ecu-testing.pdf

ECU Testing

ECU Testing with dSPACE dSPACE Simulator Simulator Cutting-edge systems for ECU/controller testing

Original equipment manufacturers manufacturers (OEMs) today face pressures on multiple fronts. The time to market is shrinking while the content and complexity of the vehicle electronics is rapidly increasing. Almost every automotive innovation effects the electronics in the vehicle. Test drives in test vehicles can scarcely cope with the volume of systematic testing needed, especially close to start of production. The growing number of recalls is a clear indication of this. It i s little wonder that testing and error finding have become key tasks in the development process. Systematic and Reproducible Reproducible Testing in Hardware-in-the-loop (HIL) simulation is a viable alternative, allowing new electronic control units (ECUs) and software to be tested largely in a virtual environment, without real vehicles or prototypes. Such tests are very systematic and also completely safe, even when critical thresholds are exceeded, while allowing ECU errors to be reproduced whenever and however required.

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74 2005

Catalog 2005 • dSPACE • Technologiepark 25 • 33100 Paderborn • Germany • [email protected] • www.dspace.de

dSPACE Simulator Introduction

Improving ECU Software Quality HIL simulation improves quality even at an early stage. A major Japanese automobile manufacturer states that HIL simulation finds 90% of ECU errors, and almost all the errors that it is possible to find before the calibration phase. Recall campaigns and associated damage to the company’s image are minimized. The investments made in HIL systems and in developing tests have usually paid off after only a few months. Just a few of the reasons:  Hardware-in-the-loo p simulation avoids recall campaigns and loss of corporate image  Fewer prototypes, fewer test drives, lower costs  More comprehensive comprehensive and more systematic tests tests in a shorter time  Higher quality, lower risks  Start of production production on schedule using using fewer resources

Key Ke y Fe Feat atur ures es of dS dSP PAC ACE E Si Simu mula lato torr

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State-of-the-art modeling and maximum compatibility with existing models or third-party models

integration into the dSPACE tool chain

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Maximum reusability reusability of models, test scripts, layouts and knowledge

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Solution-oriented products products and powerful test automation

 Savings

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Easy access to the real-time model, states and parameters, even during run time Fast, graphical programming via drag & drop

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Full integration of MATLAB/Simulink, MATLAB/Simulink, the world‘s leading design and modeling tool

You ourr Ben Benefi efits ts

 Full

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 Product

maturity as the world’s most used HIL simulator: 1,100 in operation worldwide  Best options for networking and expandability

in time and money  Greatly improved software quality  Homogeneous and efficient user interfaces  Steep learning curves  Fast iterations  Competitive advantage  dSPACE‘s

extensive experience in the fields of hardware-in-the-loop hardware-in-the-loop simulation and test automation

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75 Catalog 2005 • dSPACE • Technologiepark 25 • 33100 Paderborn • Germany • [email protected] • www.dspace.de

2005

ECU Testing

Test Scenarios with dSPACE Simulator The complexity and multilayered architecture of modern ECU software means that the same ECU has to be tested from all perspectives. dSPACE Simulator covers every conceivable test scenario. dSPACE Simulator is not only used in the classical domains of engine, powertrain, and chassis. The system’s flexibility allows virtually any adaptation: cruise control, body electronics, and especially ECU network tests.

Transmission  Continuously variable transmission  Automatic transmission  Automated manual transmission  Double-clutch transmission

Diesel  4-12 cylinders  Turbocharger  Common rail unit injection  Passenger car and heavy-duty trucks

Otto  4-16 cylinders  Manifold injection  Direct injection  Turbocharger

Vehicle Dynamics  Bosch ESP 5.3, 5.7, 8.0  ContiTeves ESP  TRM ESP

Vehicle Types  From passenger cars to light and heavy-duty trucks to Formula One Others  Body electronics  Comfort  Air-conditioning control systems

Verifying Control Algorithms The ECUs are tested against the specification in normal operation. This is done by running virtual test runs simulating all the necessary vehicle and component variants, either manually or in automated form. Slalom tests and lane change maneuvers for vehicle dynamics control units and standard drive cycles, such as FTP75 for testing engine controls, are examples of this. dSPACE Simulator offers you a perfect environment for such tests. The ECU’s diagnostics functions are tested under closed-loop conditions, for example, you have to check the plausibility of safety-critical sensors such as steering wheel sensors and yaw rate sensors. Sensor failures (for example, a wheel speed sensor failure at high speed and during control operation) and CAN bus failures can also be simulated, and the new controller has to react to them correctly. ECU Calibration This can be carried out at a very early stage by means of modern simulators. This is important because the fast-growing number of ECU parameters and their mutual effects are making it more and more difficult to get the final vehicle right. Using realistic vehicle models, it is possible to carry out or even automate the adaptation of ECUs, which can later reduce the cost involved in the calibration process.

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Integration Tests on ECU Networks The main concern is to test problem-free interaction of all the ECUs that are communicating, e.g., via CAN and LIN. Network tests have become necessary mainly because of the growing number of ECUs from different manufacturers that perform their overall function only when networked. ECU Network Tests In an ECU network test with dSPACE Simulator, ECUs that are not yet available can be simulated and replaced by their real counterparts later on (restbus simulation). Depending on the application, you will have to test networked ECUs (for example, ECUs in powertrain or body electronics systems which together provide superior functionality). Because dSPACE Simulator is so flexible, it can easily have several ECUs connected to it.  

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Networked ECUs can be tested using a single simulator ...

In other cases, it is desirable to first test each ECU separately with different dSPACE Simulators. After successful tests, it is no problem to connect the dSPACE Simulators, in order to work with a networked simulator setup. The modularity of dSPACE Simulator makes virtually all test scenarios possible. For example, you can run all the simulators in a network or separately as single simulators. Missing ECUs can even be replaced by simulation models, without rebuilding any code.  

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... or a simulator network. ECUs that are not yet available can be simulated (software ECUs) and gradually replaced by their real counterparts (restbus simulation). All simulators can be operated from a single PC.

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2005

ECU Testing

Testing Diagnostic Functions To test diagnostic functions (e.g., OBDII and EOBD), the ECU behavior when faults occur is tested. The vehicle is simulated in a closed-loop environment and systematically drives through all the defined operating points. This allows the diagnostics to be tested systematically. Typical diagnostic tests relate to the plausibility of signals or defective electrical connections. It is important for diagnostic tests to be run completely automatically, as release tests often have to be performed within an extremely short time. dSPACE Simulator flexibly creates different scenarios for different ECUs, allowing a great diversity of versions to be handled. In the near future, AutomationDesk (p. 140) offers a powerful and convenient test automation environment to make systematic testing even more efficient.

The Benefits of dSPACE Simulator dSPACE – A Competent HIL Partner dSPACE is your partner in selecting the right system and installing and configuring your dSPACE Simulator.  Delivery on schedule (approx. 3 months for a single Simulator Full-Size, approx. 6 months for simulator networks for over 30 ECUs)  Professional project management and fast commissioning Our offices can help you get the most out of your dSPACE Simulator by offering additional services such as training sessions and on-site support. Technical Lead dSPACE Simulator is the world’s leading system for the systematic testing of electronics and software. There are currently more than 1,100 simulators with dSPACE technology in use worldwide, nearly all of them at major automotive companies such as Audi, BMW, DaimlerChrysler, DENSO, Ford, Magneti Marelli, Nissan, Opel, Renault, Toyota, Volkswagen and several Formula One teams. 

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Broad range of experience: diesel, spark ignition and direct injection engines, transmission, vehicle dynamics, and vehicle interior systems Support of networked ECUs (example: 36 ECUs, more than 7,000 signals on 4 CAN busses and 10 LIN busses, plus 2,000 further I/O signals) and even the complete vehicle electronics system Battery network management (sleep, wake-up) tested by precise measurement of sleep-mode current and operation current from 1 µA to over 100 A Exemplary hardware and software tools for error-finding and test automation Applications: cars, light and heavy-duty trucks, racing (Formula One, rally), aerospace

dSPACE Simulator offers everything you need to perform your tests: Tight integration of dSPACE software and the modeling tool MATLAB/Simulink from The MathWorks provides a powerful development environment. And the powerful and robust dSPACE hardware always sets the standards for HIL technology.

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Test Efficiency dSPACE Simulator’s graphical user interfaces provide a convenient and flexible environment. Simulated driving cycles, data acquisition, instrumentation, monitoring, test automation and all other tasks are executed graphically within dSPACE Simulator. dSPACE software gives you the greatest possible test efficiency and ease of use. Signal Generation and Measurement These are just a few of the automotive signals that can be generated and measured by dSPACE Simulator  Algorithm- and waveform-based signal generation (e.g., crankshaft, camshaft, knocking signals)  Generation of PWM sensor signals and Hall sensor signals (e.g., wheel speed, fuel level)  Generation of resistance-based sensor signals (e.g., temperature)  Generation and measurement of analog and digital sensor signals (e.g., throttle, switches, lamps, relays)  Simulation of linear lambda probes  Angle-based measurement of injection and ignition pulses  Measurement of PWM actuator signals (e.g., solenoid valves)  Connection to CAN, LIN, FlexRay and serial interfaces Example: Compensation of potential gradients caused by...  Cable resistance  The ECU’s varying power consumption in different operating conditions ...and our solutions in dSPACE Simulator:  Differential analog inputs and outputs  Potential-free resistance outputs  Output transformers for all fast analog outputs

dSPACE Simulator Components For details on dSPACE Simulator’s modular concept, please see the following pages.

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ECU Testing

Implementation Software The code for dSPACE Simulator‘s real-time hardware is generated automatically, directly from MATLAB/Simulink. Your MATLAB/Simulink model is connected to the real-time hardware via drag & drop. Powerful software tools are available for this:  Real-Time Interface for implementing Simulink and Stateflow models on dSPACE Simulator  Optional extensions to Real-Time Interface Real-Time Interface (RTI) dSPACE‘s Real-Time Interface completely integrates MATLAB/Simulink and offers additional blocks to connect models and our I/O hardware. For example, there are comprehensive libraries for the DS2211 HIL I/O Board, our most powerful I/O board for HIL applications. RTI’s graphical user interface reduces the work involved in supplementary model changes and I/O adjustments to a minimum.  Real-Time Interface (p. 108)

Graphical programming and connection to I/O, CAN bus or LIN bus: everything is done graphically in Simulink with our Real-Time Interface.

Configuring CAN and LIN Bus Communication Configuring your CAN bus communication graphically from Simulink is no problem with the additional RTI CAN Blockset. With our new RTI CAN MultiMessage Blockset, you can configure and control a large number of CAN messages (more than 200) from one single Simulink block. To simulate communication in a LIN network, we also provide the RTI LIN Blockset for effortless configuration of LIN master and slave nodes simulated on the DS4330 LIN Interface Board.  Real-Time Interface CAN Blockset (p. 116)  Real-Time Interface CAN MultiMessage Blockset (p. 118)  Real-Time Interface LIN Blockset (p. 120)

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dSPACE Simulator Software

Experiment Software: ControlDesk for Experiment Management dSPACE Simulator gives you complete control of your experiments. ControlDesk is a graphical front-end tool that forms the interactive experiment and visualization interface of dSPACE Simulator.  Graphical user interface for experiment and platform management  Generation of virtual instrument panels  Preconfigured layouts for HIL applications  Design of user-specific layouts

ControlDesk offers powerful analysis tools, such as instruments to set up virtual instrument panels.

With the integrated experiment and test environment and ControlDesk’s Simulink interface, you can monitor your experiments in Simulink and later in real-time simulation, using the same tools and the same user interfaces.  ControlDesk (p. 128)

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ECU Testing

Experiment Software: ControlDesk Failure Simulation Using ControlDesk Failure Simulation, you can simulate failures in the wiring of an electronic control unit (ECU). For example, you can simulate that an ECU pin is short-circuited to ground or the battery voltage, or that an ECU pin is not connected (cable break).  Extension of ControlDesk Standard  Remote control of the failure insertion unit in dSPACE Simulator Mid-Size or Full-Size  Import of ECU pin description files Central Failure Management ControlDesk Failure Simulation is software for driving the electrical failure simulation in the ECU cable harness. The failure simulation hardware, failure patterns, and ECU signal channels are all handled centrally via software. Electrical failures are also activated and deactivated centrally. When networked ECUs are tested, each ECU is displayed separately with its signal channels. ControlDesk Failure Simulation runs on existing dSPACE Simulators Mid-Size (p. 88) and Full-Size (p. 90). It also works hand in hand with AutomationDesk, our test automation software (p. 140). Handling Failure Simulation Hardware The Failure Simulation Navigator provides access to the failure simulation system:  Access to all connected ECU signal channels enabled for electrical failure simulation  Administration of failure patterns (failures to be simulated at the same time) Handling Failure Patterns The Failure Pattern window visualizes failure patterns and the status of the failure simulation hardware, and allows the failure patterns to be edited and saved.  ControlDesk Failure Simulation (p. 139) The Failure Simulation Navigator in ControlDesk Failure Simulation: Central handling of failure simulation hardware, failure patterns and all ECU channels.

Failure Pattern window: Every failure pattern is shown in a layout.

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dSPACE Simulator Software

Test Software: AutomationDesk AutomationDesk facilitates the task of developing and managing tests.  Automated testing in HIL simulation  Graphical user interface for managing test projects  Graphical editor for describing automation sequences AutomationDesk is ideal for automating hardware-in-the-loop tests. AutomationDesk offers a convenient test automation environment, which supports the development and handling of large test projects and test sequences. With AutomationDesk, the systematic structure, reusability, and reproducibility of test sequences are unequalled.  AutomationDesk (p. 140)

Typical Automation Tasks – Executed with AutomationDesk Setting up operating point

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Measurement

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Evaluation and test reporting

Data management

ECU initialization (e.g., failure memory reset) and simulator environment Stimulus signal generation (to switch short circuit failures or to input reference trajectories) Access to real-time variables during run time Access to ECU internal variables via diagnostic or calibration interfaces Data capturing of simulator variables

 Access

to MATLAB’s mathematical test validation capabilities or direct calculations in Python  Automated report generation based on XML with standard style sheets for HTML and PDF  Organization and storage of test sequences, parameter sets, measurement data and test reports

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2005

ECU Testing

Experiment Software: 3-D Online Animation with MotionDesk MotionDesk provides 3-D animation of mechanical systems in a virtual world.  3-D online animation of HIL simulation in real time  Graphical user interface similar to other dSPACE tools  Graphical interactive scene design  Scalable number of MotionDesk PCs for multichannel visualization, e.g., for interactive test drives  Time-stamping and AVI file generation  Simulation comparison: for example, transparent or „shadow” vehicles

Full-brake simulation or braking on different surfaces: MotionDesk makes the car’s behavior visible.

In vehicle dynamics simulation, maneuvers and critical behaviors are particularly hard to detect by conventional methods such as time histories and display instruments. A much better impression of what is happening with the vehicle is given by 3-D online animation. MotionDesk performs such 3-D animation for all objects simulated on dSPACE Simulator in real time. With MotionDesk, the results of any action in the simulation that is running become visible on your PC immediately.  MotionDesk (p. 154)

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dSPACE Simulator Hardware

dSPACE Simulator Hardware Concepts – Different Systems for Different Tasks The hardware requirements might vary immensely depending on your hardware-inthe-loop application. For example, function tests are executed with simulators that have a clear set of I/O. In contrast, acceptance tests call for modular, expandable simulator hardware that allows I/O and processing power to be scalable. dSPACE Simulator therefore comes in different hardware types, which are the basis for expansion to your specific task. dSPACE Simulator Mid-Size dSPACE Simulator Mid-Size is a standardized, off-the-shelf HIL simulator. Its hardware is based on two boards from our modular hardware, a processor board and the DS2211 HIL I/O Board. Other I/O boards can be added if required.  dSPACE Simulator Mid-Size (p. 88)

dSPACE Simulator Types: Mid-Size and Full-Size

dSPACE Simulator Full-Size dSPACE Simulator Full-Size is a modular simulator concept that is assembled with off-the-shelf components according to your needs. This results in high quality at attractive prices. dSPACE Simulator Full-Size gives you a high-quality, tailored system with enormous extension capabilities. If you need to expand or modify your simulator, dSPACE has a wide variety of components that can be integrated into your dSPACE Simulator Full-Size.  dSPACE Simulator Full-Size (p. 90) Simulator Networks Several dSPACE Simulators (of any hardware type) can be connected to set up a networked simulator environment (p. 77).

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ECU Testing

Hardware Summary

Form factor

dSPACE Simulator Mid-Size (p. 88)

dSPACE Simulator Full-Size (p. 90)

 19“

 19“

desktop rack

cabinet 17 – 37 HU modules

 Vertical

Processor hardware I/O hardware

 DS1005

PPC Board or Processor Board

 DS1005

 DS1006  DS2211

HIL I/O Board

 Any

 DS1006

PPC Board or Processor Board

number and type of dSPACE I/O boards

Further I/O hardware

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Signal conditioning

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Substitute loads

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Real-load connector

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Failure insertion unit

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Integration of simulatorspecific hardware (p. 74)

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Integration of third-party hardware, e.g., load panels

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ECU connectors

 Three

90-pin connectors  Additional connectors for additional I/O optional

Break-out box OBDII diagnostic connector / connection to diagnostic tools

 One

or more 90-pin connectors for each ECU (standardized)  Additional connectors optional

  Sub-D

connector with optional CARB adapter  CAN connector

  Standard

16-pin CARB connector  Diagnostic connectors (CAN, K-line)  Others on request

Truck applications-capable (24 V/36 V)

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42 V-capable

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Power supply (remote controlled)

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Included Available on demand

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dSPACE Simulator Hardware

Failure Simulation Summary Failure simulation can be performed with both dSPACE Simulator Mid-Size and dSPACE Simulator Full-Size. Powerful failure simulation hardware further boosts their functionality. dSPACE Simulator Mid-Size

Standard

Hardware Extension

Failure insertion units

 5

x DS749 FIU Module (each features 10 channels)  Optional: replaced with 5 x DS792 Fuse Cards

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Possible failure types

On ECU outputs:  Cable break  Short circuit to ground  Short circuit to battery voltage  Short circuit to another ECU pin via two fail planes

On ECU inputs:  Cable break (open line)  Short circuit to ground  Short circuit to battery voltage  Short circuit to another ECU pin via two fail planes

x DS793/DS794 Sensor FIU Cards (up to 2 cards, each 81 channels with CMOS switches)

dSPACE Simulator Full-Size

Failure Simulation Variant 1 Failure Simulation Variant 2


 n

x DS291 FIU Module (each features 10 channels)  n x DS281 Load Module

 1

Possible failure types

On ECU inputs and outputs:·  Open circuit  Short circuit to ground or minus pole of the battery (KL31) with connected/ disconnected load (an ECU input is disconnected from a dSPACE output channel)  Short circuit to plus pole of the battery (KL30) with connected/disconnected load (an ECU input is disconnected from a dSPACE output channel)  Short circuit to another ECU pin with or without load (via common rail)

On ECU inputs and outputs:  Open circuit with or without additional hardware (Rsim, MEAS or SOURCE) in series  Short circuit to another ECU pin directly or via additional hardware  Short circuit to 5 reference points (potential 0…4) directly or via additional hardware

x DS293 Central FIU Module  n x DS282 Load Module (10 channels)  1 x DS289 Rsim Module (simulates a resistance in the range 1 Ω ...131 kΩ in steps of 1 Ω )

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ECU Testing

dSPACE Simulator Mid-Size: Hardware Details The hardware of dSPACE Simulator Mid-Size is mounted in a 19” desktop rack (height: 6 – 9 HU). The simulation model runs on the processor board. dSPACE Simulator Mid-Size generates and measures I/O signals via the DS2211 HIL I/O Board, which also performs the signal conditioning. Additional I/O and signal conditioning can be added on request.  Hardware summary (p. 86)

Failure insertion units, load cards, external connection of real loads

ECU connectors

Spare slot

OBDII connector via adapter

Modular hardware: processor board and I/O board with signal conditioning

Remote-controlled power supply (battery simulation) Connection to Host PC All dSPACE software (p. 106) for experiment setup and control runs on your PC or notebook. The dSPACE Simulator hardware is connected to your PC via link boards (ISA, PCMCIA, or PCI, p. 322). Typical Fields of Application  Engine, transmission and vehicle dynamics HIL  Realistic software system tests/unit tests  Function integration tests  Open-loop or closed-loop environment  Automated testing of diagnostic functions that check the ECU outputs Hardware Components  Installation in 19” desktop rack (see table)  Integrated signal conditioning for all DS2211 signals Enclosure Variants dSPACE Simulator Mid-Size

Standard variant, Small variant, 2-voltage system optional 1-voltage system

DS1005 PPC Board or DS1006 Processor Board DS2211 HIL I/O Board

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Load cards

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

Power supply

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Second power supply

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−

Free ISA slots for expansion

Height units  

 1

(PX5 version, only for DS1005 PPC Board)  5 (PX10 version) 9

 1

(PX5 version, only for DS1005 PPC Board) 6

Included Optional

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dSPACE Simulator Mid-Size

Signal Conditioning  On-board for DS2211 HIL I/O Board signals  Two spare slots for additional signal conditioning (e.g., current measurement for diesel and stratified injection applications, lambda probe simulation or signal conditioning for additional I/O boards) Failure Insertion Units A standard dSPACE Simulator Mid-Size supports electrical failure simulation on all ECU output pins connected to the DS2211. A hardware extension allows electrical failures to be simulated on ECU inputs as well. The host PC controls both types of failure simulation via an RS232 interface. See p. 67 for further information.  ECU outputs: Five failure insertion units (FIUs) with 10 channels, connected to all 50 actuator channels; Optional: replaced with 5 x DS792 Fuse Cards  ECU inputs: optional, via hardware extension (p. 67)  Remote-controlled with ControlDesk Failure Simulation and (on request) automated with AutomationDesk  Simulation of shorts: shorts from ECU pins to ground or battery voltage  Cable break simulation (open wire)  Simulation of cross-wired short circuits via two fail planes  Simultaneous activation of multiple failures (latch mode) Load Capabilities  Five load cards, 10 single-ended loads or 5 double-ended loads each  2 W maximum continuous power per load (substitute loads)  8 A maximum load current per pin (real loads)  LED indicators displaying current load states (display mode selectable)  Front connector for measurement or connection of real loads VBat Jacks  Provides power voltage of both power supplies for external devices (e.g., external test or diagnostic devices)  4 mm sockets Power Supply  Programmable switched-mode power supplies (remote-controlled, 2 power supplies required for simulation of vehicle batteries in 2-voltage systems)  Support of 24-V systems with the first system  Support of 42-V systems with the second system  Three switched battery rails for each battery voltage, e.g., main relay, ECU-controlled high rail  16 A maximum current for each rail of first battery voltage  7.5 A maximum current for each rail of second battery voltage Other Hardware Components  Break-out box (optional) Expandability  Expansion with further DS2211 HIL I/O Boards (cascadable), ECU Interface or CAN Interface boards  Inclusion of real loads, additional, or customer-specific signal conditioning (e.g., current measurement for diesel or stratified injection applications) or signal conditioning for an additional I/O board  Customer-specific modifications/extensions possible

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ECU Testing

dSPACE Simulator Full-Size: Hardware Details dSPACE Simulator Full-Size is mounted in a 19” cabinet whose height depends on your requirements. The dSPACE boards are mounted in a standard PX20 Expansion Box (p. 321). The PX20 Expansion Box provides 20 ISA slots for dSPACE boards, and an additional Expansion Box can be integrated, so you never face restrictions on expandability. Open Hardware Concept The simulation model runs on the processor hardware (single-processor or multiprocessor systems, based on processor boards). dSPACE Simulator generates and measures I/O signals via the integrated dSPACE I/O boards. The signal conditioning, loads, failure insertion units and power supply are also mounted in the 19” cabinet. The number of components, and their types, depend on your requirements and are configured to fit your application.

Additional connectors (e.g., CARB, OBD)

Break-out box

ECU connector

Power supply Connector for external loads Loads and failure simulation (remote-controlled)

Signal conditioning

Modular hardware: processor boards and I/O boards Connection to Host PC All dSPACE software for setting up and controlling experiments runs on your PC or notebook. The dSPACE Simulator hardware is connected to your PC via Link Boards (ISA, PCMCIA, or PCI, p. 322).

90 2005


dSPACE Simulator Full-Size

Typical Fields of Application  Engine, powertrain, and vehicle dynamics HIL  Comprehensive closed-loop tests on ECUs, release/acceptance tests  Networked ECUs  Special requirements, e.g., with high system flexibility  Truck applications  Racing applications (Formula One, rally) Hardware Components  Installation in 19” cabinet  Single-processor or multiprocessor systems, based on processor boards  PX20 Expansion Box for modular dSPACE hardware  Freely expandable by any dSPACE I/O board (see Modular Hardware, p. 224), according to your requirements  Expandable, e.g., with hardware for signal conditioning, failure insertion and load simulation Signal Conditioning  Signal conditioning for all dSPACE I/O boards  Modular signal conditioning concept (off-the-shelf components, customer-specific configuration)  Supports almost any signal type: e.g., digital in, digital out, analog in, analog out, relay simulation, current sink/source, LVDT simulation, resistance simulation  Further modules on demand Failure Insertion Units  Failure insertion unit (FIU) for ECU inputs and outputs  Modular FIU concept (customer-specific configuration)  Remote-controlled with ControlDesk Failure Simulation (and optionally with AutomationDesk)  Simulation of shorts: shorts from ECU pins to ground, battery voltage, or switched rail  Cable break simulation (open wire)  Simulation of cross-wired short circuits  Simultaneous activation of multiple failures (latch mode) Failure Simulation Variant 1 Our standard variant for failure simulation on dSPACE Simulator Full-Size supports failure simulation on all ECU input and output pins. All digital and analog I/O boards from dSPACE are supported by failure simulation. The relay boards (DS291) for failure simulation can be used on their own or in conjunction with load boards (DS281). Failure relays are controlled via a serial RS232.  Failure Simulation Variant 1 (p. 87) Failure Simulation Variant 2 Our second failure simulation variant uses a central relay switching matrix (DS293) for failure simulation on ECU inputs and outputs. Signal channels can be switched in on three different rails via load modules (DS282). Further devices that can be connected include 5 different system potentials (for example, KL30, KL31, KL15), various measurement devices, and Rsim modules (DS289 for simulating real substitute loads). See p. 87 for further information. Failure simulation is controlled via a CAN interface.  Failure Simulation Variant 2 (p. 87)




2005

ECU Testing

Load Capabilities  Modular load concept (customer-specific configuration)  Support of single-ended and double-ended loads  Resistive loads or other kinds of equivalent loads  Connection of electrically equivalent loads or low-power resistive loads  Connection of real loads, can be integrated in the cabinet  Integration of customers‘ load panels Power Supply  Simulation of car battery  Programmable switched-mode power supply  Remote-controlled  42 V and truck-capable: 0 … 50 V voltage range Other Hardware Components  Break-out box (optional, integrated in cabinet or external)  Optional inclusion of third-party hardware; e.g., load panels, signal routing units, GPIB instruments  Power switch modules (p. 94) Expandability  Maximum flexibility through modular concept  Minimum hardware modification when requirements change  Supersets with spare signals, allowing tests on several ECU variants, even after ECU pinout changes  All signals accessible on terminal strips for additional measurement tasks  Clear and transparent system architecture  Multirack systems possible

92 2005


Simulator-Specific Hardware

Simulator-Specific Hardware If you need to expand or modify your simulator, dSPACE has a wide variety of off-the shelf components that can be integrated into your dSPACE Simulator. dSPACE Simulator Full-Size can be equipped with simulator-specific hardware for optimum tailoring to your specific needs. dSPACE Simulator Mid-Size can also be similarly equipped to a certain extent. The simulator-specific hardware includes real system components and signal conditioning, as well as measurement and diagnostic tools. The components and tools can be built and integrated by dSPACE, third-party suppliers, or you yourself. The setup shown in the illustration is typical of many application areas, and you can also add or remove as many components as you like.

            

   

 

   

  

 

 






2005

ECU Testing

Examples of Simulator-Specific Hardware Interface to Diagnostic and Calibration Hardware Many companies already have their own diagnostic and calibration hardware to perform tasks such as reading out internal ECU variables from the failure memory. If you do not intend to run this functionality on dSPACE Simulator, the hardware is connected to dSPACE Simulator via appropriate interfaces, which might in some cases need a little engineering. You can connect any kind of measuring device, digital scope, and diagnostic device you like with special protocols such as GPIB or RS232. Real System Components In some cases, the real system components (such as injection valves, hydraulic components, and sensors) have to be integrated into dSPACE Simulator. This is necessary, for example, if ECUs and related components come from different suppliers and have to be checked within the simulated environment. Moreover, not every vehicle component can be simulated with a justifiable amount of time and money, and many ECUs require real loads at their outputs in order to function at all. Break-Out Boxes An optional break-out box makes all ECU pins directly accessible. This simplifies the measurement and input of signals. The break-out boxes can be i ntegrated into dSPACE Simulator, or take the form of external desktop boxes. Third-party break-out adapters can also be included (available for dSPACE Simulator Mid-Size and Full-Size). Relay and Failure Insertion Units Any number and type of open circuits and short circuits can be simulated by using relay and failure boxes. Besides our failure insertion unit, it is also possible to integrate customer-specific and third-party solutions. Programmable Power Supply The programmable power unit supplies the components to be tested and enables the simulation of real voltages such as the battery voltage of a vehicle during start-up. The power supply unit is remote-controlled from within the real-time model. Power Switch Module ECUs consume power even when the vehicle is parked. Many modern ECUs have a sleep mode to avoid draining the vehicle’s electrical system unnecessarily. Some ECUs therefore contain a CAN transceiver capable of sleep mode, which allows the ECU to run only if it is needed and switches it off otherwise. Power switch modules provide network management for such systems to be tested, e.g., with sleep mode and wake-up functions. Moreover, systems with networked ECUs often require different power supply vol tage levels. Each power switch module therefore handles two power supplies to simulate different vehicle electrical systems within dSPACE Simulator. Even the sequence when a vehicle is starting up can be simulated. A measurement unit allows the precise current measurement of each ECU in different current ranges, even in the microampere range. For example, current consumption during ECU sleep mode can be compared with normal operation mode behavior. The module is controlled by software via a CAN interface.

94 2005


Simulator-Specific Hardware

Signal Conditioning Real components usually cannot be connected directly to the real-time hardware. The signal level of the ECU and other connected components must first be adapted to the I/O interfaces of the real-time hardware. The signal conditioning necessary for adaptation is an important part of dSPACE Simulator and includes protection circuits, signal preparation, etc., in addition to level adaptations. CAN Gateway In large-scale CAN networks, the testing of bus communication plays a key role. Engineers need to test the behavior of ECUs and distributed functions when an expected CAN message fails to arrive or contains unexpected signals. To simulate errors, a CAN gateway is inserted into the CAN network (see graphic). Each ECU can be connected individually to one of the two CAN controllers. Signal manipulation by software allows you to manipulate any CAN messages from any ECU, with a predefined effect on the other ECUs in the CAN network. The CAN software (RTI CAN MultiMessage Blockset) generates error situations right up to message or individual signal level.

    

 







   

 



   

 

 

   CAN gateway for simulating errors in large ECU networks. Simulation of Linear Lambda Probes LSU is a new signal conditioning module for dSPACE Simulator Full-Size and Mid-Size that simulates the behavior of linear lambda probes. These probes measure the air-fuel ratio in a car‘s catalytic converter. The engine ECU reacts continuously to this information so that the catalytic converter can operate at an optimal performance rate. The LSU module allows Nernst cell voltage to be generated on two independent channels, according to pump current and Nernst cell inner resistance. The module functions as a linear probe or as a jump probe. Parameters such as maximum/ minimum Nernst cell voltage can be adjusted.

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2005

ECU Testing

Real-Time Models for dSPACE Simulator Models from MATLAB/Simulink/Stateflow For hardware-in-the-loop simulation, you need real-time models to simulate the real environment. dSPACE Simulator is optimally equipped for integrating simulation models from MATLAB/Simulink/Stateflow. Thanks to years of cooperation between The MathWorks and dSPACE, the tools from these two companies are perfectly tailored to each other. This way, you can can use your own real-time models – or third-party models. For example, our partner TESIS DYNAware, Munich, Germany, offers Simulink-based simulation models for HIL simulators that really make your dSPACE Simulator come alive.

Model-Based Development After you develop your simulation model, you can test it with Simulink and ControlDesk‘s Simulink interface and then in real time on dSPACE Simulator – with the same layouts, test scripts and parameter sets. Services for Real-Time Models Based on years of know-how in hardware-in-the-loop simulation, dSPACE also offers modeling services such as  Integration of models into dSPACE Simulator  Parameterization of models based on customer data  Model interfaces  Integration of different modeling tools (Dymola, AmeSim, C-Code, others)  Adaptation of customer models

96 2005


Configuration Examples

Configuration Example: dSPACE Simulator for Testing Single ECUs dSPACE Simulator Mid-Size is the perfect choice for testing single ECUs or for test projects with fixed ECU wiring.   





  

        

        



 





      



    

 

Possible ECU Testing Tasks for This Configuration  Functional tests for single ECUs  Integration tests for single ECUs  Acceptance tests for single ECUs  Release tests for single ECUs  Virtual vehicles (when networked with other dSPACE Simulators) Possible Test Areas for This Configuration  Gasoline engine  Diesel engine  Transmission  Vehicle dynamics  Climate control  Comfort functions  12 … 42 V applications Components (Example) Third-Party Components

Further Details

PC

−

Modeling software

 MATLAB

/ Simulink / Stateflow from The MathWorks

p. 35

Real-time model

 Real-time

models for dSPACE Simulator

p. 96

Real-time code generation



Real-Time Workshop

p. 36

Software Components Implementation software

Further Details 

Real-Time Interface

 PowerPC

Experiment software

compiler

p. 108 p. 127

 ControlDesk

p. 128

ControlDesk Failure Simulation  AutomationDesk

p. 139



p. 140

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2005

ECU Testing

Hardware Components Modular hardware

Off-the-shelf hardware

Further Details Processor Board:  DS1005 PPC Board

p. 230

I/O boards:  DS2211 HIL I/O Board

p. 254

 Failure

p. 87

 Load

insertion units

boards

p. 87

or two power supplies (two for 2-voltage system simulation)

p. 94

 One

 Others

−

Configuration Example: dSPACE Simulator for Testing Networked ECUs dSPACE Simulator Full-Size is perfect for projects with higher I/O requirements. The hardware is expandable and flexible, and can be quickly adapted, for example, for system tests with changing ECU wiring.   



 



                      

              

Possible ECU Testing Tasks for This Configuration  Function tests for single or networked ECUs  Integration tests for single or networked ECUs  Acceptance tests for single or networked ECUs  Release tests for single or networked ECUs  Virtual vehicles with greatest possible flexibility Possible Test Areas for this Configuration  Gasoline engine  Diesel engine  Transmission  Vehicle dynamics  Climate control  Comfort function  Tests with high currents  12 … 42 V applications  Power consumption test (airport test)  Very complex real-time models (multiprocessing or networked simulators)

98 2005


ecu-testing.pdf

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