (0-100% duty cycle)– Short/open circuit diagnostics and protection
• Spark Driver Module Kit– 8-Ch. Inductive ignition coil drivers– Short circuit and thermal protection
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Drivven Automotive cRIO Modules
• GDI / Common Rail Diesel Injector Driver Module Kit– Internal boost power supply up to 150 V– 3-Ch., configurable peak (30 A) / hold (12 A) injector drivers – Short/open circuit diagnostics and thermal protection
• Electronic Throttle Driver Module Kit– 2-Ch., Electronic throttle drivers– Short circuit and thermal protection
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Drivven Automotive cRIO Modules
• O2 Sensor Module Kit– 2-Ch. wide-band Bosch LSU-4.2 oxygen sensor controllers– 4-Ch. narrow-band Oxygen sensor inputs– Sensor diagnostics and short circuit protection– Add custom calibration for specialized fuels
• Low Side Driver Module Kit– 8-Ch. General purpose solenoid drivers (0-100% duty cycle)– Short/open circuit diagnostics and protection– Software option for 0-2A solenoid current control
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Drivven EPT VIs
• Engine Position Tracking (EPT) VIs– Track angular position of crankshaft to sub-degree resolution– Supports most common trigger patterns in the industry
• N-M (example: 60-2)• Plus 1 (example: 6+1)• Encoder (example 360 count optical encoder)• Chrysler 36-4
– Use to internally simulate crank/cam patterns for easy bench testing during application development
– Drivven can quickly develop EPT for custom patterns
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Using Drivven Products
• Common interface between EPT VIs and engine-synchronous output module kits
• Module FPGA and RT software handles precise timing of fuel/spark outputs so that researchers only program in terms of engineering units (msec, crank-angle degrees, frequency, duty cycle, etc.)
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Using Drivven Products
• Growing engine control application template base– Open source LabVIEW applications– Open source engine control algorithms– Develop custom engine control application in days, not
months• Turn-key solutions, so powertrain engineers can focus on their research without getting side-tracked by efforts to get an engine under control
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Drivven Online
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Drivven Online
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Where to Start?
• Determine control / DAQ requirements and select:– CompactRIO?– PXI?
• Gather engine I/O requirements– Crank/cam sensors, pressure sensors, thermistors,
switches, potentiometers, battery-level voltages, O2, etc.– Fuel injectors, ignition coils, pressure regulator, EGR valve,
throttle, wastegate, etc.
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Where to Start?
• Does baseline calibration data exist for this engine? If not…– OEM ECU mapping is possible with Drivven / NI products– Collect and analyze data (Drivven has examples)– Format data for control use (Drivven has example)
• Wiring harness – OEM or custom?– Spare OEM ECUs are handy for harness connection points– Wiring and connector decisions play big role in project success
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• CompactRIO installation example
Examples
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Examples
• Yamaha YZFR6 Wiring Example
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Examples
• John Deere lean, split-engine control strategy
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Examples
• Turbo-charged motorcycle development for Formula SAE
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Building the Control Application
• This is where the Powerpoint portion of the presentation ends and the application exploration begins
• From here, there will be only place holder slides describing the topics of discussion
• We will browse the application VIs and discuss the steps involved with building an application from scratch
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Building the Control Application
• Project Explorer• Create cRIO target and
FPGA target• Add generic cRIO modules• Add FPGA I/O• Add blank top level FPGA
and RT VIs
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Building the Control Application
• Drivven product directories
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Building the Control Application
• LabVIEW FPGA VI– Single Cycle Loop
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Building the Control Application
• LabVIEW FPGA VI– Cluster interfaces
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Building the Control Application
• LabVIEW RT VI– Top level layout
• Outer Flat Sequence Structure• Calibration loading/saving• Timed Loop• Inner Flat Sequence Structure• Use of local variables• Hierarchical design
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Building the Control Application
• LabVIEW RT VI– Reading Inputs– Making engineering units from
FPGA data
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Building the Control Application
• LabVIEW RT VI– Performing engine calculations– Open source algorithms from
Drivven
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Building the Control Application
• LabVIEW RT VI– Writing Outputs– Converting engineering units to
FPGA data
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Building the Control Application
• Calibration Display– Drivven’s CalVIEW
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Building the Control Application
• Run engine control demo
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Q & A
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Contact Drivven for Full Authority ECU Prototyping
Drivven, Inc.San Antonio, [email protected]+1 970.212.3366