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
