ID 020C: Hardware-in-Loop: System Testing Without the System

Marcella Haghgooie

Sr. Field Applications Engineer

Version: 1.2

Applied Dynamics International

13 October 2010

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Marcella HaghgooieSr. Field Applications Engineer, Applied Dynamics International

Over 30 years experience in Systems Engineering for applied physics applications of real-time hardware-in-loop simulation supplying robust development and test facility tools to aerospace, automotive, power, and medical industries.

MSEE from Northeastern University,

BS Physics from Brandeis University

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Renesas Technology and Solution Portfolio

Microcontrollers& Microprocessors

#1 Market shareworldwide *

Analog andPower Devices#1 Market share

in low-voltageMOSFET**

Solutionsfor

Innovation

Solutionsfor

InnovationASIC, ASSP& Memory

Advanced and proven technologies

* MCU: 31% revenue basis from Gartner "Semiconductor Applications Worldwide Annual Market Share: Database" 25 March 2010

** Power MOSFET: 17.1% on unit basis from Marketing Eye 2009 (17.1% on unit basis).

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Renesas Technology and Solution Portfolio

Microcontrollers& Microprocessors

#1 Market shareworldwide *

Analog andPower Devices#1 Market share

in low-voltageMOSFET**

ASIC, ASSP& Memory

Advanced and proven technologies

* MCU: 31% revenue basis from Gartner "Semiconductor Applications Worldwide Annual Market Share: Database" 25 March 2010

** Power MOSFET: 17.1% on unit basis from Marketing Eye 2009 (17.1% on unit basis).

Solutionsfor

Innovation

Solutionsfor

Innovation

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Microcontroller and Microprocessor Line-up

Superscalar, MMU, Multimedia Up to 1200 DMIPS, 45, 65 & 90nm process Video and audio processing on Linux Server, Industrial & Automotive

Up to 500 DMIPS, 150 & 90nm process 600uA/MHz, 1.5 uA standby Medical, Automotive & Industrial

Legacy Cores Next-generation migration to RX

High Performance CPU, FPU, DSC

Embedded Security

Up to 10 DMIPS, 130nm process350 uA/MHz, 1uA standbyCapacitive touch

Up to 25 DMIPS, 150nm process190 uA/MHz, 0.3uA standbyApplication-specific integration

Up to 25 DMIPS, 180, 90nm process 1mA/MHz, 100uA standby Crypto engine, Hardware security

Up to 165 DMIPS, 90nm process 500uA/MHz, 2.5 uA standby Ethernet, CAN, USB, Motor Control, TFT Display

High Performance CPU, Low Power

Ultra Low PowerGeneral Purpose

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Microcontroller and Microprocessor Line-up

Superscalar, MMU, Multimedia Up to 1200 DMIPS, 45, 65 & 90nm process Video and audio processing on Linux Server, Industrial & Automotive

Up to 500 DMIPS, 150 & 90nm process 600uA/MHz, 1.5 uA standby Medical, Automotive & Industrial

Legacy Cores Next-generation migration to RX

High Performance CPU, FPU, DSC

Embedded Security

Up to 10 DMIPS, 130nm process350 uA/MHz, 1uA standbyCapacitive touch

Up to 25 DMIPS, 150nm process190 uA/MHz, 0.3uA standbyApplication-specific integration

Up to 25 DMIPS, 180, 90nm process 1mA/MHz, 100uA standby Crypto engine, Hardware security

Up to 165 DMIPS, 90nm process 500uA/MHz, 2.5 uA standby Ethernet, CAN, USB, Motor Control, TFT Display

High Performance CPU, Low Power

Ultra Low PowerGeneral Purpose

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Innovation

Embedded Control Systems need Hardware-in-Loop Simulation

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Innovation using HIL Simulation

Simulation Architecture must include real-time simulation components

pseudo real-time environments and displays

global time stamping for synchronization

Improved hardware capabilities compute power

communication bandwidth

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Hardware-In-Loop with Renesas and ADI

Renesas provides the

MCU families to integrate

easily into your products

and your Hardware-In-

Loop (HIL) test facilities.

Applied Dynamics International (ADI) has over 50 years experience supplying tools for Hardware-In-Loop (HIL) Systems.

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The Need…

Renesas MCU ADI’s HIL Simulators

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Agenda What is HIL?

Virtual Systems integrated with HIL Simulation Systems

Process Improvements using HIL

Real-time HIL as Risk Reduction Platform

From Model-based Development to HIL-based System Testing

Q&A

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Key Takeaways

Understand how Hardware-in-Loop (HIL) simulation and testing can be useful in your product

development process

Identify systems development where HIL is beneficial

List tool characteristics that enable HIL integration and test

Highlights of the HIL demo in Lab Session: 020L SH2A Model Based Design (MBD),

Virtualization & Hardware in the Loop (HIL) Lab

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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

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Real-time HIL Simulation Applications:Test and Rapid-Prototyping

Stimulate

Monitor Response

Open-loop Testing

Real-time Simulator

Stimulate

Monitor Response

Closed-loop Testing

Real-time Simulator

Stimulate

Monitor Response

Rapid Prototyping

Real-time Simulator

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System Test BenchSystem 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

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System Test BenchSystem 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

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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 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

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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.

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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

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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 testing span life cycle Early fault detection minimizes late process high-cost changes

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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

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100% Successful 1ST Missions

Standard Validation Platform

Fly Spacecraft on the Ground

Satellite Emulator

Boeing Satellite Development CenterBoeing Satellite Development Center

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Gulfstream AerospaceGulfstream Aerospace

75% Test Time Reduction

ITF and ARDL

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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).

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HIL Modular Simulation

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

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HIL Modular Simulation

Real-time simulation models and tools for device emulation

Requirements for real-time simulation plant models Emulated embedded processor transitions to actual processor in

the loop Example: SimuQuest Engine model, Renesas Control Processor

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HIL Modular Simulation

Signal conditioning for actuators and sensors

Easy integration of the embedded processor toolset

Integrated data acquisition and performance estimates

HIL is safe, low cost platform to perform experiments

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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.

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I/O Considerations

ADI’s PCI-Engine is a specialized PCI solution providing engine signal emulation including the hall effect sensors

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Breakout PanelBreakout Panel

ADI Emul8 PCI-Engine ADI Emul8 PCI-Engine Installed Installed

in HIL Systemin HIL System

Simulink ModelSimulink Model

ECUECU

Engine Emulation

HIL Demonstration

Emulated Engine Closed-loop with ECUEmulated Engine Closed-loop with ECU

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HIL Demonstration

Real-Time Simulator

8-Cylinder

Simulink Engine Model

PC

I-E

ngin

eP

CI-

The

rm

8 spark measurement

8 fuel measurement

Thermistor emulation

Oxygen sensor

Manifold absolute pressure

Mass airflow

CAN throttle position sensor

Battery voltage power moding

Hall effect cam emulation

Hall effect crank emulation

Engine Controller

Breakout

Panel

rtX HIL SystemrtX HIL System

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ECU Testing with Emulated Engine

Open-LoopOpen-Loop

StimulateStimulate

MonitorMonitor

ECUECU

Closed-LoopClosed-Loop

Real-Time Real-Time Engine ModelEngine Model

ECUECU

Test:Test:• ECU control algorithm effectiveness ECU control algorithm effectiveness • Response time and control stability Response time and control stability • Adaptive capability of controllerAdaptive capability of controller

Test ECU’s recognition of an event and the Test ECU’s recognition of an event and the appropriateness of the ECU responseappropriateness of the ECU response

• Simple as a set of potentiometers and Simple as a set of potentiometers and switchesswitches

• ECU response is measured to determine ECU response is measured to determine that it is within tolerancethat it is within tolerance

• Multiple input events to ECU may be Multiple input events to ECU may be generated simultaneouslygenerated simultaneously

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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

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HIL Modular Simulation - PCI-Engine

PCI-Engine was integrated with the Renesas Controller and the SimuQuest Engine Model for HIL automated testing

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HIL Summary

Hardware-in-the-Loop SimulationModel-based development and testing of a single

subsystem

System IntegrationModel-based integration testing of stand-alone

functionality and subsystem interoperability

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Innovation

Embedded Control Systems need Hardware-in-Loop Simulation

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Questions?

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Feedback Form

Please fill out the feedback form! If you do not have one, please raise your hand

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Thank You!