CarSim/TruckSim/BikeSimReal-Time Hardware In the Loop

Mechanical Simulation Corporation

www.carsim.com

What is Hardware In the Loop (HIL)?•Pure Simulation – Software In the Loop (SIL)

§Plant Model Simulation with/without sub models. §There is no timing control and runs as fast as possible. §The integration time step can be continuous.

•Pure Real Time Simulation§Run SIL on the computer with Real Time Operation System (RTOS). §There is an accurate timing control. §The integration time step must be fixed.

•Hardware In the Loop Simulation§Pure Real Time simulation + real components (ECUs and actuators).

Vehicle Plant Model

External ControllerExternal ControllerExternal Controller

SIL HIL

Why do we need Hardware In the Loop?

•Verify model - can it run in hard real time?

•Verify hardware controllers

•Some parts are difficult to simulate (non-linear behavior, environmental variances)

•Components laboratory testing (reliability, vibration, temperature, EMF)

•Save cost to test real vehicles

•Save development time

•Easily reproduce/repeat test conditions

•Safe for testing for some dangerous conditions (rollover, pre-crash)

Example Applications

n Brake Testingl Test prototype and production ECUs

l Hydraulic lines and calipers

l Environmental chamber

l Applications – temperature and EMI reliability, brake dyno control

n Active Damper Systeml Physical dampers difficult to model

l Complex suite of test conditions (roads and maneuvers)

l Applications – 7 post rig, stability control, ride optimization

n Driving Simulator for Active Safetyl Human in the Loop

l Drive vehicle through complex traffic scenarios

l Freeform testing

l Visual sensor representations

l Applications – active cruise control, crash mitigation, lane departure

Case Study – Braking ROIEvaluation of Physical Testing vs. HIL

CarSim HILOne Time Costs

Lab construction $120K

Recurring Costs

Energy $2k

Installation $5k

Labor $20k

Uptime 99%

Uptime issues

Test component failure

Physical TestingOne Time Costs

Instrumentation $50k

Recurring Costs

Mule Car w/installation $40k

Transportation $20k

Fuel $8k

Staff $180k

Uptime less than 80%

Uptime issues

Weather, driver availability, fueling, non-productive driving, vehicle component failure, remote locations, driver accuracy, driver safety

RT-Lab Target dSPACE Target Linux RT Based Target LabVIEW RT Target(LabCar, A&D, Fujitsu-Ten)

CarSim/TruckSim/BikeSim supported RT System

CarSim/TruckSim/BikeSim supported RT System

n Opal-RT: RT-Lab

RT-Lab Target Settings

Simulink Model for RT-Lab System

Run on TargetSubsystem

Run on HostSubsystem

Input from ECU

Output to ECU

CarSim/TruckSim/BikeSim supported RT System

n dSPACE l DS1006, DS1005 (PPC 800+ MHz), DS1103 (PPC 800+

MHz), MicroAutobox (PPC 800 MHz)

CarSim vehicle model runs on

compact dSPACE chassis with DS1006 and DS2211(IO)

ABS controller runs on dSPACE

MicroAutobox

dSPACE Target Settings

Simulink Model for dSPACE System

DS2211 IO Card

Runs on DS1006 Board

n ETAS LabCar

CarSim/TruckSim/BikeSim supported RT System

Linux RT Based Target Settings

Simulink Model for ETAS LabCar

LabCar IO Ports

n LabVIEW RT

CarSim/TruckSim/BikeSim supported RT System

ESC Controller

LabVIEW RT Target

Host PC

Target Monitor (option)

Real-Time Animator (option)

LabVIEW-RT Target Settings

LabVIEW Model for LabVIEW-RT System

LabVIEW Front Panel

LabVIEW Background Connection

Timed Loop. dT= 1 msTimed Loop. dT= 1 ms

Outputs to ECU

Inputs from ECU

CarSim Vehicle Solver.Update each time step

Initialize CarSim Vehicle Solver.

Terminate CarSimVehicle Solver.

Engineering Tool• Drive on your proving ground

• Instantaneous A/B/C/D/…comparison of vehicle components

• Drive a road before it is built

• HIL testing of ECUs or complete chassis systems

HIL+Human In the Loop: Driving Simulators

CarSim/TruckSim Inside• Integrate the CarSim/TruckSim

math models with other technologies

• Advanced vehicle controls

• Driver training

• Entertainment

Thank You