ETAS Webinar: LABCAR - Scalable HiL Solution

Transcription

1 1 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

2 Agenda Content 1 ECU testing methods 2 Need for HiL 3 Tests on ETAS LABCAR 4 Components of ETAS LABCAR 5 Portfolio of ETAS LABCAR 6 Benefits of ETAS LABCAR 7 Customer references 2 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

3 Need for HiL Do you want to be the test driver? Dear John, (test driver) Here is the new version of the ECU. I implemented a new software function for the electronic braking system yesterday evening. Would you be so kind as to build this ECU into your test vehicle and try it out with some high-speed braking manoeuvres? It works fine as far as I can tell. Thanks in advance Dave (function developer) Can we test different scenarios (environment, driver, failures) safely and independent of the environment? 3 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

4 Need for HiL What is a HiL? Vehicle Testing Lab Testing HiL simulates driver, vehicle and environment so that the functionality of the ECU can be tested as if it were in a real vehicle ETAS HiL offering is called LABCAR 4 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

5 Need for HiL Concept of LABCAR User Simulation Loop Real ECU Hardware I/O Hardware (Signal Generation) ECU input signals (Sensors) User Configuration Manual / Automated Testing I/O Hardware (Signal Measurement) Real-time Simulation Vehicle Dynamics Engine, Drive Train Sensors/Actuators Environment Residual Bus E-Motor Signal Generation Load Simulation ECU output signals (Loads) ECU Connected to simulator HW Connected to real loads Connected to bus systems 5 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

6 Need for HiL Benefits of LABCAR Safety critical testing in safe and real time environment Testing without prototypes Testing early in development cycle Automated testing 6 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

7 Agenda Content 1 ECU testing methods 2 Need for HiL 3 Tests on ETAS LABCAR 4 Components of ETAS LABCAR 5 Portfolio of ETAS LABCAR 6 Benefits of ETAS LABCAR 7 Customer references 7 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

8 Test on ETAS LABCAR Tests performed on a LABCAR Environmental Tests Shaking, temperature, humidity Hardware Tests Current and voltage range tests Overvoltage, undervoltage ( Pin Test ), standby current, endurance test, EMV test Electrical failure simulation Basic Software Tests Communication tests: CAN, FlexRay Wakeup, sleep mode Response tests Test of diagnostics Runtime tests (delay, timing) Performance tests Stress tests Component Tests (test of single ECU functionality) Example: Power Train Engine ECU tests, closed loop, OEM+T1 With either real or simulated loads sensors and actuators Integration Tests (test of distributed ECU functionality) Entire ECU network or parts of ECU network + bus simulation With either real or simulated loads Sensors and actuators 8 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

9 Agenda Content 1 ECU testing methods 2 Need for HiL 3 Tests on ETAS LABCAR 4 Components of ETAS LABCAR 5 Portfolio of ETAS LABCAR 6 Benefits of ETAS LABCAR 7 Customer references 9 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

10 Components of ETAS LABCAR ETAS LABCAR Takasago/Lambda/Toellner, etc. ETAS 3 rd -Party 2 Engineering 7 ES4105/4100 Signal I/Os VME Ethernet 1 Ethernet 3 5 Operation PC Real Time PC ES4440 Error Simulation Breakout Box ECU Harness 6 4 LABCAR-IP/EE/AUTOMATION ES4408 Load Simulation ECU 10 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

11 Components of ETAS LABCAR Components of HiL : RTPC Main Function: Real time simulation of driver, environment and vehicle Computation Power of standard Intel Multi-Core processors Distribute Tasks to multiple cores at a mouse click Parallel simulation of complex models increases performance LINUX operating system with RT extensions Real-time PC in PT LABCAR Open interfaces for 3rd party Hardware and Software 11 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

12 Components of ETAS LABCAR Components of HiL : Signal IO Main Function: Generate electrical values as required by ECU Housed in VME chassis with VME controller or in RTPC over PCI Bus Modular and highly scalable Includes signal conditioning and galvanic isolation Portfolio covers all signals required in automotive testing Supports 12V/24V systems 12 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

13 Components of ETAS LABCAR Components of HiL : Fault Insertion Unit (FIU) Main Function: Simulate electrical defects on sensors and loads to test diagnostics Failure generation in real-time Complete set of OBD / ECU test relevant failures Channels in compact unit (19, 3U): 64 High current channels: 20A, 30V 16 High voltage channels: 10A, 400V Easy integration via Ethernet or CAN 13 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

14 Components of ETAS LABCAR Components of HiL : Load Chassis Main Function: Simulate loads for ECU testing done without real loads Modular : Easy selection of loads Electrical loads up to 60 V DC or 20 A Loads can be calibrated Two major classes of loads: Load Simulation for Common Rail, GDI Piezo Injectors Pull Up/Pull Down Ethernet interface, can be changed in real time Easy integration into other HiL-Systems via Ethernet 14 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

15 Components of ETAS LABCAR Components of HiL : Software LABCAR Operator Main Function: Integrate different components, UI for tester Integration Platform Integration of Behavior Models Connection of Signals Configuration of Real-Time OS Configuration of CAN/LIN/FlexRay Bus Simulation Code generation for LABCAR-RTPC Experiment Environment Integration of Behavior Models Connection of Signals Configuration of Real-Time OS Configuration of CAN/LIN/FlexRay Code generation for LABCAR-RTPC 15 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

16 Components of ETAS LABCAR Domain Components of HiL : Software LABCAR Automation Main Function: Enable automation by connection to LABCAR Operator Powertrain Fully automated test in HiL environment Chassis and Driver Assistance same way Systems Highly reproducible tests Drive cycles are executed exactly the No human interaction Fast test execution General Simulation Tools Efficient testing of all vehicle variants Automatic report generation and classification of test results Models - Partnerproducts ASCET AMESim 16 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

17 Agenda Content 1 ECU testing methods 2 Need for HiL 3 Tests on ETAS LABCAR 4 Components of ETAS LABCAR 5 Portfolio of ETAS LABCAR 6 Benefits of ETAS LABCAR 7 Customer references 17 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

18 Portfolio of ETAS LABCAR Desk LABCAR RTPC + PCIe Card with 40 signals Use cases can be: Open Loop Closed Loop With Camera vision system With FPGA on card Electric Motor Ethernet RTPC BOB ECU Simulation Host PC * With LCA Automation With CAN Card CAN Bus Simulations DESK-LABCAR brings HIL technology on your desk for a competitive price Open and scalable system considers todays and tomorrows requirements Multiple use cases One start! 18 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

19 Portfolio of ETAS LABCAR Desk LABCAR Picture 19 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

20 Portfolio of ETAS LABCAR PT LABCAR PT specific input simulations CAM, CRANK, Knock Sensors (Analog, Resistive simulations) Battery voltage and nodes Lambda Sensor PT specific output (load) simulation Injector loads and measurements Configurable pull up/down loads Failure Injection Unit PT models co-developed with Bosch On board signal conditioning and galvanic isolation 20 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

21 Portfolio of ETAS LABCAR Chassis LABCAR Chassis specific input simulations Wheel speed simulation supports all types of sensor simulation - DF11i, passive, type DF10, type DF10-RotDir, type VDA Different type of sensor for each wheel possible Chassis specific output(load) simulations Pressure sensor and valve detection unit (hydraulic adapter) Can be used with real hydraulics (comprising valves, pump motor controlling fluid supply) ETAS SW open to integrate with third party models (VeDyna, CarSim, CarMaker) 21 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

22 Portfolio of ETAS LABCAR Body LABCAR High number of digital O/P s possible Connection to real loads or simulated loads possible Current measurement possible 22 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

23 Portfolio of ETAS LABCAR Electric : Battery Simulators Cell supply range: V upto 3A (6A, 12A) Accuracy: +/- 1mV, Resolution 76microvolt Active and Passive Balancing Current measurement +/- 3A with accuracy +/- 2 microa Coulomb Measurement, accuracy 1x10-7 As Communication over CAN Up to 400 cells Integrated failure simulation 23 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

24 Portfolio of ETAS LABCAR Electric: Motor Simulations FPGA based simulation; cycle time 850ns ETAS motor models (IM, PMSM) Customer specific models / can be integrated with additional tool chain Free configuration of output signals at DAC Simulation at signal and power levels Can be simulated as Desk LABCAR configuration 24 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

25 Portfolio of ETAS LABCAR Vehicle Simulators 25 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

26 Agenda Content 1 ECU testing methods 2 Need for HiL 3 Tests on ETAS LABCAR 4 Components of ETAS LABCAR 5 Portfolio of ETAS LABCAR 6 Benefits of ETAS LABCAR 7 Customer references 26 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

27 Benefits of ETAS LABCAR LABCAR is an easy to use, scalable test system Value added Modern software designed for ease of use allows short learning effort and efficiency in the daily work With a scalable system, it is possible to increase/decrease the system size as needed by small steps. But the user interface does not change, software assets can be reused easily due to the modular experiment setup and the HW components can be reused in other systems. There is no low-end hardware that can only be used in one specific configuration 27 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

28 Benefits of ETAS LABCAR 28 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

29 Benefits of ETAS LABCAR LABCAR is an open, PC-based simulation investment protection Value added The ETAS RTPC is a standard PC system operating system is real-time LINUX which is widely used in embedded industry Customers can easily upgrade to the latest PC HW technology (e.g. new processor) as needed at very little cost Customers can make use or profit from all assets that are being created by the LINUX community like high-speed drivers (enabling even faster turnaround times), graphical debuggers of the real-time system, drivers for all 3rd party PC I/O boards, real-time testing capabilities, 29 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

30 Benefits of ETAS LABCAR LABCAR has fast Real-Time Simulation PC. Now and in future! Value added Our customers are always equipped with cutting edge technologies enabling fast, precise, low-latency and high-quality real-time simulation Since LABCAR RTPC is a standard PC hardware, with a standard OS, whenever Intel releases a new and faster/more powerful CPU or when there is a new industry PC motherboard with even more optimized memory access and speed, the customer can almost instantly make use of that new system. Without changing the system software or configuration 30 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

31 Benefits of ETAS LABCAR ETAS and Bosch know-how : Profit from our knowledge Value added Efficient HiL Testing requires in-depth knowledge of ECUs, ECU functions, testing techniques, standards and norms Successful HiL Projects require experienced and professional project management and global operations 31 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

32 Benefits of ETAS LABCAR LABCAR offers powerful real-time fault insertion unit Value added Customer can generate reproducible electrical faults in real-time (fault is set within 200µs) Very low resistance between in- and outputs: 25mOhm Many different types of faults possible (open load, short circuit to +/- UBatt A/B, Pin-to-Pin resistance, Leakage current to +/- Ubatt A/B, Inline resistance, loose contact) Open API for operation with different HiL system/automation tools. A lot of competitor simulators are equipped with the ETAS original ES4440 box 32 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

33 Benefits of ETAS LABCAR LABCAR enables true White-Box Testing of ECUs Value added Customers can make use of an ETK interface on the ECU and access ECU internal data in real-time from within the simulator. Thus, test depth and test efficiency are highly increased Customers are able to perform precise actioreaction tests and response time tests with the HiL simulator. If INCA is used at the customer, no other HiL Simulator has a fast and time synchronous access to INCA 33 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

34 Benefits of ETAS LABCAR Customer Benefit Value added ETAS is a comprehensive HiL supplier: People to guide through procurement process People to support installation, training, commissioning Resident engineers to work with your teams to boot strap knowledge 34 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

35 Benefits of ETAS LABCAR ETAS offers Consultancy Services to increase our customers processes, efficiency and improve operation ETAS invests in Process consulting services Test consulting services Embedded software consulting services Calibration consulting services to complete our verification and validation portfolio and offer a complete solution to our customers 35 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

36 Agenda Content 1 ECU testing methods 2 Need for HiL 3 Tests on ETAS LABCAR 4 Components of ETAS LABCAR 5 Portfolio of ETAS LABCAR 6 Benefits of ETAS LABCAR 7 Customer references 36 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

37 Customer reference : GM - Versatile resource LABCAR can be re-configured in a matter of minutes RealTimes : Customer reports 15 minutes to reconfigure the test bench for another ECU Increased utilization of the test bench Share test bench among multiple ECU programs 37 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

38 Customer reference : Consumer Electronics OEM Generic systems Washing Machine Control Panel Washing Machine Simulation Model ETAS LABCAR Test Hardware 38 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

39 Customer reference : Consumer Electronics OEM Generic systems Challenge High effort to manually test all variations of long running wash cycles Low availability of washing machine prototypes Incomplete testing done today due to large number of variants ETAS Solution Closed loop Mini LABCAR plus signal conditioning for 230V AC ETAS Variant Management System to manage complexity Fully automated test scripts with LABCAR Automation Resident engineer to ensure quick introduction of LABWASH into testing process Customer Benefits Fast and completely automated test execution to reduce time to market Flexibility to reconfigure the system for different washing machines / dishwashers Reduced dependency on hardware prototypes 39 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

40 Customer reference : MAN Complex systems Application Areas: Powertrain Chassis Systems Applications: Testing of electrical failure scenarios in a interconnected ECU environment. Engine Controller Engine CAN Central Board Computer Instrument Cluster Instrument CAN ECU system test Release/Validation test Vehicle Management Drivetrain CAN Engine application Brake Controller Transmission Controller Air Pressure Monitor Retarder Controller Number of LabCar Systems: 2 x LabTruck System ( 5 individual single LabCar systems per LabTruck) 2 X LabCar PT Trailer CAN 40 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

41 Customer reference : BOSCH Robust systems BOSCH presentation February 2011 Development of Gasoline and Diesel ECUs Several hundred Simulation Models and variants >200 identical ETAS PT LABCARs 10 locations globally Regression testing of all variants Release testing of all new software Endurance testing (tests run over 6 weeks) Using the entire LABCAR tool chain Seamless integration of LABCAR AUTOMATION in the development process 41 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

42 Customer reference : Japanese OEM Automation Challenge: Customer requested a automated, scalable test system for Network integration tests incl. ext. fault simulation with up to 8 ECUs Operating different simulation models (3rd-party and original) Using 3rd-party developed scenarios and test cases Solutions: Customized 4-rack ETAS LC system supporting connection Operation of up to eight ECUs and automated fault simulation 1.stage: network (Rack A and loadbox) 2.stage: network,engine (Rack A,B and loadbox) 3.stage: network,engine, brake,esp,abs,amt (Rack A,B,C and loadbox) Network Integration with LABCAR ETAS GmbH All rights reserved. The names and designations used in this document are trademarks or brands belonging to their respective owners. 42 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

43 Customer references Indian OEM: complete solution providers Indian OEM using LABCAR as vehicle simulator with body, chassis and powertrain controller Challenge: To integrate ECUs from different vendors and verify algorithms, communication and diagnostics Solution: Complete vehicle simulator LABCAR HiL with the possibility: Connection of real and virtual loads Fault insertion for all inputs and outputs for diagnostics testing Test of full fledged body control module integrated with instrument cluster Virtual vehicle dynamics simulation environment Customer benefit: Early verification of algorithms, communication and diagnostics Reduced dependency on vehicle prototypes Automation testing and report generation HiL also was re-used for individual ECU test 43 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,

44 Questions 44 Public ETIN/STI ETAS GmbH All rights reserved, also regarding any disposal, exploitation, reproduction,