ECU Testing With dSPACE Simulator

ECU Testing
ECU Testing with

dSPACE Simulator
Cutting-edge systems
for ECU/controller testing
Original equipment manufacturers (OEMs) today face pressures on multiple fronts.

The time to market is shrinking while the content and complexity of the vehicle
electronics is rapidly increasing. Almost every automotive innovation effects the
electronics in the vehicle.
Test drives in test vehicles can scarcely cope with the volume of systematic testing
needed, especially close to start of production. The growing number of recalls is a
clear indication of this. It is little wonder that testing and error finding have become
key tasks in the development process.
Systematic and Reproducible
Testing in Hardware-in-the-loop (HIL) simulation is a viable alternative, allowing new
electronic control units (ECUs) and software to be tested largely in a virtual environment, without real vehicles or prototypes. Such tests are very systematic and also
completely safe, even when critical thresholds are exceeded, while allowing ECU
errors to be reproduced whenever and however required.
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Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de
dSPACE Simulator Introduction
Improving ECU Software Quality

HIL simulation improves quality even at an early
stage. A major Japanese automobile manufacturer
states that HIL simulation finds 90% of ECU errors, and almost all the errors that it is possible
to find before the calibration phase. Recall campaigns and associated damage to the companys
image are minimized. The investments made in
HIL systems and in developing tests have usually
paid off after only a few months. Just a few of
the reasons:
Hardware-in-the-loop simulation
avoids recall campaigns and
loss of corporate image
Fewer prototypes, fewer test drives,
lower costs
More comprehensive and more systematic tests in a shorter time
Higher quality, lower risks
Start of production on schedule using fewer resources
Key Features of dSPACE Simulator
Your Benefits
Full integration of MATLAB/Simulink,
State-of-the-art modeling and
the worlds leading design and

modeling tool
Full integration into
the dSPACE tool chain
Solution-oriented products and
powerful test automation
Easy access to the real-time model,
states and parameters,

even during run time
Fast, graphical programming
via drag & drop
Product maturity as the worlds most
used HIL simulator:

1,100 in operation worldwide
Best options for
networking and expandability
maximum compatibility with existing

models or third-party models
Maximum reusability of models, test
scripts, layouts and knowledge
Savings in time and money
Greatly improved software quality
Homogeneous and efficient
user interfaces
Steep learning curves
Fast iterations
Competitive advantage
dSPACEs extensive experience in
the fields of hardware-in-the-loop
simulation and test automation
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ECU Testing
Test Scenarios with dSPACE Simulator

The complexity and multilayered architecture of modern ECU software means that
the same ECU has to be tested from all perspectives. dSPACE Simulator covers every
conceivable test scenario. dSPACE Simulator is not only used in the classical domains
of engine, powertrain, and chassis. The systems flexibility allows virtually any adaptation: cruise control, body electronics, and especially ECU network tests.
Transmission
Continuously variable transmission
Automatic transmission
Automated manual transmission
Double-clutch transmission
Diesel
4-12 cylinders
Turbocharger
Common rail unit injection
Passenger car and
heavy-duty trucks
Otto
4-16 cylinders
Manifold injection
Direct injection
Turbocharger
Vehicle Dynamics
Bosch ESP 5.3, 5.7, 8.0
ContiTeves ESP
TRM ESP
Vehicle Types
From passenger cars to
light and heavy-duty
trucks to Formula One
Others
Body electronics
Comfort
Air-conditioning control systems
Verifying Control Algorithms

The ECUs are tested against the specification in normal operation. This is done by
running virtual test runs simulating all the necessary vehicle and component variants,
either manually or in automated form. Slalom tests and lane change maneuvers for
vehicle dynamics control units and standard drive cycles, such as FTP75 for testing
engine controls, are examples of this.
dSPACE Simulator offers you a perfect environment for such tests. The ECUs diagnostics functions are tested under closed-loop conditions, for example, you have to
check the plausibility of safety-critical sensors such as steering wheel sensors and
yaw rate sensors. Sensor failures (for example, a wheel speed sensor failure at high
speed and during control operation) and CAN bus failures can also be simulated,
and the new controller has to react to them correctly.
ECU Calibration
This can be carried out at a very early stage by means of modern simulators. This is
important because the fast-growing number of ECU parameters and their mutual
effects are making it more and more difficult to get the final vehicle right. Using
realistic vehicle models, it is possible to carry out or even automate the adaptation
of ECUs, which can later reduce the cost involved in the calibration process.
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Integration Tests on ECU Networks

The main concern is to test problem-free interaction of all the ECUs that are communicating, e.g., via CAN and LIN. Network tests have become necessary mainly
because of the growing number of ECUs from different manufacturers that perform
their overall function only when networked.
ECU Network Tests
In an ECU network test with dSPACE Simulator, ECUs that are not yet available can
be simulated and replaced by their real counterparts later on (restbus simulation).
Depending on the application, you will have to test networked ECUs (for example,
ECUs in powertrain or body electronics systems which together provide superior
functionality). Because dSPACE Simulator is so flexible, it can easily have several
ECUs connected to it.
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Networked ECUs can be tested

using a single simulator ...
In other cases, it is desirable to first test each ECU separately with different dSPACE
Simulators. After successful tests, it is no problem to connect the dSPACE Simulators, in order to work with a networked simulator setup. The modularity of dSPACE
Simulator makes virtually all test scenarios possible. For example, you can run all the
simulators in a network or separately as single simulators. Missing ECUs can even
be replaced by simulation models, without rebuilding any code.
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... or a simulator network. ECUs that are

not yet available can be simulated (software
ECUs) and gradually replaced by their
real counterparts (restbus simulation). All
simulators can be operated from a single PC.
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ECU Testing
Testing Diagnostic Functions

To test diagnostic functions (e.g., OBDII and EOBD), the ECU behavior when faults
occur is tested. The vehicle is simulated in a closed-loop environment and systematically drives through all the defined operating points. This allows the diagnostics to
be tested systematically. Typical diagnostic tests relate to the plausibility of signals or
defective electrical connections. It is important for diagnostic tests to be run completely automatically, as release tests often have to be performed within an extremely
short time. dSPACE Simulator flexibly creates different scenarios for different ECUs,
allowing a great diversity of versions to be handled. In the near future, AutomationDesk (p. 140) offers a powerful and convenient test automation environment
to make systematic testing even more efficient.
The Benefits of dSPACE Simulator

dSPACE A Competent HIL Partner
dSPACE is your partner in selecting the right system and installing and
configuring your dSPACE Simulator.
Delivery on schedule (approx. 3 months for a single Simulator Full-Size,
approx. 6 months for simulator networks for over 30 ECUs)
Professional project management and fast commissioning
Our offices can help you get the most out of your dSPACE Simulator by
offering additional services such as training sessions and on-site support.
Technical Lead
dSPACE Simulator is the worlds leading system for the systematic testing of
electronics and software. There are currently more than 1,100 simulators with
dSPACE technology in use worldwide, nearly all of them at major automotive
companies such as Audi, BMW, DaimlerChrysler, DENSO, Ford, Magneti Marelli,
Nissan, Opel, Renault, Toyota, Volkswagen and several Formula One teams.
Broad range of experience: diesel, spark ignition and direct injection

engines, transmission, vehicle dynamics, and vehicle interior systems
Support of networked ECUs (example: 36 ECUs, more than 7,000 signals
on 4 CAN busses and 10 LIN busses, plus 2,000 further I/O signals) and
even the complete vehicle electronics system
Battery network management (sleep, wake-up) tested by precise
measurement of sleep-mode current and operation current from
1 A to over 100 A
Exemplary hardware and software tools for error-finding and test
automation
Applications: cars, light and heavy-duty trucks, racing (Formula One, rally),
aerospace
dSPACE Simulator offers everything you need to perform your tests: Tight
integration of dSPACE software and the modeling tool MATLAB/Simulink from
The MathWorks provides a powerful development environment. And the powerful
and robust dSPACE hardware always sets the standards for HIL technology.
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Test Efficiency
dSPACE Simulators graphical user interfaces provide a convenient and
flexible environment. Simulated driving cycles, data acquisition, instrumentation,
monitoring, test automation and all other tasks are executed graphically within
dSPACE Simulator.
dSPACE software gives you the greatest possible test efficiency and ease of
use.
Signal Generation and Measurement
These are just a few of the automotive signals that can be generated and
measured by dSPACE Simulator
Algorithm- and waveform-based signal generation
(e.g., crankshaft, camshaft, knocking signals)
Generation of PWM sensor signals and Hall sensor signals
(e.g., wheel speed, fuel level)
Generation of resistance-based sensor signals (e.g., temperature)
Generation and measurement of analog and digital sensor signals
(e.g., throttle, switches, lamps, relays)
Simulation of linear lambda probes
Angle-based measurement of injection and ignition pulses
Measurement of PWM actuator signals (e.g., solenoid valves)
Connection to CAN, LIN, FlexRay and serial interfaces
Example: Compensation of potential gradients caused by...
Cable resistance
The ECUs varying power consumption in different operating conditions
...and our solutions in dSPACE Simulator:
Differential analog inputs and outputs
Potential-free resistance outputs
Output transformers for all fast analog outputs
dSPACE Simulator Components

For details on dSPACE Simulators modular concept, please see the following
pages.
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ECU Testing
Implementation Software
The code for dSPACE Simulators real-time hardware is generated automatically,
directly from MATLAB/Simulink. Your MATLAB/Simulink model is connected to the
real-time hardware via drag & drop. Powerful software tools are available for this:
Real-Time Interface for implementing Simulink and Stateflow models on
dSPACE Simulator
Optional extensions to Real-Time Interface
Real-Time Interface (RTI)
dSPACEs Real-Time Interface completely integrates MATLAB/Simulink and offers
additional blocks to connect models and our I/O hardware. For example, there are
comprehensive libraries for the DS2211 HIL I/O Board, our most powerful I/O board
for HIL applications. RTIs graphical user interface reduces the work involved in
supplementary model changes and I/O adjustments to a minimum.
Real-Time Interface (p. 108)
Graphical programming and connection to

I/O, CAN bus or LIN bus: everything is done
graphically in Simulink with our Real-Time
Interface.
Configuring CAN and LIN Bus Communication

Configuring your CAN bus communication graphically from Simulink is no problem
with the additional RTI CAN Blockset.
With our new RTI CAN MultiMessage Blockset, you can configure and control a large
number of CAN messages (more than 200) from one single Simulink block.
To simulate communication in a LIN network, we also provide the RTI LIN Blockset
for effortless configuration of LIN master and slave nodes simulated on the DS4330
LIN Interface Board.
Real-Time Interface CAN Blockset (p. 116)
Real-Time Interface CAN MultiMessage Blockset (p. 118)
Real-Time Interface LIN Blockset (p. 120)
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dSPACE Simulator Software
Experiment Software:
ControlDesk for Experiment Management
dSPACE Simulator gives you complete control of your experiments. ControlDesk is
a graphical front-end tool that forms the interactive experiment and visualization
interface of dSPACE Simulator.
Graphical user interface for experiment and platform management
Generation of virtual instrument panels
Preconfigured layouts for HIL applications
Design of user-specific layouts
ControlDesk offers powerful analysis tools, such as instruments to set up virtual

instrument panels.
With the integrated experiment and test environment and ControlDesks Simulink interface, you can monitor your experiments in Simulink and later in real-time
simulation, using the same tools and the same user interfaces.
ControlDesk (p. 128)
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ECU Testing
ControlDesk Failure Simulation
Using ControlDesk Failure Simulation, you can simulate failures in the wiring of
an electronic control unit (ECU). For example, you can simulate that an ECU pin is
short-circuited to ground or the battery voltage, or that an ECU pin is not connected
(cable break).
Extension of ControlDesk Standard
Remote control of the failure insertion unit in dSPACE Simulator
Mid-Size or Full-Size
Import of ECU pin description files
Central Failure Management
ControlDesk Failure Simulation is software for driving the electrical failure simulation in the ECU cable harness. The failure simulation hardware, failure patterns, and
ECU signal channels are all handled centrally via software. Electrical failures are also
activated and deactivated centrally. When networked ECUs are tested, each ECU is
displayed separately with its signal channels. ControlDesk Failure Simulation runs on
existing dSPACE Simulators Mid-Size (p. 88) and Full-Size (p. 90). It also works hand
in hand with AutomationDesk, our test automation software (p. 140).
Handling Failure Simulation Hardware
The Failure Simulation Navigator provides access to the failure simulation system:
Access to all connected ECU signal channels enabled for
electrical failure simulation
Administration of failure patterns (failures to be simulated at the same time)
Handling Failure Patterns
The Failure Pattern window visualizes failure patterns and the status of the failure
simulation hardware, and allows the failure patterns to be edited and saved.
ControlDesk Failure Simulation (p. 139)
The Failure Simulation Navigator
in ControlDesk Failure Simulation:
Central handling of failure simulation
hardware, failure patterns and
all ECU channels.
Failure Pattern window: Every failure

pattern is shown in a layout.
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dSPACE Simulator Software
Test Software:
AutomationDesk
AutomationDesk facilitates the task of developing and managing tests.
Automated testing in HIL simulation
Graphical user interface for managing test projects
Graphical editor for describing automation sequences
AutomationDesk is ideal for automating hardware-in-the-loop tests. AutomationDesk
offers a convenient test automation environment, which supports the development
and handling of large test projects and test sequences. With AutomationDesk, the systematic structure, reusability, and reproducibility of test sequences are unequalled.
AutomationDesk (p. 140)
Typical Automation Tasks Executed with AutomationDesk

Setting up operating point
ECU initialization (e.g., failure memory
reset) and simulator environment

Stimulus signal generation (to switch
Measurement
Evaluation and test reporting
Data management
short circuit failures or to input

reference trajectories)
Access to real-time variables during
run time
Access to ECU internal variables via
diagnostic or calibration interfaces
Data capturing of simulator variables
Access to MATLABs mathematical
test validation capabilities or direct
calculations in Python
Automated report generation based
on XML with standard style sheets for
HTML and PDF
Organization and storage of
test sequences, parameter sets,
measurement data and test reports
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ECU Testing
3-D Online Animation with MotionDesk
MotionDesk provides 3-D animation of mechanical systems in a virtual world.
3-D online animation of HIL simulation in real time
Graphical user interface similar to other dSPACE tools
Graphical interactive scene design
Scalable number of MotionDesk PCs for multichannel visualization,
e.g., for interactive test drives
Time-stamping and AVI file generation
Simulation comparison: for example, transparent or shadow vehicles
Full-brake simulation or braking on different surfaces: MotionDesk makes the

cars behavior visible.
In vehicle dynamics simulation, maneuvers and critical behaviors are particularly hard
to detect by conventional methods such as time histories and display instruments.
A much better impression of what is happening with the vehicle is given by 3-D
online animation.
MotionDesk performs such 3-D animation for all objects simulated on dSPACE
Simulator in real time. With MotionDesk, the results of any action in the simulation
that is running become visible on your PC immediately.
MotionDesk (p. 154)
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dSPACE Simulator Hardware
dSPACE Simulator Hardware Concepts

Different Systems for Different Tasks
The hardware requirements might vary immensely depending on your hardware-inthe-loop application. For example, function tests are executed with simulators that
have a clear set of I/O. In contrast, acceptance tests call for modular, expandable
simulator hardware that allows I/O and processing power to be scalable.
dSPACE Simulator therefore comes in different hardware types, which are the basis
for expansion to your specific task.
dSPACE Simulator Mid-Size
dSPACE Simulator Mid-Size is a standardized, off-the-shelf HIL simulator. Its hardware
is based on two boards from our modular hardware, a processor board and the
DS2211 HIL I/O Board. Other I/O boards can be added if required.
dSPACE Simulator Mid-Size (p. 88)
dSPACE Simulator Types:

Mid-Size and Full-Size
dSPACE Simulator Full-Size

dSPACE Simulator Full-Size is a modular simulator concept that is assembled with
off-the-shelf components according to your needs. This results in high quality at
attractive prices. dSPACE Simulator Full-Size gives you a high-quality, tailored system with enormous extension capabilities. If you need to expand or modify your
simulator, dSPACE has a wide variety of components that can be integrated into
your dSPACE Simulator Full-Size.
dSPACE Simulator Full-Size (p. 90)
Simulator Networks
Several dSPACE Simulators (of any hardware type) can be connected to set up a
networked simulator environment (p. 77).
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ECU Testing
Hardware Summary
dSPACE Simulator
Mid-Size (p. 88)
dSPACE Simulator
Full-Size (p. 90)
Form factor
19 desktop rack
19 cabinet 17 37 HU
Processor hardware
DS1005 PPC Board or
DS1005 PPC Board or
DS1006 Processor Board
DS2211 HIL I/O Board
Any number and type of
Vertical modules
I/O hardware
dSPACE I/O boards

Further I/O hardware
Signal conditioning
Substitute loads
Real-load connector
Failure insertion unit
Integration of simulatorspecific hardware

(p. 74)
Integration of third-party
hardware, e.g., load panels
ECU connectors
Three 90-pin connectors
Additional connectors
for additional I/O
optional
Break-out box
OBDII diagnostic
connector /
connection to
diagnostic tools
z
One or more 90-pin
connectors for each ECU

(standardized)
optional
Sub-D connector with
optional CARB adapter

CAN connector
Standard 16-pin CARB
connector
Diagnostic connectors
(CAN, K-line)
Others on request
Truck applications-capable
(24 V/36 V)
42 V-capable
Power supply
(remote controlled)
z Included
Available on demand
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dSPACE Simulator Hardware
Failure Simulation Summary

Failure simulation can be performed with both dSPACE Simulator Mid-Size and
dSPACE Simulator Full-Size. Powerful failure simulation hardware further boosts
their functionality.
dSPACE Simulator
Mid-Size
Standard
Failure insertion units 5 x DS749 FIU Module

(each features 10 channels)
Optional: replaced with
5 x DS792 Fuse Cards
Possible failure types On ECU outputs:
Cable break
Short circuit to ground
Short circuit to
battery voltage
Short circuit to another
ECU pin via two fail planes
dSPACE Simulator
Full-Size
Hardware Extension
n x DS793/DS794 Sensor
FIU Cards (up to 2 cards,

each 81 channels with
CMOS switches)
On ECU inputs:
Cable break (open line)
Short circuit to ground
Short circuit to
battery voltage
ECU pin via two fail planes
Failure Simulation Variant 1 Failure Simulation Variant 2
Failure insertion units n x DS291 FIU Module

1 x DS293 Central FIU
(each features 10 channels)
Module
n x DS281 Load Module
n x DS282 Load Module
(10 channels)
1 x DS289 Rsim Module
(simulates a resistance in
the range 1 ...131 k
in steps of 1 )
Possible failure types On ECU inputs and outputs: On ECU inputs and outputs:
Open circuit
Open circuit with or
without additional
Short circuit to ground or
hardware (Rsim, MEAS or
minus pole of the battery
SOURCE) in series
(KL31) with connected/
disconnected load (an ECU Short circuit to another
input is disconnected from
ECU pin directly or via
a dSPACE output channel)
additional hardware
Short circuit to plus pole
Short circuit to 5 reference
of the battery (KL30) with
points (potential 04)
connected/disconnected
directly or via additional
load (an ECU input is
hardware
disconnected from a
dSPACE output channel)
ECU pin with or without
load (via common rail)
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ECU Testing
dSPACE Simulator Mid-Size:

Hardware Details
The hardware of dSPACE Simulator Mid-Size is mounted in a 19 desktop rack (height:
6 9 HU). The simulation model runs on the processor board. dSPACE Simulator
Mid-Size generates and measures I/O signals via the DS2211 HIL I/O Board, which
also performs the signal conditioning. Additional I/O and signal conditioning can
be added on request.
Hardware summary (p. 86)
Failure insertion units,
load cards, external
connection of real loads
ECU connectors
Spare slot
OBDII connector
via adapter
Modular hardware:
processor board and
I/O board with signal
conditioning
Remote-controlled
power supply
(battery simulation)
Connection to Host PC
All dSPACE software (p. 106) for experiment setup and control runs on your PC or
notebook. The dSPACE Simulator hardware is connected to your PC via link boards
(ISA, PCMCIA, or PCI, p. 322).
Typical Fields of Application
Engine, transmission and vehicle dynamics HIL
Realistic software system tests/unit tests
Function integration tests
Open-loop or closed-loop environment
Automated testing of diagnostic functions that check the ECU outputs
Hardware Components
Installation in 19 desktop rack (see table)
Integrated signal conditioning for all DS2211 signals
Enclosure Variants
Standard variant,
Small variant,
2-voltage system optional 1-voltage system
DS1005 PPC Board or

z
z
Failure insertion units
Load cards
Power supply
Second power supply
Free ISA slots for expansion
1 (PX5 version, only for
DS1005 PPC Board)

5 (PX10 version)
Height units
z
1 (PX5 version, only
for DS1005 PPC

Board)
6
Included
Optional
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Signal Conditioning
On-board for DS2211 HIL I/O Board signals
Two spare slots for additional signal conditioning (e.g., current measurement
for diesel and stratified injection applications, lambda probe simulation or
signal conditioning for additional I/O boards)
Failure Insertion Units
A standard dSPACE Simulator Mid-Size supports electrical failure simulation on all
ECU output pins connected to the DS2211. A hardware extension allows electrical
failures to be simulated on ECU inputs as well. The host PC controls both types of
failure simulation via an RS232 interface. See p. 67 for further information.
ECU outputs: Five failure insertion units (FIUs) with 10 channels, connected to
all 50 actuator channels; Optional: replaced with 5 x DS792 Fuse Cards
ECU inputs: optional, via hardware extension (p. 67)
Remote-controlled with ControlDesk Failure Simulation and (on request)
automated with AutomationDesk
Simulation of shorts: shorts from ECU pins to ground or battery voltage
Cable break simulation (open wire)
Simulation of cross-wired short circuits via two fail planes
Simultaneous activation of multiple failures (latch mode)
Load Capabilities
Five load cards, 10 single-ended loads or 5 double-ended loads each
2 W maximum continuous power per load (substitute loads)
8 A maximum load current per pin (real loads)
LED indicators displaying current load states (display mode selectable)
Front connector for measurement or connection of real loads
VBat Jacks
Provides power voltage of both power supplies for external devices
(e.g., external test or diagnostic devices)
4 mm sockets
Power Supply
Programmable switched-mode power supplies (remote-controlled, 2 power
supplies required for simulation of vehicle batteries in 2-voltage systems)
Support of 24-V systems with the first system
Support of 42-V systems with the second system
Three switched battery rails for each battery voltage,
e.g., main relay, ECU-controlled high rail
16 A maximum current for each rail of first battery voltage
7.5 A maximum current for each rail of second battery voltage
Other Hardware Components
Break-out box (optional)
Expandability
Expansion with further DS2211 HIL I/O Boards (cascadable),
ECU Interface or CAN Interface boards
Inclusion of real loads, additional, or customer-specific signal conditioning
(e.g., current measurement for diesel or stratified injection applications) or
signal conditioning for an additional I/O board
Customer-specific modifications/extensions possible
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ECU Testing
dSPACE Simulator Full-Size:

Hardware Details
dSPACE Simulator Full-Size is mounted in a 19 cabinet whose height depends on
your requirements. The dSPACE boards are mounted in a standard PX20 Expansion
Box (p. 321). The PX20 Expansion Box provides 20 ISA slots for dSPACE boards,
and an additional Expansion Box can be integrated, so you never face restrictions
on expandability.
Open Hardware Concept
The simulation model runs on the processor hardware (single-processor or multiprocessor systems, based on processor boards).
dSPACE Simulator generates and measures I/O signals via the integrated dSPACE
I/O boards. The signal conditioning, loads, failure insertion units and power supply
are also mounted in the 19 cabinet. The number of components, and their types,
depend on your requirements and are configured to fit your application.
(e.g., CARB, OBD)
Break-out box
ECU connector
Power supply
Connector for
external loads
Loads and failure
simulation
(remote-controlled)
Signal conditioning
Modular hardware:
processor boards
and I/O boards
Connection to Host PC
All dSPACE software for setting up and controlling experiments runs on your PC or
notebook. The dSPACE Simulator hardware is connected to your PC via Link Boards
(ISA, PCMCIA, or PCI, p. 322).
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2005
dSPACE Simulator Full-Size
Typical Fields of Application

Engine, powertrain, and vehicle dynamics HIL
Comprehensive closed-loop tests on ECUs, release/acceptance tests
Networked ECUs
Special requirements, e.g., with high system flexibility
Truck applications
Racing applications (Formula One, rally)
Hardware Components
Installation in 19 cabinet
Single-processor or multiprocessor systems, based on processor boards
PX20 Expansion Box for modular dSPACE hardware
Freely expandable by any dSPACE I/O board (see Modular Hardware, p. 224),
according to your requirements
Expandable, e.g., with hardware for signal conditioning,
failure insertion and load simulation
Signal Conditioning
Signal conditioning for all dSPACE I/O boards
Modular signal conditioning concept (off-the-shelf components,
customer-specific configuration)
Supports almost any signal type: e.g., digital in, digital out, analog in,
analog out, relay simulation, current sink/source, LVDT simulation,
resistance simulation
Further modules on demand
Failure Insertion Units

Failure insertion unit (FIU) for ECU inputs and outputs
Modular FIU concept (customer-specific configuration)
Remote-controlled with ControlDesk Failure Simulation
(and optionally with AutomationDesk)
Simulation of shorts: shorts from ECU pins to ground,
battery voltage, or switched rail
Cable break simulation (open wire)
Simulation of cross-wired short circuits
Simultaneous activation of multiple failures (latch mode)
Failure Simulation Variant 1
Our standard variant for failure simulation on dSPACE Simulator Full-Size supports
failure simulation on all ECU input and output pins. All digital and analog I/O boards
from dSPACE are supported by failure simulation. The relay boards (DS291) for failure
simulation can be used on their own or in conjunction with load boards (DS281).
Failure relays are controlled via a serial RS232.
Failure Simulation Variant 1 (p. 87)
Failure Simulation Variant 2
Our second failure simulation variant uses a central relay switching matrix (DS293)
for failure simulation on ECU inputs and outputs. Signal channels can be switched
in on three different rails via load modules (DS282). Further devices that can be
connected include 5 different system potentials (for example, KL30, KL31, KL15),
various measurement devices, and Rsim modules (DS289 for simulating real
substitute loads). See p. 87 for further information. Failure simulation is controlled
via a CAN interface.
Failure Simulation Variant 2 (p. 87)
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ECU Testing
Load Capabilities
Modular load concept (customer-specific configuration)
Support of single-ended and double-ended loads
Resistive loads or other kinds of equivalent loads
Connection of electrically equivalent loads or low-power resistive loads
Connection of real loads, can be integrated in the cabinet
Integration of customers load panels
Power Supply
Simulation of car battery
Programmable switched-mode power supply
Remote-controlled
42 V and truck-capable: 0 50 V voltage range
Other Hardware Components
Break-out box (optional, integrated in cabinet or external)
Optional inclusion of third-party hardware;
e.g., load panels, signal routing units, GPIB instruments
Power switch modules (p. 94)
Expandability
Maximum flexibility through modular concept
Minimum hardware modification when requirements change
Supersets with spare signals, allowing tests on several ECU variants,
even after ECU pinout changes
All signals accessible on terminal strips for additional measurement tasks
Clear and transparent system architecture
Multirack systems possible
92
2005
Simulator-Specific Hardware
If you need to expand or modify your simulator, dSPACE has a wide variety of off-the
shelf components that can be integrated into your dSPACE Simulator.
dSPACE Simulator Full-Size can be equipped with simulator-specific hardware for
optimum tailoring to your specific needs. dSPACE Simulator Mid-Size can also be
similarly equipped to a certain extent.
The simulator-specific hardware includes real system components and signal conditioning, as well as measurement and diagnostic tools. The components and tools
can be built and integrated by dSPACE, third-party suppliers, or you yourself.
The setup shown in the illustration is typical of many application areas, and you can
also add or remove as many components as you like.
)NTERFACETO$IAGNOSTIC
AND#ALIBRATION(ARDWARE
2EAL3YSTEM#OMPONENTS
3IMULATOR(ARDWARE
"REAK /UT"OXES
2ELAYAND&AILURE5NITS
-ODULAR(ARDWARE
#ONTROLLER%#5
0ROGRAMMABLE0OWER3UPPLY
0OWER3WITCH-ODULES
3IGNAL#ONDITIONING
#!.'ATEWAY
/THERS
93
2005
ECU Testing
Examples of Simulator-Specific Hardware

Interface to Diagnostic and Calibration Hardware
Many companies already have their own diagnostic and calibration hardware to
perform tasks such as reading out internal ECU variables from the failure memory.
If you do not intend to run this functionality on dSPACE Simulator, the hardware is
connected to dSPACE Simulator via appropriate interfaces, which might in some cases
need a little engineering. You can connect any kind of measuring device, digital scope,
and diagnostic device you like with special protocols such as GPIB or RS232.
Real System Components
In some cases, the real system components (such as injection valves, hydraulic components, and sensors) have to be integrated into dSPACE Simulator. This is necessary,
for example, if ECUs and related components come from different suppliers and
have to be checked within the simulated environment. Moreover, not every vehicle
component can be simulated with a justifiable amount of time and money, and many
ECUs require real loads at their outputs in order to function at all.
Break-Out Boxes
An optional break-out box makes all ECU pins directly accessible. This simplifies the
measurement and input of signals. The break-out boxes can be integrated into dSPACE
Simulator, or take the form of external desktop boxes. Third-party break-out adapters
can also be included (available for dSPACE Simulator Mid-Size and Full-Size).
Relay and Failure Insertion Units
Any number and type of open circuits and short circuits can be simulated by using
relay and failure boxes. Besides our failure insertion unit, it is also possible to integrate
customer-specific and third-party solutions.
Programmable Power Supply
The programmable power unit supplies the components to be tested and enables the
simulation of real voltages such as the battery voltage of a vehicle during start-up.
The power supply unit is remote-controlled from within the real-time model.
Power Switch Module
ECUs consume power even when the vehicle is parked. Many modern ECUs have
a sleep mode to avoid draining the vehicles electrical system unnecessarily. Some
ECUs therefore contain a CAN transceiver capable of sleep mode, which allows the
ECU to run only if it is needed and switches it off otherwise. Power switch modules
provide network management for such systems to be tested, e.g., with sleep mode
and wake-up functions.
Moreover, systems with networked ECUs often require different power supply voltage
levels. Each power switch module therefore handles two power supplies to simulate
different vehicle electrical systems within dSPACE Simulator. Even the sequence when
a vehicle is starting up can be simulated.
A measurement unit allows the precise current measurement of each ECU in different
current ranges, even in the microampere range. For example, current consumption
during ECU sleep mode can be compared with normal operation mode behavior.
The module is controlled by software via a CAN interface.
94
2005
Signal Conditioning
Real components usually cannot be connected directly to the real-time hardware.
The signal level of the ECU and other connected components must first be adapted
to the I/O interfaces of the real-time hardware. The signal conditioning necessary
for adaptation is an important part of dSPACE Simulator and includes protection
circuits, signal preparation, etc., in addition to level adaptations.
CAN Gateway
In large-scale CAN networks, the testing of bus communication plays a key role.
Engineers need to test the behavior of ECUs and distributed functions when an
expected CAN message fails to arrive or contains unexpected signals.
To simulate errors, a CAN gateway is inserted into the CAN network (see graphic).
Each ECU can be connected individually to one of the two CAN controllers. Signal
manipulation by software allows you to manipulate any CAN messages from any
ECU, with a predefined effect on the other ECUs in the CAN network. The CAN
software (RTI CAN MultiMessage Blockset) generates error situations right up to
message or individual signal level.
#!.GATEWAYSOFTWARE
3IGNALMANIPULATION
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MANIPULATION
2X
4X
2X
#!.
CONTROLLER
%#5
4X
#!.
CONTROLLER
%#5
%#5N
#!.GATEWAYHARDWARE
CAN gateway for simulating errors in large ECU networks.
Simulation of Linear Lambda Probes
LSU is a new signal conditioning module for dSPACE Simulator Full-Size and
Mid-Size that simulates the behavior of linear lambda probes. These probes measure the air-fuel ratio in a cars catalytic converter. The engine ECU reacts continuously to this information so that the catalytic converter can operate at an optimal
performance rate.
The LSU module allows Nernst cell voltage to be generated on two independent
channels, according to pump current and Nernst cell inner resistance. The module
functions as a linear probe or as a jump probe. Parameters such as maximum/
minimum Nernst cell voltage can be adjusted.
95
2005
ECU Testing
Real-Time Models for dSPACE Simulator

Models from MATLAB/Simulink/Stateflow
For hardware-in-the-loop simulation, you need real-time models to simulate the real
environment. dSPACE Simulator is optimally equipped for integrating simulation
models from MATLAB/Simulink/Stateflow. Thanks to years of cooperation between
The MathWorks and dSPACE, the tools from these two companies are perfectly
tailored to each other. This way, you can can use your own real-time models or
third-party models. For example, our partner TESIS DYNAware, Munich, Germany,
offers Simulink-based simulation models for HIL simulators that really make your
dSPACE Simulator come alive.
Model-Based Development
After you develop your simulation model, you can test it with Simulink and
ControlDesks Simulink interface and then in real time on dSPACE Simulator with
the same layouts, test scripts and parameter sets.
Services for Real-Time Models
Based on years of know-how in hardware-in-the-loop simulation, dSPACE also offers
modeling services such as
Integration of models into dSPACE Simulator
Parameterization of models based on customer data
Model interfaces
Integration of different modeling tools (Dymola, AmeSim, C-Code, others)
Adaptation of customer models
96
2005
Configuration Examples
Configuration Example:
dSPACE Simulator for Testing Single ECUs
dSPACE Simulator Mid-Size is the perfect choice for testing single ECUs or for test
projects with fixed ECU wiring.
D30!#%3IMULATOR-ID 3IZE
%#5
0#
-ODULARHARDWARE
OFF THE SHELF
$3
$3
2EAL 4IMEMODEL
EXECUTEDBY$3
/FF THE SHELFHARDWARE

&AILURE)NSERTION5NITS
,OAD#ARDS

,OAD#ARDS
-ODELINGSOFTWARE
)MPLEMENTATIONSOFTWARE
%XPERIMENTSOFTWARE
0OWERSUPPLIES
Possible ECU Testing Tasks for This Configuration

Functional tests for single ECUs
Integration tests for single ECUs
Acceptance tests for single ECUs
Release tests for single ECUs
Virtual vehicles (when networked with other dSPACE Simulators)
Possible Test Areas for This Configuration
Gasoline engine
Diesel engine
Transmission
Vehicle dynamics
Climate control
Comfort functions
12 42 V applications
Components (Example)
Third-Party Components
Further Details
PC
Modeling software
Real-time model
Real-time code generation
MATLAB / Simulink /
Stateflow from The

MathWorks
Real-time models for
dSPACE Simulator
Real-Time Workshop
Software Components
Implementation software
Experiment software
p. 35
p. 96
p. 36
Further Details
Real-Time Interface
p. 108
PowerPC compiler
p. 127
ControlDesk
p. 128
ControlDesk Failure
p. 139
Simulation
AutomationDesk
p. 140
97
2005
ECU Testing
Hardware Components
Modular hardware
Further Details
p. 230
Processor Board:
DS1005 PPC Board
Off-the-shelf hardware
I/O boards:
Failure insertion units
Load boards
p. 254
One or two power
p. 94
p. 87
p. 87
supplies (two for

2-voltage system
simulation)
Others
Configuration Example:
dSPACE Simulator for Testing Networked ECUs
dSPACE Simulator Full-Size is perfect for projects with higher I/O requirements. The
hardware is expandable and flexible, and can be quickly adapted, for example, for
system tests with changing ECU wiring.
D30!#%3IMULATOR&ULL 3IZE
0#
0OWERSUPPLIES
%#5S

,OAD#ARDS
3IGNALCONDITIONING
/THERS
-ODELINGSOFTWARE
)MPLEMENTATIONSOFTWARE
%XPERIMENTSOFTWARE
-ODULARHARDWARE
OFF THE SHELF
0ROCESSORBOARDS
)/BOARDS
2EAL 4IMEMODEL
EXECUTEDBYPROCESSORBOARDS
Possible ECU Testing Tasks for This Configuration

Function tests for single or networked ECUs
Integration tests for single or networked ECUs
Acceptance tests for single or networked ECUs
Release tests for single or networked ECUs
Virtual vehicles with greatest possible flexibility
Possible Test Areas for this Configuration
Gasoline engine
Diesel engine
Transmission
Vehicle dynamics
Climate control
Comfort function
Tests with high currents
12 42 V applications
Power consumption test (airport test)
Very complex real-time models (multiprocessing or networked simulators)
98
2005

ECU Testing With dSPACE Simulator

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ECU Testing With dSPACE Simulator

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ECU Testing

ECU Testing with

Original equipment manufacturers (OEMs) today face pressures on multiple fronts.

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de

dSPACE Simulator Introduction

Improving ECU Software Quality

Key Features of dSPACE Simulator

Full integration of MATLAB/Simulink,

State-of-the-art modeling and

the worlds leading design and

states and parameters,

used HIL simulator:

maximum compatibility with existing

Test Scenarios with dSPACE Simulator

Verifying Control Algorithms

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de

dSPACE Simulator Introduction

Integration Tests on ECU Networks

Networked ECUs can be tested

... or a simulator network. ECUs that are

Testing Diagnostic Functions

The Benefits of dSPACE Simulator

Broad range of experience: diesel, spark ignition and direct injection

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de

dSPACE Simulator Introduction

dSPACE Simulator Components

Graphical programming and connection to

Configuring CAN and LIN Bus Communication

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de

dSPACE Simulator Software

ControlDesk offers powerful analysis tools, such as instruments to set up virtual

Failure Pattern window: Every failure

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de

dSPACE Simulator Software

Typical Automation Tasks Executed with AutomationDesk

ECU initialization (e.g., failure memory

reset) and simulator environment

Evaluation and test reporting

short circuit failures or to input

Full-brake simulation or braking on different surfaces: MotionDesk makes the

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de

dSPACE Simulator Hardware

dSPACE Simulator Hardware Concepts

dSPACE Simulator Types:

dSPACE Simulator Full-Size

DS1005 PPC Board or

DS1005 PPC Board or

DS1006 Processor Board

DS1006 Processor Board

DS2211 HIL I/O Board

Any number and type of

dSPACE I/O boards

Failure insertion unit

Integration of simulatorspecific hardware

connectors for each ECU

Sub-D connector with

optional CARB adapter

Standard 16-pin CARB

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de

dSPACE Simulator Hardware

Failure Simulation Summary

Failure insertion units 5 x DS749 FIU Module

FIU Cards (up to 2 cards,