Open, Scalable Real-Time Solutions Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th, 2005

Open, Scalable Real-Time Solutions Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th, 2005

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.

Progression of ECU use in Vehicles Electronics share of a vehicles’ value: (Source: ABI Research)

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...

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

Open, Scalable Real-Time Solutions Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th, 2005

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

Is TestDrive an HIL Simulator? An HIL simulator is: Used for closed loop simulation Mainly for verification and validation test Expensive to buy and to operate ($$) Requires model development (  ) Requires substantial set up time (  ) Uses Matlab/Simulink/RTW for modeling ($$) Requires special training or background to use ($  ) Signal Mapping and Power Moding Module Power Supply

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

Open, Scalable Real-Time Solutions Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th, 2005

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

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

RT-LAB TestDrive – Chassis Real-time target computer with Pentium 4 CPU 25A power moding lines and connections including battery voltage, ignition, accessories, radio. Rear high-density 56-way ELCO connectors for direct ECU connection Slots for I/O modules with signal conditioning and monitoring 10U desktop simulator, external dimension: 17” (w) x 16” (h) x 12” (d) TCP/IP connection to host PC PCI slots for optional modules, such as CAN bus, GPIB, and IEEE 1394

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

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

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)

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

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

Open, Scalable Real-Time Solutions Background Introducing TestDrive TestDrive Hardware TestDrive Software Mathieu Dubé-Dallaire Application Engineer August 30 th, 2005

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

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

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

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

RT-LAB TestDrive Configuration Scripts and Macros Python Editor System Configuration Panel Module Configuration Panels Signal Mapping Interface Panel Design Interface LabVIEW and compiled LabVIEW Model Design Matlab/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

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

Where Does RT-LAB TestDrive Fit … Design Specification & Requirements Definition Plant Simulation Controller Algorithm Development Coding and Unit Testing System Validation Integration Testing Functional Checkout in the design process (TestDrive vs. Full Scale Dynamic HIL Simulators) Signal Mapping and Power Moding Module Power Supply

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

Uses of TestDrive at Delphi Europe US Program 1 Program 2 Simulator Team India Compiled model Template GUI panels Template scripts Program specific panels and scripts Program specific panels and scripts shared within the team TestDrive is now used by several companies and is being evaluated by DENSO

Fully Programmable Powertrain and Vehicle Simulation for ECU-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