HIL Powertrain Simulation and Testing

An Automotive Industry Standard

Alexandru CHERĂSCU, HIL Specialist

February, 2015
Summary

1. Introduction to HIL
2. HIL environment description
3. Remote use of HIL benches

February, 2015 Alexandru CHERASCU 2

HIL Simulation

HIL = Hardware In the Loop

Dynamic test technique that uses a real-time simulated system that replaces
the real environment of an embedded controller.

Where is HIL used?

In any domain that uses embedded systems for control functions: automotive,
aeronautics, naval, electronic and robotic systems etc.

February, 2015 Alexandru CHERASCU 3

Why HIL?
Real
Vehicle
Real
Vehicle

February, 2015 Alexandru CHERASCU 4

Why HIL?
Real
PC Remote Vehicle
Connection

HIL
Simulator

HIL
Simulation Real
Powertrain

Electronic Control
Unit (ECU)

February, 2015 Alexandru CHERASCU 5

Why HIL?

Cheaper than a prototype car

Increased productivity
More tests can be done at the same time

Shorter development time

HIL
Simulator No need for the prototype vehicle to be available

Safer than a real vehicle
No need to drive a vehicle for safety tests

More flexible than a real vehicle

Quick access to wiring and simulated parameters

Well suited for repetitive tests

Simulated cycles can be repeated indefinitely

Well suited for automatic tests

The simulation can run without human input

Precise enough for software validation

February, 2015 Alexandru CHERASCU 6

HIL in the Automotive Industry

Inputs of Outputs of
Electronic Control Module (ECU)
embedded system embedded system
Makes the comparison between the signal
value from the sensor and the set point
value of the signal. Gives an output signal
for the actuator.

Sensors Actuators
Measure the physical value from the system and Receive an input signal from the ECU and
transform it in an electrical signal. The electrical transform it in a physical value. This physical
signal will be an input for the ECU value will be the input command for the system.

Real Time Simulator:

Dynamically evolves in function of
Outputs of the physical value imposed by the Inputs of
RT simulator actuator. RT simulator

February, 2015 Alexandru CHERASCU 7

HIL in the Software V Cycle

Pré-Calibration Calibration
Function
Development (SIL)

Integration tests Intersystem

Rapid Prototyping System Test

Unitary Tests Non-Regression Tests
(HIL)
(HIL)

Software Test
(HIL)
Functional Tests

Specification
Strategies
Unitary Test Tests Code and Integration
(HIL)

Coding

February, 2015 Alexandru CHERASCU 8

Summary

1. Introduction to HIL
2. HIL environment description
3. Remote use of HIL benches

February, 2015 Alexandru CHERASCU 9

HIL Environment

Whole assembly needed for HIL software validation:

model, HIL bench, wiring, ECU, auxiliary tools…

Remote
user PC
dSPACE bench
ECU
Electrical
Harness
bench PC failures

Model From sensors

Network

ControlDesk I/Os
(RT processor)
To actuators

Diag Tool
USB CAN
diag

CANalyzer

INCA
Load rack
ETAS

February, 2015 Alexandru CHERASCU 10

HIL Bench Structure
Diagnostic connector for
Main power
Diag tool
220V / 14V

Hypertronics connector
Break-out box (BOB)
ECU + TRM

LoadRack

Contains real components : Signal conditioning:

injectors, EGR valve, … Electrical faults
Load simulation of the
bench

Simulated Battery

Computer on rack (PX)

I/O boards of the bench
Real-time processor
running the physical model.
Communicates with the PC
bench by optical fiber.

February, 2015 Alexandru CHERASCU 11

Loadrack

The elements in the Loadrack are necessary to create the « electrical representativity »
of the HIL environment.

The Loadrack must reproduce the same technical definition as the real vehicle (by real
component or by electric equivalent).

Every ECU output should be connected to an element in the Loadrack:

To give the signal the right reference;

To allow the ECU to consume the expected current;

To allow the voltage levels of the ECU outputs to be inside the expected ranges.

February, 2015 Alexandru CHERASCU 12

Summary

1. Introduction to HIL
2. HIL environment description
3. Remote use of HIL benches

February, 2015 Alexandru CHERASCU 13

 HIL Powertrain Simulation and Testing
An Automotive Industry Standard

THANK YOU FOR YOUR ATTENTION !

February, 2015