© 2008 University of
Warwick
A Flexible and Reconfigurable A Flexible and Reconfigurable HardwareHardware--inin--thethe--loop Simulator for a loop Simulator for a Vehicle Vehicle ProgrammeProgramme at Jaguar & at Jaguar & LandRoverLandRover
Dr Suguna ThanagasundramDr Suguna ThanagasundramInternational Automotive Research International Automotive Research CentreCentreUniversity of WarwickUniversity of Warwick
2A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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IntroductionIntroduction
Research Fellow in the Electrical & Simulations group in the IARC
Peter Jones & Ross McMurran
Evolutionary Validation of Complex Systems (EVoCS)
VITAL (Virtual Integration and Test Automation Laboratory) at JLR (Whitley)
Alexandros Mouzakitis & team
3A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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Seminar OutlineSeminar Outline
Electronics in a vehicle
ECU
Hardware-in-Loop (HIL) platform
Limitations of this platform
Reconfigurable & Flexible HIL platform based on patented add2 Genix technology
4A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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Just about everything!
Electronics in a CarElectronics in a Car
5A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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FunctionGrowth
The vast majority of new technology looks like this:
Embedded control system usageEmbedded control system usageAdaptive Cruise Control
Electronic Towbar
2000 2010
PTC HeaterTelematics
Satellite Radio
ACC
Adaptive Headlamps
Blind Spot Detection
IVDC
Active steering
EM Valves
ISG
Remote Diagnostics
Keyless Vehicle
E-Connectivity
Brake-by-Wire
El. Water Pump
In Car PC
Fuel Cell
Rear Multi-media
Auto lights
SurroundSound
Voice Activation
Optical Buses
Auto wipers
Steer-by-Wire
Lane-keeping
CY1980
ABSInstruments
Body Elec.
Engine Control Transmission Control
1990
Airbag
SecurityAdv.
RestraintsESP EPAS
Adaptive suspension
Navigation
DSC
Traction Control
6A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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Typical automotive electrical architectureTypical automotive electrical architecture
DASHBOARD (GATEWAY)
DOOR CONTROL
ECUS
BODY CONTROL MODULE
ELECTRIC SEAT
CONTROL ECUS
CLIMATE
SYSTEM
DOOR MODULES
SEAT MODULES
KEYLESS VEHICLE
SYSTEM
PARKING AID
SYSTEM
TIRE PRESSURE MONITORING SYSTEM
HOOD CONTROL SYSTEM
BATTERY BACKED
SOUNDERADAPTIVE
CRUISE CONTROL
ELECTRONIC PARKING
BARKE
TRANSMISSION CONTROL SYSTEM
ENGINE MANAGEMENT
SYSTEM
DYNAMIC STABILITY CONTROL
GEAR SHIFT
SYSTEMRESTRAINTS
CONTROL SYSTEM
INFORMATION CONTROL MODULE
HUMAN MACHINE INTERFACE
PHONEBLUETOOTH RADAR RADIO
TELEMATICS
LOW SPEED CAN
LIN
ELECTRONIC BODY SYSTEMS
HIGH SPEED CAN
MOST
INFOTAINMENT
POWERTRAIN
- CAN TERMINATION
600-700 I/O pins
7A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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Electronic Control Unit (ECU) OverviewElectronic Control Unit (ECU) Overview
ECU is the generic term for automotive electronic control units
8A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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What is inside an ECUWhat is inside an ECU
Power Supply
ECU Data Network
Hardwired I/O (Sensors/ Actuators)
Connector
Hardware
Application Programming Interface
Application Software implementing controller algorithms and diagnostic
functions
ECU
Communication Interface
Base Software Functional Layer (Operating System, Communication…)
ECU
9A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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The Hardware Interface of an ECUThe Hardware Interface of an ECU
INPUTS from Sensors OUTPUTS to Loads/Actuators
10A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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ECU Development ProcessECU Development Process
OEM
ACTIVITIES
SUPPLIER
ACTIVITIES
ECU#1
HW SPEC
ECU#1
Software SPEC
Hardware
Design
Handcode
Software
ECU#1
ECU#2
HW SPEC
ECU#2
MODEL-BASED SPEC
Hardware
Design
Autocode
Generation
ECU#2
11A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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HIL SystemsHIL Systems
MicroAutoBox
AutoboxMicrogen
LabCar (ETAS)PXI (National Instrument)RT-Lab (Opal-RT)
12A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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Various Interactions between ECU & HILVarious Interactions between ECU & HIL
Real ECU Plant Model
Model of ECU Plant Model
Real ECU Real Actuator like the Wiper
Model of ECU Real Actuator like the Wiper
Real ECU Real ECU
13A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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A Typical HIL SystemA Typical HIL System
14A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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The inside of a typical HIL systemThe inside of a typical HIL system
I/O Cards
HIL System
Hardwired I/O
Connector
Connector
Connector
Power Supply
BUS Communication
Main Processor System Running Real –time Code LIN
CAN
MOST
FLEXRAY
Fault Insertion
Signal Conditioning(not software configurable)
LAN
EC
UE
CU
Memory
15A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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Advantages of using a HIL platformAdvantages of using a HIL platform
Advantages of using a HIL platform for validation of ECU functionality
Reduced development costs and timescales
Availability of the system for 24 hours
Safer testing conditions because of the ability to simulate operating conditions like fault and damaged conditions
Functionality testing can begin earlier in the design process with models of the ECUs even before the actual ECU hardware become available
16A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
Warwick
Weaknesses of existing HIL Platform Weaknesses of existing HIL Platform
Main weaknesses are:
Wiring harness HIL simulation platform needs to be redone each time the hardware interface of an ECU changes
Uncertainty in module specifications
Number of likely model variants
Requirement for reusing HIL system in different applications
Reusability of the HIL platforms from one vehicle programme to another is limited
17A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Jaguar Reconfigurable HIL PlatformJaguar Reconfigurable HIL Platform
Programmable PSU’s
LIN Switching
CAN Switching
Genix SC Pods
ECU PSU Switching
dSPACE PX20
I/O Routers I/O Routers
Real-Time Target
18A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Jaguar Reconfigurable HIL PlatformJaguar Reconfigurable HIL Platform
19A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Connector Panel Arrangement for an add2 HIL simulator
20A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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GenixGenix SubrackSubrack
21A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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BackPlaneBackPlane of of GenixGenix SubRackSubRack
22A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Outline illustration of add2 HIL Simulator
23A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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The The GenixGenix PodPod
DG – Differential Genix
DGF – Differential Genix with Fault Insertion
DGLF – Differential Genix with Load & Fault Insertion
DGELF – Differential Genix with External Load and Fault Insertion
24A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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GenixGenix PodsPods
25A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Typical Front Panel WiringTypical Front Panel Wiring
26A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Type DGType DG
27A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Type DGFType DGF
28A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Type DGELFType DGELF
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The HIL Power Supply SystemThe HIL Power Supply System
Each Genix Pod can be connected to three different external voltage sources (Vext1, Vext2 or Vext3) as the high power rail
one of two different 0V references (0V1 or 0V2) as the two low power rail
A typical Genix Pod will reference to Vext1 which is supplied by PSU1, normally used as the VBatt supply, and 0V1 which is tied to ground.
When a programmable power supply is used as a source, the voltage can be continuously varied within the operating range of 5 to 22V
30A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Signal conditioning which is reconfigurable by Signal conditioning which is reconfigurable by softwaresoftware
The unique and novel innovation in this HIL platform is the use of Genix configurable signal conditioning.
Each of the channel can be configured individually under software control
The front end can be designed and customized for different kind of sensors and has the capability to support all feasible combinations of the I/O interface of the ECUs.
31A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Signal Conditioning which is software Signal Conditioning which is software reconfigurablereconfigurable
The Genix based Pods have the capability to configure each channel according to its
signal type
Direction
Bandwidth
Gain
Loading requirements
internal loads can be pulled up to a supply rail or pulled down to ground
32A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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Signal Conditioning which is software Signal Conditioning which is software reconfigurablereconfigurable
has the ability to support either internal or external loads
digital input circuit has a configurable threshold detection capability
gain of the analogue inputs and outputs can be varied
Analogue inputs can be conditioned using one of 3 preset filters
33A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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HIL Configuration Utility (HCU)HIL Configuration Utility (HCU)
34A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Genix Module Input/Output Capability
35A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Genix Module Configuration Capability
36A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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The CAN Switching StrategyThe CAN Switching Strategy
CANAHCANBHCANCH
CANDH
CANCL
CANDL
CANBLCANAL
TO CHANS 1..4
COMMON FAULT RELAYS
ECU
CANH
CANL
CANFAULTL
CANFAULTH
VEXT
ECU 0V
Rterm
37A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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Other Key Features of the Software Other Key Features of the Software Reconfigurable HIL platformReconfigurable HIL platform
CAN, Power Supply and LIN Switching either the HCU software or using the CAN based configuration bus
High Current Capabilities
Fault Insertion Capabilities
Digital Current Output Modules
7mA
14mA
High Current Output
Low Current Output
38A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
© 2008 University of
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ExampleExample
Pull up to Vext
Configurable Resistive
Load
Gain Filter
ECUAnalog Input
to HIL Simulator
Vext
GND
Connection to
External Load
Fault ControlConfiguration
Bus
Signal Conditioning
Vin+V
Pull down to ground
To dSPACE
ADC card
Simulator
Fault Insertion
39A Flexible and Reconfigurable Hardware-in-the-loop Simulator for a Vehicle Programme at Jaguar
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ConclusionConclusion
Software reconfigurable HIL platform described was fully implemented for a vehicle programme at JLR
Reconfigurable platform has guaranteed high flexibility and portability in interfacing all kinds of ECUs, sensors and actuators
Easier to suit the wiring harness of the test rig to adapt the ECU under test
Robustness inbuilt in its design through its ability to support high current loads
The unique feature of the Genix signal conditioning module is that it has external load capabilities, fault insertion capabilities and high current capabilities all on one Pod card.
Genix modules have signal conditioning that is configurable by software.
