ecu-testing.pdf

8/10/2019 ecu-testing.pdf

1/25Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany [email protected] www.dspace.de2005

74

ECU Testing

ECU Testing withdSPACE Simulator

Cutting-edge systems

for ECU/controller testing

Original equipment manufacturers (OEMs) today face pressures on multiple fronts.

The time to market is shrinking while the content and complexity of the vehicleelectronics 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 is little wonder that testing and error finding have become

key tasks in the development process.

Systematic and 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 environ-

ment, without real vehicles or prototypes. Such tests are very systematic and also

completely safe, even when critical thresholds are exceeded, while allowing ECUerrors to be reproduced whenever and however required.


2/25Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany [email protected] www.dspace.de

2005

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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 er-

rors, and almost all the errors that it is possible

to find before the calibration phase. Recall cam-

paigns and associated damage to the companys

image are minimized. The investments made in

HIL systems and in developing tests have usuallypaid off after only a few months. Just a few of

the reasons:

Hardware-in-the-loop simulation

avoids recall campaigns and

loss of corporate image

Fewer prototypes, fewer test drives,

lower costs

More comprehensive and more systematic tests in a shorter time

Higher quality, lower risks

Start of production on schedule using fewer resources

dSPACE Simulator Introduction

Key Features of dSPACE Simulator Your Benefits

Full integration of MATLAB/Simulink,

the worlds leading design and

modeling tool

State-of-the-art modeling and

maximum compatibility with existing

models or third-party models

Full integration into

the dSPACE tool chain

Maximum reusability of models, test

scripts, layouts and knowledge

Solution-oriented products and

powerful test automation

Savings in time and money

Greatly improved software quality

Easy access to the real-time model,

states and parameters,

even during run time

Fast, graphical programming

via drag & drop

Homogeneous and efficient

user interfaces

Steep learning curves

Fast iterations

Competitive advantage

Product maturity as the worlds most

used HIL simulator:

1,100 in operation worldwide

Best options for

networking and expandability

dSPACEs extensive experience in

the fields of hardware-in-the-loop

simulation and test automation



76

ECU Testing

Test Scenarios with dSPACE SimulatorThe 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 systems flexibility allows virtually any adapta-

tion: cruise control, body electronics, and especially ECU network tests.

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 ECUs diag-

nostics 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.

Vehicle Dynamics

Bosch ESP 5.3, 5.7, 8.0

ContiTeves ESP

TRM ESP

Otto

4-16 cylinders Manifold injection

Direct injection

Turbocharger

Diesel

4-12 cylinders

Turbocharger

Common rail unit injection

Passenger car and

heavy-duty trucks

Transmission

Continuously variable transmission

Automatic transmission

Automated manual transmission

Double-clutch transmission

Others

Body electronics Comfort

Air-conditioning control systems

Vehicle Types

From passenger cars to

light and heavy-duty

trucks to Formula One



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Integration Tests on ECU Networks

The main concern is to test problem-free interaction of all the ECUs that are com-

municating, 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.

... 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.


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 Simula-tors, 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.



78

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 systemati-

cally 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 com-

pletely 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, Automa-

tionDesk (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 worlds 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.

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 A 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 Simulators 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 ECUs 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 Simulators modular concept, please see the following

pages.



80

ECU Testing

Implementation SoftwareThe code for dSPACE Simulators 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)

dSPACEs 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. RTIs 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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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 ControlDesks Simu-

link 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)

dSPACE Simulator Software



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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 simula-

tion 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 onexisting 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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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 sys-

tematic structure, reusability, and reproducibility of test sequences are unequalled.

AutomationDesk (p. 140)

Typical Automation Tasks Executed with AutomationDesk

Setting up operating point 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

Measurement Access to ECU internal variables via

diagnostic or calibration interfaces

Data capturing of simulator variables

Evaluation and test reporting Access to MATLABs mathematical

test validation capabilities or direct

calculations in Python

Automated report generation based

on XML with standard style sheets for

HTML and PDF

Data management Organization and storage of

test sequences, parameter sets,

measurement data and test reports

dSPACE Simulator Software



84

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

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)

Full-brake simulation or braking on different surfaces: MotionDesk makes the

cars behavior visible.



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dSPACE Simulator Hardware Concepts Different Systems for Different Tasks

The hardware requirements might vary immensely depending on your hardware-in-

the-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 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 sys-

tem 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).

dSPACE Simulator Hardware

dSPACE Simulator Types:

Mid-Size and Full-Size



86

ECU Testing

Hardware Summary

dSPACE Simulator

Mid-Size (p. 88)

dSPACE Simulator

Full-Size (p. 90)

Form factor 19 desktop rack 19 cabinet 17 37 HU

Vertical modules

Processor hardware DS1005 PPC Board or

DS1006 Processor Board

DS1005 PPC Board or


I/O hardware DS2211 HIL I/O Board Any number and type of

dSPACE I/O boards

Further I/O hardware

Signal conditioning

Substitute loads

Real-load connector

Failure insertion unit

Integration of simulator-

specific hardware

(p. 74)

Integration of third-partyhardware, e.g., load panels

ECU connectors Three 90-pin connectors

Additional connectors

for additional I/O

optional

One or more 90-pin

connectors for each ECU

(standardized)


optional

Break-out box

OBDII diagnostic

connector /

connection to

diagnostic tools

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)

42 V-capable

Power supply

(remote controlled)

Included

Available on demand



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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-SizeStandard Hardware Extension

Failure insertion units 5 x DS749 FIU Module

(each features 10 channels)

Optional: replaced with

5 x DS792 Fuse Cards

n x DS793/DS794 Sensor

FIU Cards (up to 2 cards,

each 81 channels with

CMOS switches)

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


ECU pin via two fail planes

dSPACE Simulator

Full-SizeFailure Simulation Variant 1 Failure Simulation Variant 2

Failure insertion units n x DS291 FIU Module

(each features 10 channels)

n x DS281 Load Module

1 x DS293 Central FIU

Module

n x DS282 Load Module

(10 channels)

1 x DS289 Rsim Module

(simulates a resistance in

the range 1 ...131 k

in steps of 1 )

Possible failure types On ECU inputs and outputs:

Open circuitShort 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)


ECU pin with or without

load (via common rail)

On ECU inputs and outputs:

Open circuit with orwithout additional

hardware (Rsim, MEAS or

SOURCE) in series


ECU pin directly or via

additional hardware

Short circuit to 5 reference

points (potential 04)

directly or via additional

hardware

dSPACE Simulator Hardware



88

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

Spare slot

Modular hardware:processor board and

I/O board with signal

conditioning

OBDII connector

via adapter

ECU connectors

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-SizeStandard variant,

2-voltage system optional

Small variant,

1-voltage system

DS1005 PPC Board or


DS2211 HIL I/O Board

Failure insertion units

Load cards

Power supply

Second power supply

Free ISA slots for expansion 1 (PX5 version, only for

DS1005 PPC Board)

5 (PX10 version)

1 (PX5 version, only

for DS1005 PPC

Board)

Height units 9 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



90

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 multi-

processor 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.


(e.g., CARB, OBD)

Power supply

Break-out box ECU connector

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).



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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)



92

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



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Simulator-Specific Hardware

Simulator-Specific HardwareIf 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 con-

ditioning, 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.



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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 com-

ponents, 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 integrated 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 SupplyThe 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 vehicles 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 voltage

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.



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95

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 mea-

sure the air-fuel ratio in a cars catalytic converter. The engine ECU reacts continu-

ously 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.

Simulator-Specific Hardware



96

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

ControlDesks 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



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97

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 Further Details

Implementation software Real-Time Interface p. 108

PowerPC compiler p. 127

Experiment software ControlDesk p. 128

ControlDesk Failure

Simulation

p. 139

AutomationDesk p. 140


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ECU Testing

Hardware Components Further Details

Modular hardware Processor Board:

DS1005 PPC Board

p. 230

I/O boards:

DS2211 HIL I/O Board

p. 254

Off-the-shelf hardware Failure insertion units p. 87

Load boards p. 87

One or two power

supplies (two for

2-voltage system

simulation)

p. 94

Others

Configuration Example:dSPACE Simulator for Testing Networked ECUsdSPACE 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)

Documents

ecu-testing.pdf