Transcript ID_020C_Haghgooie_HIL - Renesas e

ID 020C: Hardware-in-Loop: System
Testing Without the System
Applied Dynamics International
Marcella Haghgooie
Sr. Field Applications Engineer
13 October 2010
Version: 1.2
Marcella Haghgooie
Sr. 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 share
worldwide *
ASIC, ASSP
& Memory
Advanced and
proven technologies
Solutions
for
Innovation
Analog and
Power Devices
#1 Market share
in low-voltage
MOSFET**
* 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 share
worldwide *
Solutions
for
Innovation
ASIC, ASSP
& Memory
Advanced and
proven technologies
Analog and
Power Devices
#1 Market share
in low-voltage
MOSFET**
* 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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Microcontroller and Microprocessor Line-up
Superscalar, MMU, Multimedia
High Performance CPU, Low Power
High Performance CPU, FPU, DSC
 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
 Up to 165 DMIPS, 90nm process
 500uA/MHz, 2.5 uA standby
 Ethernet, CAN, USB, Motor Control, TFT Display
 Legacy Cores
 Next-generation migration to RX
General Purpose
 Up to 10 DMIPS, 130nm process
 350 uA/MHz, 1uA standby
 Capacitive touch
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Ultra Low Power
Embedded Security
 Up to 25 DMIPS, 150nm process  Up to 25 DMIPS, 180, 90nm process
 190 uA/MHz, 0.3uA standby
 1mA/MHz, 100uA standby
 Application-specific integration  Crypto engine, Hardware security
Microcontroller and Microprocessor Line-up
Superscalar, MMU, Multimedia
High Performance CPU, Low Power
High Performance CPU, FPU, DSC
 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
 Up to 165 DMIPS, 90nm process
 500uA/MHz, 2.5 uA standby
 Ethernet, CAN, USB, Motor Control, TFT Display
 Legacy Cores
 Next-generation migration to RX
General Purpose
 Up to 10 DMIPS, 130nm process
 350 uA/MHz, 1uA standby
 Capacitive touch
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Ultra Low Power
Embedded Security
 Up to 25 DMIPS, 150nm process  Up to 25 DMIPS, 180, 90nm process
 190 uA/MHz, 0.3uA standby
 1mA/MHz, 100uA standby
 Application-specific integration  Crypto engine, Hardware security
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
Applied Dynamics
International (ADI)
has over 50 years
experience supplying
tools for Hardware-InLoop (HIL) Systems.
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Renesas provides the
MCU families to integrate
easily into your products
and your Hardware-InLoop (HIL) test facilities.
The Need…
 Renesas MCU
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 ADI’s HIL
Simulators
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
Closed-loop
Testing
Real-time Simulator
Monitor
Response
Real-time Simulator
Open-loop
Testing
Stimulate
Monitor
Response
Real-time Simulator
Rapid
Prototyping
Stimulate
Monitor
Response
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System Test Bench
System Testing without the System
The system test bench starts with model-based simulation.
Models can consist of:
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Physics-based plant models
Control algorithms
Experimental data
Mathematical Function data
Subsystem implementations
Communication Databus
Interface documents describe model I/O
System Test Bench
System Testing without the System
The system test bench includes the Embedded Control System:
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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
System Test Bench Benefits
System Testing without the System
The system test bench provides the platform for:
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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 Modelbased 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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Boeing Satellite Development Center
 100% Successful 1ST Missions
 Standard Validation Platform
 Fly Spacecraft on the Ground
 Satellite Emulator
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Gulfstream 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 8cylinder engine with signal
measurement and
generation that is crankbased 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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HIL Demonstration
Emulated Engine Closed-loop with ECU
ECU
ADI Emul8 PCI-Engine
Installed
in HIL System
Simulink Model
Engine Emulation
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Breakout Panel
HIL Demonstration
rtX HIL System
8-Cylinder
Simulink Engine
Model
PCITherm
PCI-Engine
Real-Time Simulator
B
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k
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P
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n
e
l
8 spark measurement
8 fuel measurement
CAN throttle position sensor
Hall effect cam emulation
Hall effect crank emulation
Thermistor emulation
Battery voltage power moding
Oxygen sensor
Manifold absolute pressure
Mass airflow
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Engine
Controller
ECU Testing with Emulated Engine
Open-Loop
Stimulate
Monitor
Test ECU’s recognition of an event and the
appropriateness of the ECU response
• Simple as a set of potentiometers and
switches
• ECU response is measured to determine
that it is within tolerance
• Multiple input events to ECU may be
generated simultaneously
ECU
Closed-Loop
ECU
Real-Time
Engine Model
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Test:
• ECU control algorithm effectiveness
• Response time and control stability
• Adaptive capability of controller
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 Simulation
 Model-based development and testing of a single
subsystem
 System Integration
 Model-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!
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