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dSPACE HIL Solutions Overview - M
dSPACE HIL Solutions Overview - M
August 2023
dSPACE – Innovative Solutions for Hardware in the loop testing
▪From
Text Autonomous
in Ebene 1 Driving to Zero Emissions Key takeaways
Simulation Models
Platform and I/O configuration Experimentation and Management and Automation Open Interfaces
Model Configuration
Rest bus configuration Visualization
Road and Maneuver Definition
ECU interfaces
Env. sensor
interfaces
Unit under test I/O, and network interfaces SCALEXIO LabBox SCALEXIO OTS HIL Customized HIL Testbenches
▪ Comprehensive support of
automotive bus/network
protocolls
Testing with full electrical power without a rotating motor Key takeaways
▪ Outstanding & most
realistic current emulation
▪ Reduction of development
time and improve safety
(LV123 and ISO/DIS 21498)
▪ Mature technology
>15 years experience with
Power HIL systems
Traction controller Motor and battery emulator dSPACE HIL,
with actual inverter (e.g. 250 kVA, >1000V, 600A peak)
> Full-service provider
power supply
Separated Model Implementation and I/O Configuration for Building Real-Time Applications
▪ One tool for various environments (Simulink, FMI, V-ECU, etc.)
▪ Less influence on Simulink modeling style (golden model)
but still strong interaction (I/O mapping, jumping, remote access)
▪ I/O configuration reuse for different models
▪ Portable models (e.g., for different hardware, VEOS)
▪ Faster I/O configuration (better overview, multiselection)
▪ Comprehensive help, display of conflicts and solutions Simulink®
ARXML
ARXML,
DBC, LDF,
FIBEX, ..
RT Simulations Systems
Experiment Tool & Bus-
Monitoring
<
Processor-based
latency or simulation models with high time
DC resolution.
Computation
FPGA-based DC
Computation
▪ Easy implementation of customer-specific
time interfaces and functions, e.g. communication
resol. protocols or I/O data preprocessing.
Nanosec Microsec Millisec
I/O Modules
* Requires newest version of the bracket. Migration to new brackets for all I/O boards will be finished until end of 2022
Limitations (currently):
• Requires newest version of the bracket
• Migration to new brackets for all I/O boards will be finished
until end of 2022
• Please inquire Product Management
▪ Fasting brackets with recesses for the coding ▪ Male D-Sub connectors with integrated coding
elements and pins: elements
Simulation on FPGA powered by Electrical Power Systems Simulation Package Key takeaways
Speed up model setup for
power electronics
Expandability by established
simulation models and high-
voltage power loads
Circuit diagram
Simscape Electrical Specialized
Power Systems model dSPACE EPSS dSPACE HIL
▪ Ethernet raw data mirror charging station Conformance test library and
▪ Manipulation of communication interoperability tests
▪ USB logging interface
▪ Grid manipulation options
BMS test systems with precise cell voltage emulation Key takeaways
Precise battery cell emulation
Simulation of high-voltage batteries at cell voltage level boards
Open real time simulation models simulating Modular approach allows
the behaviour of the battery customized designs that are still
flexible and extendable
High fidelity open battery
models
BMS CSC
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CSC
delta model
of cell i Ducell i
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Application Area
▪ Advanced driver assistance systems (ADAS)
with radar sensors, lidar sensors, ultrasonic
sensors
▪ Traffic sign recognition, lane departure
warning systems, parking assistant, Car2x, etc.
Important Aspects
▪ Numerous test runs to be repeated under
different conditions
dSPACE Solution
▪ dSPACE provides realistic simulation
scenarios for hardware-in-the-loop testing
Application Area
▪ Electric motors are being used more often
Important Aspects
▪ Highly dynamic behavior of the electric motor
▪ High ECU clock rate
dSPACE Solution
▪ dSPACE supplies special FPGA hardware and
software solutions for HIL simulation of electric
machines
▪ ECUs with typical clock rates of 10-20 kHz can
be tested in closed-loop operation
Application Area
▪ Hybrid electric vehicles (HEV)
▪ Combined simulation of the combustion engine, electric
motors and transmission
Important Aspects
▪ Electric motors can reach 90% of their maximum torque in
only a few milliseconds
▪ ECUs for electric machines have cycle times of approx. 60
to 200 microseconds
▪ Requires HIL simulation speed faster than 60 microseconds
dSPACE Solution
▪ High-resolution signal capturing with the DS2655 EMH
Solution
Application Area
▪ The battery management system (BMS)
monitors the electric and thermic state of the
batteries
▪ Influences each battery and its cells to provide
the necessary energy and maintain optimal
operation
Important Aspects
▪ Batteries for electric vehicles have extremely
high voltages and currents
▪ FIU is needed dSPACE Solution
▪ Restbus simulation for simulating unavailable cells
▪ dSPACE offers specialized hardware and software for
testing a BMS (e.g., ASM multi-cell models)
Application Area
▪ Testing one single ECU or several networked
ECUs of an internal combustion engine
Important Aspects
▪ Crankshaft and camshaft simulation
dSPACE Solution
▪ High-resolution signal capturing with the ▪ Parameterizable simulation models for
DS2680 I/O Board different engines
▪ Both boards contain a high-resolution angular ▪ Scalable and adaptable HIL simulators
processing unit (APU) ▪ Exchangeable load racks
Application Area
▪ Vehicle dynamics systems like ESP are
extremely safety-relevant
Important Aspects
▪ Require comprehensive HIL tests that make
tough demands on the test system
▪ This requires a very realistic vehicle model
▪ The ECUs perform plausibility and function
checks very precisely. If the ECUs detect
implausibilities, they shut down immediately
dSPACE Solution
▪ dSPACE has many years of experience in
setting up HIL test systems for vehicle
dynamics ECUs, and gives customers every
kind of support needed
Application Area
▪ ECU has integrated sensors and actuators
▪ HIL simulator cannot be connected at electric power
level
Important Aspects
▪ Physical signals have to be provided to stimulate the
ECU's sensors and actuators
▪ The ECU has to be mounted on a mechanical test bench
dSPACE Solution: Mechatronic parts can also be tested
▪ HIL simulators including integrated pressure, engine
speed and temperature sensors, acceleration sensors,
and yaw rate sensors
Application Area
▪ Sometimes the ECU of electronic power
steering (EPS) or electronic power-
assisted steering (EPAS) systems cannot
be accessed at signal level
Important Aspects
▪ ECUs must be stimulated physically at
mechanical power level, real parts are
needed
dSPACE Solution
▪ HIL simulator equipped with electric
motor simulation is connected with the
mechanical test bench and controls its
components
47 dSPACE-Confidential