id 020c: hardware-in-loop: system testing without the system marcella haghgooie sr. field...
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ID 020C: Hardware-in-Loop: System Testing Without the System
Marcella Haghgooie
Sr. Field Applications Engineer
Version: 1.2
Applied Dynamics International
13 October 2010
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Marcella HaghgooieSr. 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
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Renesas Technology and Solution Portfolio
Microcontrollers& Microprocessors
#1 Market shareworldwide *
Analog andPower Devices#1 Market share
in low-voltageMOSFET**
Solutionsfor
Innovation
Solutionsfor
InnovationASIC, ASSP& Memory
Advanced and proven technologies
* 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).
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Renesas Technology and Solution Portfolio
Microcontrollers& Microprocessors
#1 Market shareworldwide *
Analog andPower Devices#1 Market share
in low-voltageMOSFET**
ASIC, ASSP& Memory
Advanced and proven technologies
* 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).
Solutionsfor
Innovation
Solutionsfor
Innovation
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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
Up to 500 DMIPS, 150 & 90nm process 600uA/MHz, 1.5 uA standby Medical, Automotive & Industrial
Legacy Cores Next-generation migration to RX
High Performance CPU, FPU, DSC
Embedded Security
Up to 10 DMIPS, 130nm process350 uA/MHz, 1uA standbyCapacitive touch
Up to 25 DMIPS, 150nm process190 uA/MHz, 0.3uA standbyApplication-specific integration
Up to 25 DMIPS, 180, 90nm process 1mA/MHz, 100uA standby Crypto engine, Hardware security
Up to 165 DMIPS, 90nm process 500uA/MHz, 2.5 uA standby Ethernet, CAN, USB, Motor Control, TFT Display
High Performance CPU, Low Power
Ultra Low PowerGeneral Purpose
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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
Up to 500 DMIPS, 150 & 90nm process 600uA/MHz, 1.5 uA standby Medical, Automotive & Industrial
Legacy Cores Next-generation migration to RX
High Performance CPU, FPU, DSC
Embedded Security
Up to 10 DMIPS, 130nm process350 uA/MHz, 1uA standbyCapacitive touch
Up to 25 DMIPS, 150nm process190 uA/MHz, 0.3uA standbyApplication-specific integration
Up to 25 DMIPS, 180, 90nm process 1mA/MHz, 100uA standby Crypto engine, Hardware security
Up to 165 DMIPS, 90nm process 500uA/MHz, 2.5 uA standby Ethernet, CAN, USB, Motor Control, TFT Display
High Performance CPU, Low Power
Ultra Low PowerGeneral Purpose
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Innovation
Embedded Control Systems need Hardware-in-Loop Simulation
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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
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Hardware-In-Loop with Renesas and ADI
Renesas provides the
MCU families to integrate
easily into your products
and your Hardware-In-
Loop (HIL) test facilities.
Applied Dynamics International (ADI) has over 50 years experience supplying tools for Hardware-In-Loop (HIL) Systems.
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The Need…
Renesas MCU ADI’s HIL Simulators
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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
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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
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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
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Real-time HIL Simulation Applications:Test and Rapid-Prototyping
Stimulate
Monitor Response
Open-loop Testing
Real-time Simulator
Stimulate
Monitor Response
Closed-loop Testing
Real-time Simulator
Stimulate
Monitor Response
Rapid Prototyping
Real-time Simulator
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System Test BenchSystem 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
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System Test BenchSystem 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
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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
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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 Model-based development.
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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
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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
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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
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100% Successful 1ST Missions
Standard Validation Platform
Fly Spacecraft on the Ground
Satellite Emulator
Boeing Satellite Development CenterBoeing Satellite Development Center
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Gulfstream AerospaceGulfstream Aerospace
75% Test Time Reduction
ITF and ARDL
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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).
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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
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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
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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
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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 crank-
based and time-based.
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I/O Considerations
ADI’s PCI-Engine is a specialized PCI solution providing engine signal emulation including the hall effect sensors
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Breakout PanelBreakout Panel
ADI Emul8 PCI-Engine ADI Emul8 PCI-Engine Installed Installed
in HIL Systemin HIL System
Simulink ModelSimulink Model
ECUECU
Engine Emulation
HIL Demonstration
Emulated Engine Closed-loop with ECUEmulated Engine Closed-loop with ECU
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HIL Demonstration
Real-Time Simulator
8-Cylinder
Simulink Engine Model
PC
I-E
ngin
eP
CI-
The
rm
8 spark measurement
8 fuel measurement
Thermistor emulation
Oxygen sensor
Manifold absolute pressure
Mass airflow
CAN throttle position sensor
Battery voltage power moding
Hall effect cam emulation
Hall effect crank emulation
Engine Controller
Breakout
Panel
rtX HIL SystemrtX HIL System
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ECU Testing with Emulated Engine
Open-LoopOpen-Loop
StimulateStimulate
MonitorMonitor
ECUECU
Closed-LoopClosed-Loop
Real-Time Real-Time Engine ModelEngine Model
ECUECU
Test:Test:• ECU control algorithm effectiveness ECU control algorithm effectiveness • Response time and control stability Response time and control stability • Adaptive capability of controllerAdaptive capability of controller
Test ECU’s recognition of an event and the Test ECU’s recognition of an event and the appropriateness of the ECU responseappropriateness of the ECU response
• Simple as a set of potentiometers and Simple as a set of potentiometers and switchesswitches
• ECU response is measured to determine ECU response is measured to determine that it is within tolerancethat it is within tolerance
• Multiple input events to ECU may be Multiple input events to ECU may be generated simultaneouslygenerated simultaneously
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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
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HIL Modular Simulation - PCI-Engine
PCI-Engine was integrated with the Renesas Controller and the SimuQuest Engine Model for HIL automated testing
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HIL Summary
Hardware-in-the-Loop SimulationModel-based development and testing of a single
subsystem
System IntegrationModel-based integration testing of stand-alone
functionality and subsystem interoperability
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Innovation
Embedded Control Systems need Hardware-in-Loop Simulation
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Questions?
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Feedback Form
Please fill out the feedback form! If you do not have one, please raise your hand
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Thank You!
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