Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved. Class ID: Using Cost Effective Distributed HIL for Rapid Prototyping Marcella Haghgooie, Senior Field Applications Engineer 0C21B

© 2012 Renesas Electronics America Inc. All rights reserved.2 Marcella Haghgooie Sr. Field Applications Engineer, Applied Dynamics International Over 30 years experience in Systems Engineering for applied physics applications. Using real-time hardware-in-loop simulation to supply smart development and test facility tools to aerospace, automotive, power, and medical industries. MSEE from Northeastern University, BS Physics from Brandeis University

© 2012 Renesas Electronics America Inc. All rights reserved.3 Enabling Smart Solutions Embedded Control Systems need Hardware-in-Loop Simulation

© 2012 Renesas Electronics America Inc. All rights reserved.4 Innovation using HIL Simulation Simulation Architecture must include real-time simulation components pseudo real-time environments and displays global time stamping for synchronization distributed components Smart hardware capabilities include compute power communication bandwidth

© 2012 Renesas Electronics America Inc. All rights reserved.5 Hardware-In-Loop (HIL) with Renesas and ADI Renesas provides the MCU families to integrate easily into your smart products and your Hardware-In-Loop (HIL) test facilities. Applied Dynamics International (ADI) has been supplying HIL Real-time Systems and simulation tools for over 50 years.

© 2012 Renesas Electronics America Inc. All rights reserved.6 Smart Technologies require … Renesas MCU ADI’s HIL Simulators

© 2012 Renesas Electronics America Inc. All rights reserved.7 What is HIL, Distributed HIL and Rapid Prototyping? Using Virtual Systems integrated with HIL Simulation Systems Process Improvements using Distributed HIL for Rapid Prototyping Risk Reduction using Real-time HIL Platform Best Practices (Model-based Development, HIL Simulation) Q&A Agenda

© 2012 Renesas Electronics America Inc. All rights reserved.8 Key Takeaways Understand how Hardware-in-Loop (HIL) simulation and testing can be useful in your smart product development process Identify product development where HIL is beneficial List tool characteristics that enable HIL integration and test Highlights of the HIL demo using Model Based Design (MBD), Virtualization & Hardware in the Loop (HIL)

© 2012 Renesas Electronics America Inc. All rights reserved.9 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

© 2012 Renesas Electronics America Inc. All rights reserved.10 Real-time HIL Simulation Applications: Test and Rapid-Prototyping Stimulate Monitor Response Open-loop Testing Real-time Simulator Scenarios Monitor Response Closed-loop Testing Real-time Simulator Stimulate Monitor Response Rapid Prototyping Real-time Simulator

© 2012 Renesas Electronics America Inc. All rights reserved.11 System Test Bench System 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

© 2012 Renesas Electronics America Inc. All rights reserved.12 System Test Bench System 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

© 2012 Renesas Electronics America Inc. All rights reserved.13 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 and end-user 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 Early evaluation of end-user experience through simulation enables smart solutions

© 2012 Renesas Electronics America Inc. All rights reserved.14 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.

© 2012 Renesas Electronics America Inc. All rights reserved.15 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

© 2012 Renesas Electronics America Inc. All rights reserved.16 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 testcases that span product life cycles Early fault detection can eliminate high-cost recalls

© 2012 Renesas Electronics America Inc. All rights reserved.17 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

© 2012 Renesas Electronics America Inc. All rights reserved.18  100% Successful 1 ST Missions  Standard Validation Platform  Fly Spacecraft on the Ground  Satellite Emulator Boeing Satellite Development Center

© 2012 Renesas Electronics America Inc. All rights reserved.19 Gulfstream Aerospace  75% Test Time Reduction  ITF and ARDL

© 2012 Renesas Electronics America Inc. All rights reserved.20 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) Distributed HIL lets you explore new technology for your product by easy insertion and connection into existing test configurations

© 2012 Renesas Electronics America Inc. All rights reserved.21 University of Michigan ARC has current research and experiments using Internet-Distributed HIL (ID-HIL) Principal Investigator:Tulga Ersal, UofM,Tulga Ersal The Automotive Research Center (ARC) Goal: Evaluate a novel hybrid power management strategy by integrating the engine and battery testing facilities at the University of Michigan Case Study Team includes: University of Michigan TARDEC ADI

© 2012 Renesas Electronics America Inc. All rights reserved.22 ID-HIL Hardware Resources Walter E. Lay Automotive Laboratory Battery Testing Laboratory Engine Testing Laboratory Driver Interface

© 2012 Renesas Electronics America Inc. All rights reserved.23 ID-HIL Selecting Coupling Points Walter E. Lay Automotive Laboratory Battery Testing Laboratory Engine Testing Laboratory Driver Interface

© 2012 Renesas Electronics America Inc. All rights reserved.24 ID-HIL Selecting Coupling Points Battery Testing Laboratory Engine Testing Laboratory Driver Interface

© 2012 Renesas Electronics America Inc. All rights reserved.25 ID-HIL Selecting Coupling Points Battery Testing Laboratory Engine Testing Laboratory Driver Interface

© 2012 Renesas Electronics America Inc. All rights reserved.26 HIL Modular Simulation Tools 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

© 2012 Renesas Electronics America Inc. All rights reserved.27 HIL Modular Simulation supports Real-time simulation models and hardware for device emulation Real-time simulation plant models Easy transition from emulated embedded system to actual embedded processor and code in the loop Demonstration: ADI HIL, SimuQuest Engine model, Renesas Control Processor

© 2012 Renesas Electronics America Inc. All rights reserved.28 HIL Modular Simulation includes Signal conditioning for actuators and sensors Integration of the embedded processor toolset Integrated data acquisition and performance estimates A safe, low cost platform to perform experiments

© 2012 Renesas Electronics America Inc. All rights reserved.29 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.

© 2012 Renesas Electronics America Inc. All rights reserved.30 I/O Considerations ADI’s PCI-Engine is a specialized PCI solution providing engine signal emulation including the hall effect sensors

© 2012 Renesas Electronics America Inc. All rights reserved.31 Breakout Panel ADI Emul8 PCI-Engine Installed in HIL System Simulink Model ECU Engine Emulation HIL Demonstration Emulated Engine Closed-loop with ECU

© 2012 Renesas Electronics America Inc. All rights reserved.32 HIL Demonstration ADI rtX HIL System

© 2012 Renesas Electronics America Inc. All rights reserved.33 ECU Testing with Emulated EngineOpen-LoopStimulateMonitor ECU Closed-Loop Real-Time Engine Model ECU Test: ECU control algorithm effectivenessECU control algorithm effectiveness Response time and control stabilityResponse time and control stability Adaptive capability of controllerAdaptive capability of controller Test ECU’s recognition of an event and the appropriateness of the ECU response Simple as a set of potentiometers and switchesSimple as a set of potentiometers and switches ECU response is measured to determine that it is within toleranceECU response is measured to determine that it is within tolerance Multiple input events to ECU may be generated simultaneouslyMultiple input events to ECU may be generated simultaneously

© 2012 Renesas Electronics America Inc. All rights reserved.34 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 PCI-Engine was integrated with the Renesas Controller and the SimuQuest Engine Model for HIL automated testing

© 2012 Renesas Electronics America Inc. All rights reserved.35 HIL Summary Hardware-in-the-Loop Simulation Model-based development and testing of a single subsystem System Integration Model-based integration testing of stand-alone functionality and subsystem interoperability Rapid Prototyping Plant model with control algorithm development using a simulation centric process

© 2012 Renesas Electronics America Inc. All rights reserved.36 Innovation Embedded Control Systems need Hardware-in-Loop Simulation

© 2012 Renesas Electronics America Inc. All rights reserved.37 Questions? Questions? Company Logo HERE

© 2012 Renesas Electronics America Inc. All rights reserved.38 Please utilize the ‘Guidebook’ application to leave feedback or Ask me for the paper feedback form for you to use… Please Provide Your Feedback…

Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved.