Hardware in the Loop (HIL) Testing Seminar
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Transcript of Hardware in the Loop (HIL) Testing Seminar
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Hardware-in-the-Loop (HIL)
Testing
Sajid M
12AT60R07
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Hardware in the loop Testing
technique that is used in the development and test of complex real-time embedded systems.
a form of real-time simulation with a real component in the loop.
A HILS provide all of the electrical stimuli needed to fully exercise the controlunit thus fooling an embedded system into thinking that it is operating withreal-world inputs and outputs.
Inputs to the HILS are mirrors of the embedded systems outputs
Outputs are mirrors of the embedded systems inputs.
Allows experimentation with physical parts in a controlled syntheticenvironment
http://en.wikipedia.org/wiki/Embedded_systemshttp://en.wikipedia.org/wiki/Embedded_systemshttp://en.wikipedia.org/wiki/Embedded_systemshttp://en.wikipedia.org/wiki/Embedded_systemshttp://en.wikipedia.org/wiki/Embedded_systems -
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Closed-Loop Control
DC Motor
Motor
Command
Disturbance
Measured
Speed
Desired
Speed Motor
Controller
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Examplethe automobile3 ECUs 15 to 70 ECUs in 10 years
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Embedded Control System Challenges
Increasing application complexity
Increasing reliability requirements
Decreasing time-to-market
Reduce development cost
Are these mutually exclusive?
Test
Challenges
Test
Resources
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Testing Embedded Control SystemsSystem Level Testing
DC Motor
Motor
Command
Measured
Speed
Desired
SpeedMotor
Controller
Disturbance
Test System
Test ProfileLogging/ Analysis
UUT
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Testing Embedded Control SystemsSystem Level Testing
What if the DC Motoris not available yet?
What if test failures could damage the DC Motor?
What if the DC Motoris very expensive (capital,
maintenance, operation, facilities)?
What ifDC Motor
conditions are not
repeatable?
What if there are numerous
variations of the DC
Motor?
DC Motor
MotorCommand
MeasuredSpeed
Disturbance
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Testing Embedded Control SystemsComponent Level Testing
Motor
Command
Desired
SpeedMotor
Controller
Test System
Test ProfileLogging/ Analysis
UUT
Measured
Speed
Disturbance
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What is HIL Simulation?
Types of Test
Functional
Parametric
Validation (V&V)
Durability (HALT/HAST)
End-of-line
Test Methods
Temperature/power
variation
Salt/sand spray EM radiation
Mechanical
loading/resistance HIL Simulation
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Virtual Realityfor your UUT
What does your UUT knowabout the world around it?
Voltage
Current
Impedance
Timing
Motor
CommandMotor
Controller
UUT
Measured
Speed
Desired
Speed
PWM
ENCODER
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Testing Embedded Control SystemsVirtualSystem Level Testing
Stimulus=
MODEL(test profile, UUT response)
Motor
Command
Desired
SpeedMotor
Controller
Test System
Test ProfileLogging/ Analysis
UUT
Measured
Speed
MODEL
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Testing Embedded Control SystemsVirtualSystem Level Testing
Motor
Command
Desired
SpeedMotor
Controller
Test System
Test ProfileLogging/ Analysis
UUT
Measured
Speed
MODEL
Stimulus=
MODEL(test profile, UUT response)
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What is a Model?
c
m
k
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Dynamic System Models
Simulink is a registered trademark of The MathWorks, Inc. All other trademarks are theproperty of their respective owners.
The MathWorks, Inc. Simulink Software
NI LabVIEWMapleSoft MapleSim
Esterel SCADE
ANSI C
NI MATRIXx SystemBuild
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You Need a Model
Motor
Command
Desired
SpeedMotor
Controller
Test System
Test ProfileLogging/ Analysis
UUT
Measured
Speed
MODEL
Stimulus=
MODEL(test profile, UUT response)
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Control Design Process
System
Testing
Modeling
and Design
Targeting
Rapid
Prototyping
Hardware-
in-the-Loop
Testing
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Modeling and Design
Modeling and Design Produce Controller and Plant
Models
Kc
Controller
Kp
Plant
Error
Control
Output FeedbackSetpoint
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Modeling and Design Software Tools
NI LabVIEW Simulation Module
NI MATRIXx
The MathWorks Inc., Simulink
ApplicationSoftware
MSC CarSim
Hand-coded models (C, Fortran, etc.)
Simulink is a registered trademark of The MathWorks, Inc.
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Rapid Control Prototyping
Creating a Functional Prototype of the Controller
Kc
Controller
Kp
Plant
Error
Control
Output FeedbackSetpoint
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Hardware-in-the-Loop Simulation
Testing Production Controller with Simulated Plant
Kc
Controller
Kp
Plant
Error
Control
Output FeedbackSetpoint
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HIL System Architecture
ECUFault Insertion
Unit (FIU)
Loads / PowerHost PC
Real-Time
Simulator
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Sequencer/Profiler
HIL Functional Architecture
Datalogging
Simulated Fault Insertion
Plant Model
RT IO Interfaces
Data Manager
User Interface
ECU Loads
PowerSupply
FPGA IO AIO/DIO
Fault Insertion Unit (Switching)
SigCon
Break-out
RF /
GPIB
Cal / Diag
Interfaces
IO InterfacesSimulator Interface
Bus IO DMM/Scope
Analysis &Reporting
ModelManager
Test Sequence
Vision
Host
RTSimulator
IO
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System Design
Driver Powertrain Chassis
Road Load
Driving
Cycle
Speed
Actual
SpeedReal Real Real
Simulated
EPA System
Driver Powertrain Chassis
Road Load
Driving
Cycle
Speed
Actual
SpeedSimulated Real Simulated
Simulated
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University of Washington 25
Topography of Autonomous Flight
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University of Washington 26
Hardware-in-the-Loop Simulator
Avionics Tray
HiL Simulator
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University of Washington 27
Hardware-in-the-Loop Simulator
Groundstation Aircraft
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Why Hardware-in-the-Loop (HIL) testing?
Software is a safety criticalcomponent and HIL testing Improves test coverage
Reduces testing time and cost
Reduces product development cycle
Improves test repetability and allowssystem variability
Real-time simulation model(vehicle dynamics, actuators,
Sensors, disturbances)
Engine Control Unit
real life controller
http://catless.ncl.ac.uk/Risks/
http://catless.ncl.ac.uk/Risks/http://catless.ncl.ac.uk/Risks/ -
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Hardware In-the-LoopExample: ECU In-the-Loop
RT Simulator
(3 x Pentium 3, 1 GHz CPU)
ECU
under test
Host PC
(development env.)
Allowing controller development while mechanical system is being built
Achieving a high degree of test coverage in the lab before driving mechanical system
Reducing test effort through automated regression
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References T. Hwang, J. Rohl, K. Park, J. Hwang, K. H. Lee, K. Lee, S.-J. Lee, and Y.-J. Kim,
"Development of HIL Systems for active Brake Control Systems", SICE-ICASEInternational Joint Conference, 2006
S.Raman, N. Sivashankar, W. Milam, W. Stuart, and S. Nabi, "Design and Implementationof HIL Simulators for Powertrain Control System Software Development", Proceedingsof the American Control Conference,1999.
A. Cebi, L. Guvenc, M. Demirci, C. Karadeniz, K. Kanar, and E. Guraslan, "A low cost,
portable engine electronic control unit hardware-in-the-loop test system", Proceedingsof the IEEE International Symposium on Industrial Electronics, 2005.
A. Palladino, G. Fiengo, F. Giovagnini, and D. Lanzo, "A Micro Hardware-In-the-Loop TestSystem", IEEE European Control Conference, 2009.
J. Wu and N. N.Schulz, Experimental Design for Remote Hardware-In-the-Loop testing,Proceedings of ASNE Reconfiguration and Survivability Symposium, Jacksonville, Florida,Feb. 2005.
H. Krisp, K. Lamberg, R. Leinfellner (2007, April),Automated Real- Time Testing ofElectronic Control Units. Presented at SAE World Congress & Exhibition, April 2007.[Online]. Available: www.sae.org/technical/papers/2007-01-0504.
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THANK YOU!!!!!
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Mission Environments
Robots to handle dirty, dangerous and dull missions
Cluttered
Low visibility
Smoke
Dust
Weather conditions
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Testing power electronics controls is costly
PE Hardware
PE Controller
O l ti H d i th L f PE
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controls
A machine
Our solution: Hardware-in-the-Loop for PE
controls
Power electronics hardware
Real-time software
Typhoon RTDS HIL solution for hybrid vehicle power electronics/power system
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yp y p p y
testing
http://www.hybridsynergydrive.com/en/mechanism.html
Power electronics model
Typhoon RTDS processor
Toyota Prius
propulsion system
Typhoon RTDS I/O
H d i h L f P El i
http://www.hybridsynergydrive.com/en/mechanism.htmlhttp://www.hybridsynergydrive.com/en/mechanism.html -
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Hardware-in-the-Loop for Power Electronics
Replaces high-power laboratory testing
Allows testing under nominal, transient and fault operatingconditions
Automates design, test and qualification of systems
Accelerates development and gives confidence
Reduces time-to-market
Helps with the sales process
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Typhoon makes testing power electronics control easy
Real-time Hardware Emulation
PE Controller
W l t th T h f t f l t i
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Welcome to the Typhoon future of power electronics
Typhoon processor
Typhoon application software
50 ti f t th th t t f th t
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50 times faster than the state-of-the-art
Circuit Compiler
Schematic Editor
Live measurements
Hardware-In-the-Loop
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Hardware In the LoopAutomatic Transmission In-the-Loop
Moving engineering development from expensive test vehicles to lab
Increasing repeatability through controlled environments
Accelerating test cycles with minimum operator intervention
E i S ABS/ECU
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Experiment Setup ABS/ECU
V
E
HI
C
L
E
EC
U
B
R
A
KE
S
Solenoid
Signals
Brake
Torques
Wheel Speeds
Brake Pedal
Input
HITL f ECU E l ti
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HITL for ECU Evaluation
ECU
Solenoid Signals
Wheel Speeds
D
A
Q
B
oa
r
d
s
Co
n
d
i
t
io
n
i
n
g
SoftwareBrake Model
C
ar
Si
m
RTLAB
RT Vehicle Dynamics Simulation:
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RT Vehicle Dynamics Simulation:CarSim
Manufacturing test of hydraulic
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Manufacturing test of hydraulic
actuatorsCustomer: Parker Hannifin
Application Integrate measurements with control
Control actuator movement deterministically
Easily change motion profile for each unit
Solution LabVIEW Real-Time
Modular PXI hardware platform
NI DAQ I/O modules
Saved 44 weeks of development time and reduced cost by6x
Lockheed Martin Simulator
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Lockheed Martin Simulator
(PXI, LabVIEW Real-Time, SIT, VISA)
Application Prototype integrated avionics unit in
XSS-11
Create hardware-in-the-loop/HIL
simulator to test LIDAR (light detectionand ranging system) controller
Key points LabVIEW and NI hardware provide
future flexibility
NI helped create an interface to a third-party synchronous serial interface usingNI-VISA