Hardware-in-the-Loop (HIL) Testing

Sajid M 12AT60R07

Hardware in the loop Testing

technique that is used in the development and test of complex realtime embedded systems. a form of real-time simulation with a real component in the loop. A HILS provide all of the electrical stimuli needed to fully exercise the control unit thus fooling an embedded system into thinking that it is operating with real-world inputs and outputs. Inputs to the HILS are mirrors of the embedded systems outputs Outputs are mirrors of the embedded systems inputs. Allows experimentation with physical parts in a controlled synthetic environment

Closed-Loop Control
Disturbance

Desired Speed

Motor
Controller

Motor Command DC Motor

Measured Speed

Closed-Loop Control
Engine Control

Navigation Control

Flight Control

Steam Turbine Control

Dryer Cycle Control

Print Head Control

Medical Device Control

Examplethe automobile
3 ECUs 15 to 70 ECUs in 10 years

Embedded Control System Challenges

Increasing application complexity
Test Challenges

Increasing reliability requirements

Decreasing time-to-market Reduce development cost
Are these mutually exclusive?

Test Resources

Testing Embedded Control Systems

System Level Testing
Test System
Test Profile
Logging/ Analysis

UUT
Disturbance Desired Speed Motor Command DC Motor Measured Speed

Motor Controller

Testing Embedded Control Systems

System Level Testing
What if the DC Motor is not available yet? What if test failures could damage the DC Motor? What if the DC Motor is very expensive (capital, maintenance, operation, facilities)? What if DC Motor conditions are not repeatable? What if there are numerous variations of the DC Motor?

Disturbance Motor Command DC Motor Measured Speed

Testing Embedded Control Systems

Component Level Testing
Test System
Test Profile
Logging/ Analysis

UUT
Disturbance Desired Speed Motor Command

Motor Controller Measured Speed

What is HIL Simulation?

Types of Test

Test Methods

Functional Parametric Validation (V&V) Durability (HALT/HAST) End-of-line

Temperature/power variation Salt/sand spray EM radiation Mechanical loading/resistance HIL Simulation

Virtual Reality for your UUT

What does your UUT know about the world around it?

UUT

Voltage
Desired Speed Motor Controller Measured Speed Motor Command

Current Impedance Timing

PWM

ENCODER

Testing Embedded Control Systems

Virtual System Level Testing
Test System
Test Profile MODEL
Logging/ Analysis

UUT
Desired Speed Motor Command

Motor Controller Measured Speed

Stimulus = MODEL(test profile, UUT response)

Testing Embedded Control Systems

Virtual System Level Testing
Test System
Test Profile MODEL
Logging/ Analysis

UUT
Desired Speed Motor Command

Motor Controller Measured Speed

Stimulus = MODEL(test profile, UUT response)

What is a Model?

Dynamic System Models

NI LabVIEW MapleSoft MapleSim

ANSI C

The MathWorks, Inc. Simulink Software

Esterel SCADE

NI MATRIXx SystemBuild

Simulink is a registered trademark of The MathWorks, Inc. All other trademarks are the property of their respective owners.

You Need a Model

Test System
Test Profile MODEL
Logging/ Analysis

UUT
Desired Speed Motor Command

Motor Controller Measured Speed

Stimulus = MODEL(test profile, UUT response)

Control Design Process

Modeling and Design System Testing

Rapid Prototyping

Hardwarein-the-Loop Testing

Targeting

Modeling and Design

Setpoint Error Kc Controller Control Output Kp Plant Feedback

Modeling and Design Produce Controller and Plant Models

Modeling and Design Software Tools

NI LabVIEW Simulation Module NI MATRIXx The MathWorks Inc., Simulink Application Software MSC CarSim Hand-coded models (C, Fortran, etc.)
Simulink is a registered trademark of The MathWorks, Inc.

Rapid Control Prototyping

Setpoint Error Kc Controller Control Output Kp Plant Feedback

Creating a Functional Prototype of the Controller

Hardware-in-the-Loop Simulation
Setpoint Error

Kc
Controller

Control Output

Kp
Plant

Feedback

Testing Production Controller with Simulated Plant

HIL System Architecture

Host PC

Loads / Power

Real-Time Simulator

Fault Insertion Unit (FIU)

ECU

HIL Functional Architecture

User Interface Data Manager Model Manager Simulator Interface
RT Simulator

Test Sequence

Analysis & Reporting IO Interfaces

Host

Datalogging

Sequencer/Profiler Plant Model

Simulated Fault Insertion

RT IO Interfaces
Power Supply

DMM/ FPGA IO AIO/DIO Bus IO Vision Scope SigCon Fault Insertion Unit (Switching) Break-out
ECU

RF / GPIB

Cal / Diag Interfaces

IO

Loads

System Design

Simulated

EPA System

Road Load Powertrain

Real

Driving Cycle Speed

Driver
Real

Chassis
Real

Actual Speed

Simulated

Road Load
Driving Cycle Speed Driver
Simulated

Powertrain
Real

Chassis
Simulated

Actual Speed

Topography of Autonomous Flight

University of Washington

25

Hardware-in-the-Loop Simulator

Avionics Tray
HiL Simulator

University of Washington

26

Hardware-in-the-Loop Simulator

Groundstation
University of Washington 27

Aircraft

Why Hardware-in-the-Loop (HIL) testing?

Software is a safety critical component and HIL testing
Improves test coverage Reduces testing time and cost Reduces product development cycle Improves test repetability and allows system variability Real-time simulation model (vehicle dynamics, actuators, Sensors, disturbances)

Engine Control Unit real life controller

http://catless.ncl.ac.uk/Risks/

Hardware In-the-Loop

Example: ECU In-the-Loop Allowing controller development while mechanical system is being built
Achieving a high degree of test coverage in the lab before driving mechanical system Reducing test effort through automated regression

Host PC (development env.)

ECU under test

RT Simulator (3 x Pentium 3, 1 GHz CPU)

References
T. Hwang, J. Rohl, K. Park, J. Hwang, K. H. Lee, K. Lee, S.-J. Lee, and Y.-J. Kim, "Development of HIL Systems for active Brake Control Systems", SICE-ICASE International Joint Conference, 2006 S.Raman, N. Sivashankar, W. Milam, W. Stuart, and S. Nabi, "Design and Implementation of HIL Simulators for Powertrain Control System Software Development", Proceedings of the American Control Conference,1999. A. Cebi, L. Guvenc, M. Demirci, C. Karadeniz, K. Kanar, and E. Guraslan, "A low cost, portable engine electronic control unit hardware-in-the-loop test system", Proceedings of the IEEE International Symposium on Industrial Electronics, 2005. A. Palladino, G. Fiengo, F. Giovagnini, and D. Lanzo, "A Micro Hardware-In-the-Loop Test System", IEEE European Control Conference, 2009. J. Wu and N. N.Schulz, Experimental Design for Remote Hardware-In-the-Loop testing, Proceedings of ASNE Reconfiguration and Survivability Symposium, Jacksonville, Florida, Feb. 2005. H. Krisp, K. Lamberg, R. Leinfellner (2007, April),Automated Real- Time Testing of Electronic Control Units. Presented at SAE World Congress & Exhibition, April 2007. [Online]. Available: www.sae.org/technical/papers/2007-01-0504.

THANK YOU!!!!!

Mission Environments

Cluttered Low visibility Smoke Dust Weather conditions

Robots to handle dirty, dangerous and dull missions

Testing power electronics controls is costly

PE Hardware

PE Controller

Our solution: Hardware-in-the-Loop for PE

Real-time software controls Power electronics hardware controls A machine

Typhoon RTDS HIL solution for hybrid vehicle power electronics/power system testing

Typhoon RTDS processor Power electronics model

Typhoon RTDS I/O

Toyota Prius propulsion system

http://www.hybridsynergydrive.com/en/mechanism.html

Hardware-in-the-Loop for Power Electronics

Replaces high-power laboratory testing Allows testing under nominal, transient and fault operating conditions

Automates design, test and qualification of systems

Accelerates development and gives confidence

Reduces time-to-market
Helps with the sales process

Typhoon makes testing power electronics control easy

Real-time Hardware Emulation

PE Controller

Welcome to the Typhoon future of power electronics

Typhoon application software

Typhoon processor

50 times faster than the state-of-the-art

Schematic Editor

Circuit Compiler

Live measurements

Hardware-In-the-Loop
Automatic Transmission In-the-Loop
Moving engineering development from expensive test vehicles to lab Increasing repeatability through controlled environments Accelerating test cycles with minimum operator intervention

Experiment Setup ABS/ECU

V E HI C L E

Wheel Speeds B R A K E S

EC U Solenoid Signals

Brake Torques

Brake Pedal Input

HITL for ECU Evaluation

RTLAB
C ar Si m D A Q B o a r d s C o n d i t i o n i n g

Wheel Speeds EC U

Solenoid Signals

Software Brake Model

RT Vehicle Dynamics Simulation:

CarSim

Manufacturing test of hydraulic actuators Customer: Parker Hannifin

Application
Integrate measurements with control Control actuator movement deterministically Easily change motion profile for each unit

Solution
LabVIEW Real-Time Modular PXI hardware platform NI DAQ I/O modules

Saved 44 weeks of development time and reduced cost by 6x

Lockheed Martin Simulator (PXI, LabVIEW Real-Time, SIT, VISA)

Application
Prototype integrated avionics unit in XSS-11 Create hardware-in-the-loop/HIL simulator to test LIDAR (light detection and ranging system) controller
LabVIEW and NI hardware provide future flexibility NI helped create an interface to a thirdparty synchronous serial interface using NI-VISA

Key points