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Open, Scalable Real-Time SolutionsOpen, Scalable Real-Time Solutions
Background
Introducing TestDrive
TestDrive Hardware
TestDrive SoftwareMathieu Dubé-Dallaire
Application Engineer
August 30th, 2005
www.opal-rt.com
Open, Scalable Real-Time SolutionsOpen, Scalable Real-Time Solutions
Background
Introducing TestDrive
TestDrive Hardware
TestDrive SoftwareMathieu Dubé-Dallaire
Application Engineer
August 30th, 2005
www.opal-rt.com
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
Electronics share of a vehicles’ value: 2001-2010(Source: ABI Research)
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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. . .
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• 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
Next Generation – Design Objectives
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Open, Scalable Real-Time SolutionsOpen, Scalable Real-Time Solutions
Background
Introducing TestDrive
TestDrive Hardware
TestDrive SoftwareMathieu Dubé-Dallaire
Application Engineer
August 30th, 2005
www.opal-rt.com
• 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
Introducing TestDrive
• 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
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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 SolutionsOpen, Scalable Real-Time Solutions
Background
Introducing TestDrive
TestDrive Hardware
TestDrive SoftwareMathieu Dubé-Dallaire
Application Engineer
August 30th, 2005
www.opal-rt.com
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
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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.
RT-LAB TestDrive – Hardware Highlights
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RT-LAB TestDrive – Chassis
Real-time target computer with Pentium 4 CPU
Real-time target computer with Pentium 4 CPU
25A power moding lines and connections including battery voltage, ignition, accessories, radio.
25A power moding lines and connections including battery voltage, ignition, accessories, radio.
Rear high-density 56-way ELCO connectors for direct ECU connection
Rear high-density 56-way ELCO connectors for direct ECU connection
Slots for I/O modules with signal conditioning and monitoring
Slots for I/O modules with signal conditioning and monitoring
10U desktop simulator, external dimension: 17” (w) x 16” (h) x 12” (d)
10U desktop simulator, external dimension: 17” (w) x 16” (h) x 12” (d)
TCP/IP connection to host PC
TCP/IP connection to host PC
PCI slots for optionalmodules, such as CAN bus, GPIB, and IEEE 1394
PCI slots for optionalmodules, such as CAN bus, GPIB, and IEEE 1394
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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
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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
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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)
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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
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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
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Open, Scalable Real-Time SolutionsOpen, Scalable Real-Time Solutions
Background
Introducing TestDrive
TestDrive Hardware
TestDrive SoftwareMathieu Dubé-Dallaire
Application Engineer
August 30th, 2005
www.opal-rt.com
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
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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
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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
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• 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
RT-LAB TestDrive User Interface
• New panels are created and edited from LabVIEW, but no wiring is needed, just the graphical layout
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RT-LAB TestDrive Configuration
Scripts and MacrosPython Editor
System Configuration Panel
Module Configuration Panels
Signal Mapping InterfacePanel Design InterfaceLabVIEW and compiled LabVIEW
Model DesignMatlab/Simulink
Real-Time Simulation RT-LAB
Graphical User Interface Software
for test set up and simulation control running from Windows host PC.
RT-LAB TestDrive Interface
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RT-LAB TestDrive Software Packages
ECU Systems Engineers• Customizing panels• Setting-up automated tests• Tools:
– TestDrive GUI– LabVIEW– Python
Software and Test Engineers• Performing interactive tests• Customizing test cases• Executing test cases• Tools:
– TestDrive GUI– Python
Simulator Engineers• Configuring simulator• Customizing models• Very few of these engineers• Tools:
– RT-LAB– Matlab/Simulink/RTW
Number of Users
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Where Does RT-LAB TestDrive Fit …
Design Specification & Requirements Definition
Plant Simulation
Controller Algorithm Development
Coding andUnit Testing
System Validation
Integration Testing
Functional Checkout
in the design process (TestDrive vs. Full Scale Dynamic HIL Simulators)
Signal Mapping andPower Moding Module
Power Supply
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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
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Uses of TestDrive at DelphiEurope
US
Program 1
Program 2
Simulator Team
India
Compiled modelTemplate GUI panelsTemplate scripts
Program specificpanels and scripts
Program specific panels and scripts shared within the team
TestDrive is now used by several companies and is being evaluated by DENSO
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Fully Programmable Powertrain Fully Programmable Powertrain and Vehicle Simulation for and Vehicle Simulation for ECU-in-the-Loop TestingECU-in-the-Loop Testing
© 2005 Opal-RT Technologies Inc
• 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