Hardware in the Loop (HIL) Testing Seminar

7/30/2019 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


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


UUT

Measured

Speed

MODEL


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Testing Embedded Control SystemsVirtualSystem Level Testing

Motor

Command

Desired

SpeedMotor

Controller

Test System


UUT

Measured

Speed

MODEL

Stimulus=



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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


UUT

Measured

Speed

MODEL

Stimulus=



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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



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Hardware-in-the-Loop Simulation

Testing Production Controller with Simulated Plant

Kc

Controller

Kp

Plant

Error

Control



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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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Hardware-in-the-Loop Simulator

Avionics Tray

HiL Simulator


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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

Hardware in the Loop (HIL) Testing Seminar

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