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© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Engine ECU HIL simulation using Matlab-Simulink
Rupen Singla Nishit Jain Sandeep Mandal Dr. Tapan Sahoo Maruti Suzuki India Ltd
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Agenda
Why Hardware-in loop (HIL) simulation
Hardware-in loop introduction and workflow
Typical HIL setup
Software components of HIL system
Matlab-Simulink Model and Results
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
- Emission norms, safety and customer convenience have been the driving factors of increasing electronic controller hardware and software complexity in the recent years.
- The increased complexity and
sophisticated specifications demand rigorous and reliable testing to ensure error free product to the customer.
- The need for testing and validation of
the controller software before proto vehicle is immense
Introduction
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
WHY HIL?
Reduction in development
cost
Earlier detection of
bugs and errors
Huge effort and time to
test ECU functions
Automated Testing
Simulation of variety of
behaviors
Open loop and closed
loop verification
Challenges
Standardization
Complex modeling
required
Why HIL?
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Signal Flows in real system and HIL system
Proto vehicle setup Simulated vehicle setup
Simulated vehicle setup (HIL)
Image Source: dSPACE Gmbh
Hardware in Loop Simulation
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Simulator
Image Source: dSPACE Gmbh
I/O + Plant model
HIL setup
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
• Real time system – For simulation of sensors and observation of actuator signals (IO-Open loop test configuration)
• Dynamic Plant model (Closed Loop test configuration)
Matlab/Simulink to describe : • The definition and configuration of the
I/O • The dynamic behavior of the plant
Sen
sors
DIG_OUT, PWM_OUT
DAC
Crank, CAM
Knock
Resistive
Act
uat
ors
DIG_IN, PWM_IN
ADC
Injection, Ignition
Software components of HIL system
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
ECU point of view architecture
Sensors Actuators
Engine
Engine IO: Sensor and actuator Interface
Simulator IO: Simulator and Relay control
Bus Systems: CAN and LIN bus interface
Vehicle Plant: Detailed engine and basic vehicle plant model
Simulink Model Architecture
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Actuator Interface
Crank and CAM sensor Interface
Ignition angle capture
Injection angle, timing capture
Knock sensor simulation
Accelerator pedal simulation
Power supply (Battery Simulation)
ECU controlled relay switching
Analog sensor simulation
Digital switch simulation
Engine-IO Model Architecture
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Virtual ECU: Basic Functionality of ECU to validate the plant model in SIL mode
Engine Model: Consists of Airpath, Fuel system and Mean torque model
Drivetrain Model: Consists of crankshaft, differential and starter model
To select between virtual ECU and Actual ECU signals (HIL mode)
To output signals to Engine IO and BusSystems
Dynamic Vehicle Plant model
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Tester Interface for Manual Closed Loop Testing
Major Outputs: Engine RPM, Vehicle speed, Indicated torque, Friction torque, Fuel injected, rail pressure, Intake manifold pressure
Tester-Simulator Interface
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Simulation results compared with actual engine dyno data
Fuel Injection Rail Pressure Mean Effective torque
Compressor Output Pressure Air mass flow
Plant Model Results
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Possible to simulate both Open loop and Closed loop tests Possible to simulate certain test cases that are not possible to
simulate on proto vehicle Automated and regressive testing
Advantages of Hardware in loop
Advantages of Matlab/Simulink in Hardware in loop
Input output libraries of major simulator providers are available in Matlab/Simulink
Customizable models from different suppliers can be integrated with ease
Reusability and standardization for different simulators and systems
Summary
© Maruti Suzuki India Limited (MSIL), 2015. No part of this presentation should be copied or reproduced without exclusive permission of MSIL.
Thank You
Q&A