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CarSim/TruckSim/BikeSimReal-Time Hardware In the Loop
Mechanical Simulation Corporation
www.carsim.com
What is Hardware In the Loop (HIL)?•Pure Simulation – Software In the Loop (SIL)
§Plant Model Simulation with/without sub models. §There is no timing control and runs as fast as possible. §The integration time step can be continuous.
•Pure Real Time Simulation§Run SIL on the computer with Real Time Operation System (RTOS). §There is an accurate timing control. §The integration time step must be fixed.
•Hardware In the Loop Simulation§Pure Real Time simulation + real components (ECUs and actuators).
Vehicle Plant Model
External ControllerExternal ControllerExternal Controller
SIL HIL
Why do we need Hardware In the Loop?
•Verify model - can it run in hard real time?
•Verify hardware controllers
•Some parts are difficult to simulate (non-linear behavior, environmental variances)
•Components laboratory testing (reliability, vibration, temperature, EMF)
•Save cost to test real vehicles
•Save development time
•Easily reproduce/repeat test conditions
•Safe for testing for some dangerous conditions (rollover, pre-crash)
Example Applications
n Brake Testingl Test prototype and production ECUs
l Hydraulic lines and calipers
l Environmental chamber
l Applications – temperature and EMI reliability, brake dyno control
n Active Damper Systeml Physical dampers difficult to model
l Complex suite of test conditions (roads and maneuvers)
l Applications – 7 post rig, stability control, ride optimization
n Driving Simulator for Active Safetyl Human in the Loop
l Drive vehicle through complex traffic scenarios
l Freeform testing
l Visual sensor representations
l Applications – active cruise control, crash mitigation, lane departure
Case Study – Braking ROIEvaluation of Physical Testing vs. HIL
CarSim HILOne Time Costs
Lab construction $120K
Recurring Costs
Energy $2k
Installation $5k
Labor $20k
Uptime 99%
Uptime issues
Test component failure
Physical TestingOne Time Costs
Instrumentation $50k
Recurring Costs
Mule Car w/installation $40k
Transportation $20k
Fuel $8k
Staff $180k
Uptime less than 80%
Uptime issues
Weather, driver availability, fueling, non-productive driving, vehicle component failure, remote locations, driver accuracy, driver safety
RT-Lab Target dSPACE Target Linux RT Based Target LabVIEW RT Target(LabCar, A&D, Fujitsu-Ten)
CarSim/TruckSim/BikeSim supported RT System
CarSim/TruckSim/BikeSim supported RT System
n Opal-RT: RT-Lab
RT-Lab Target Settings
Simulink Model for RT-Lab System
Run on TargetSubsystem
Run on HostSubsystem
Input from ECU
Output to ECU
CarSim/TruckSim/BikeSim supported RT System
n dSPACE l DS1006, DS1005 (PPC 800+ MHz), DS1103 (PPC 800+
MHz), MicroAutobox (PPC 800 MHz)
CarSim vehicle model runs on
compact dSPACE chassis with DS1006 and DS2211(IO)
ABS controller runs on dSPACE
MicroAutobox
dSPACE Target Settings
Simulink Model for dSPACE System
DS2211 IO Card
Runs on DS1006 Board
n ETAS LabCar
CarSim/TruckSim/BikeSim supported RT System
Linux RT Based Target Settings
Simulink Model for ETAS LabCar
LabCar IO Ports
n LabVIEW RT
CarSim/TruckSim/BikeSim supported RT System
ESC Controller
LabVIEW RT Target
Host PC
Target Monitor (option)
Real-Time Animator (option)
LabVIEW-RT Target Settings
LabVIEW Model for LabVIEW-RT System
LabVIEW Front Panel
LabVIEW Background Connection
Timed Loop. dT= 1 msTimed Loop. dT= 1 ms
Outputs to ECU
Inputs from ECU
CarSim Vehicle Solver.Update each time step
Initialize CarSim Vehicle Solver.
Terminate CarSimVehicle Solver.
Engineering Tool• Drive on your proving ground
• Instantaneous A/B/C/D/…comparison of vehicle components
• Drive a road before it is built
• HIL testing of ECUs or complete chassis systems
HIL+Human In the Loop: Driving Simulators
CarSim/TruckSim Inside• Integrate the CarSim/TruckSim
math models with other technologies
• Advanced vehicle controls
• Driver training
• Entertainment
Thank You
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