ETAS Webinar: LABCAR - Scalable HiL Solution

ETAS Webinar: LABCAR - Scalable HiL Solution
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Public | ETIN/STI3 | 2014-02-27 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Agenda
Content
2
1
ECU testing methods
2
Need for HiL
3
Tests on ETAS LABCAR
4
Components of ETAS LABCAR
5
Portfolio of ETAS LABCAR
6
Benefits of ETAS LABCAR
7
Customer references
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Need for HiL
Do you want to be the
test driver ?
Dear John, (test driver)
Here is the new version of the ECU.
I implemented a new software
function for the electronic braking
system yesterday evening.
Would you be so kind as to build
this ECU into your test vehicle and
try it out with some high-speed
braking manoeuvres?
It works fine as far as I can tell.
Thanks in advance
Dave
(function developer)
Can we test different scenarios (environment,
driver, failures) safely and independent of the
environment ?
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ETAS Webinar: LABCAR - Scalable HiL Solution
Need for HiL
What is a HiL?
Vehicle Testing
Lab Testing
HiL simulates driver, vehicle and environment so that the
functionality of the ECU can be tested as if it were in a real vehicle
ETAS HiL offering is called “LABCAR”
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ETAS Webinar: LABCAR - Scalable HiL Solution
Need for HiL
Concept of LABCAR
User
Simulation Loop
I/O Hardware
(Signal Generation)
I/O Hardware
(Signal Measurement)
User
− Configuration
− Manual / Automated
Testing
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Real-time Simulation
− Vehicle Dynamics
− Engine, Drive Train
− Sensors/Actuators
− Environment
− Residual Bus
− E-Motor
− Signal Generation
− Load Simulation
Real ECU Hardware
ECU input signals
(Sensors)
ECU output signals
(Loads)
ECU
− Connected to simulator HW
− Connected to real loads
− Connected to bus systems
− …
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ETAS Webinar: LABCAR - Scalable HiL Solution
Need for HiL
Benefits of LABCAR
− Safety critical testing in safe and real
time environment
− Testing without prototypes
− Testing early in development cycle
− Automated testing
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Agenda
Content
7
1
ECU testing methods
2
Need for HiL
3
Tests on ETAS LABCAR
4
Components of ETAS LABCAR
5
Portfolio of ETAS LABCAR
6
Benefits of ETAS LABCAR
7
Customer references
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Test on ETAS LABCAR
Tests performed on a LABCAR
Environmental Tests
−Shaking, temperature, humidity
Hardware Tests
−Current and voltage range tests
−Overvoltage, undervoltage („Pin Test“),
standby current, endurance test, EMV test
−Electrical failure simulation
Basic Software Tests
− Communication tests: CAN, FlexRay
− Wakeup, sleep mode
− Response tests
Component Tests (test of single ECU
functionality)
− Example: Power Train Engine ECU
tests, closed loop, OEM+T1
− With either real or simulated
loads
− sensors and actuators
Integration Tests (test of distributed
ECU functionality)
− Entire ECU network or parts of ECU
network + bus simulation
− Test of diagnostics
− With either real or simulated loads
− Runtime tests (delay, timing)
− Sensors and actuators
− Performance tests
− Stress tests
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Agenda
Content
9
1
ECU testing methods
2
Need for HiL
3
Tests on ETAS LABCAR
4
Components of ETAS LABCAR
5
Portfolio of ETAS LABCAR
6
Benefits of ETAS LABCAR
7
Customer references
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Components of ETAS LABCAR
Takasago/Lambda/Toellner, etc.
ETAS LABCAR
ETAS
2
3rd-Party
Engineering
ES4105/4100 Signal I/Os VME
7
3
1
Ethernet
Ethernet
Operation PC
5
Real Time PC
ES4440 Error Simulation
6
Breakout Box
ECU Harness
4
ECU
LABCAR-IP/EE/AUTOMATION
10
ES4408 Load Simulation
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ETAS Webinar: LABCAR - Scalable HiL Solution
Components of ETAS LABCAR
Components of HiL : RTPC
Main Function: Real time simulation of
driver, environment and vehicle
• Computation Power of standard Intel®
Multi-Core processors
• Distribute Tasks to multiple cores at
a mouse click
• Parallel simulation of complex
models increases performance
• LINUX operating system with RT
extensions
Real-time PC in PT LABCAR
• Open interfaces for 3rd party Hardware
and Software
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Components of ETAS LABCAR
Components of HiL : Signal IO
Main Function: Generate electrical values
as required by ECU
− Housed in VME chassis with VME
controller or in RTPC over PCI Bus
− Modular and highly scalable
− Includes signal conditioning and
galvanic isolation
− Portfolio covers all signals required in
automotive testing
− Supports 12V/24V systems
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ETAS Webinar: LABCAR - Scalable HiL Solution
Components of ETAS LABCAR
Components of HiL : Fault Insertion Unit (FIU)
Main Function: Simulate electrical defects
on sensors and loads to test diagnostics
− Failure generation in real-time
− Complete set of OBD / ECU test
relevant failures
− Channels in compact unit (19”, 3U):
− 64 High current channels: 20A, 30V
− 16 High voltage channels: 10A,
400V
− Easy integration via Ethernet or CAN
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Components of ETAS LABCAR
Components of HiL : Load Chassis
Main Function: Simulate loads for ECU 
testing done without real loads
− Modular : Easy selection of loads
− Electrical loads up to 60 V DC or 20 A
− Loads can be calibrated
− Two major classes of loads:
− Load Simulation for Common Rail,
GDI Piezo Injectors
− Pull Up/Pull Down
− Ethernet interface, can be changed in
real time
− Easy integration into other
HiL-Systems via Ethernet
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ETAS Webinar: LABCAR - Scalable HiL Solution
Components of ETAS LABCAR
Components of HiL : Software LABCAR Operator
Main Function: Integrate different
components, UI for tester
Integration Platform
− Integration of Behavior Models
− Connection of Signals
− Configuration of Real-Time OS
− Configuration of CAN/LIN/FlexRay Bus Simulation
− Code generation for LABCAR-RTPC
Experiment Environment
− Integration of Behavior Models
− Connection of Signals
− Configuration of Real-Time OS
− Configuration of CAN/LIN/FlexRay
− Code generation for LABCAR-RTPC
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Components of ETAS LABCAR
Domain
Models - Partnerproducts
Components of HiL : Software LABCAR Automation
Main Function: Enable automation by
Powertrain
connection to LABCAR Operator
− Fully automated test in HiL
environment
−Chassis
Highly reproducible
tests
and
− Drive cycles are executed exactly the
Driver
same way
Assistance
− No human interaction
Systems
− Fast test execution
General
− Efficient testing of all vehicle variants
Simulation
−Tools
Automatic report generation and
classification of test results
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ASCET
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editing, distribution, as well as in the event of applications for industrial property rights.
AMESim
ETAS Webinar: LABCAR - Scalable HiL Solution
Agenda
Content
17
1
ECU testing methods
2
Need for HiL
3
Tests on ETAS LABCAR
4
Components of ETAS LABCAR
5
Portfolio of ETAS LABCAR
6
Benefits of ETAS LABCAR
7
Customer references
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
Desk LABCAR
− RTPC + PCIe Card with 40 signals
− Use cases can be:
− Open Loop
− Closed Loop
− With FPGA on card Electric Motor
Simulation
Ethernet
− With Camera vision system
RTPC
BOB
Host PC *
− With LCA Automation
− With CAN Card CAN Bus Simulations
− DESK-LABCAR brings HIL technology on
your desk for a competitive price
− Open and scalable system considers
todays and tomorrows requirements
− Multiple use cases  One start!
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ECU
ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
Desk LABCAR Picture
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
PT LABCAR
− PT specific input simulations
− CAM, CRANK, Knock
− Sensors (Analog, Resistive
simulations)
− Battery voltage and nodes
− Lambda Sensor
− PT specific output (load) simulation
− Injector loads and measurements
− Configurable pull up/down loads
− Failure Injection Unit
− PT models co-developed with Bosch
− On board signal conditioning and
galvanic isolation
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
Chassis LABCAR
− Chassis specific input simulations
− Wheel speed simulation supports all
types of sensor simulation - DF11i,
passive, type “DF10”, type “DF10-RotDir”,
type “VDA”
− Different type of sensor for each wheel
possible
− Chassis specific output(load) simulations
− Pressure sensor and valve detection
unit (hydraulic adapter)
− Can be used with real hydraulics
(comprising valves, pump motor
controlling fluid supply)
− ETAS SW open to integrate with third party
models (VeDyna, CarSim, CarMaker)
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ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
Body LABCAR
− High number of digital O/P’s possible
− Connection to real loads or simulated
loads possible
− Current measurement possible
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
Electric : Battery Simulators
− Cell supply range: 0.85 – 5V upto
3A (6A, 12A)
− Accuracy: +/- 1mV, Resolution
76microvolt
− Active and Passive Balancing
− Current measurement +/- 3A with
accuracy +/- 2 microA
− Coulomb Measurement, accuracy
1x10-7 As
− Communication over CAN
− Up to 400 cells
− Integrated failure simulation
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
Electric: Motor Simulations
−FPGA based simulation; cycle time
850ns
−ETAS motor models (IM, PMSM)
−Customer specific models / can be
integrated with additional tool chain
−Free configuration of output signals at
DAC
−Simulation at signal and power levels
−Can be simulated as Desk LABCAR
configuration
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ETAS Webinar: LABCAR - Scalable HiL Solution
Portfolio of ETAS LABCAR
Vehicle Simulators
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Agenda
Content
26
1
ECU testing methods
2
Need for HiL
3
Tests on ETAS LABCAR
4
Components of ETAS LABCAR
5
Portfolio of ETAS LABCAR
6
Benefits of ETAS LABCAR
7
Customer references
Public | ETIN/STI3 | 2014-02-27 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
LABCAR is an easy to use, scalable test system
Value added
 Modern software designed for ease of use
allows short learning effort and efficiency in
the daily work
 With a scalable system, it is possible to
increase/decrease the system size as needed
by small steps. But the user interface does not
change, software assets can be reused easily
due to the modular experiment setup and the
HW components can be reused in other
systems. There is no “low-end hardware” that
can only be used in one specific configuration
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
LABCAR is an open, PC-based simulation  investment protection
Value added
 The ETAS RTPC is a standard PC system
operating system is real-time LINUX which is
widely used in embedded industry
 Customers can easily upgrade to the latest PC
HW technology (e.g. new processor) as
needed at very little cost
 Customers can make use or profit from all
assets that are being created by the LINUX
community like high-speed drivers (enabling
even faster turnaround times), graphical
debuggers of the real-time system, drivers for
all 3rd party PC I/O boards, real-time testing
capabilities,…
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
LABCAR has fast Real-Time Simulation PC. Now and in future!
Value added
 Our customers are always equipped with
cutting edge technologies enabling fast,
precise, low-latency and high-quality real-time
simulation
 Since LABCAR RTPC is a standard PC
hardware, with a standard OS, whenever Intel
releases a new and faster/more powerful CPU
or when there is a new industry PC
motherboard with even more optimized
memory access and speed, the customer can
almost instantly make use of that new system.
Without changing the system software or
configuration
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
ETAS and Bosch know-how : Profit from our knowledge
Value added
 Efficient HiL Testing requires in-depth
knowledge of ECUs,
ECU functions, testing techniques, standards
and norms
 Successful HiL Projects require experienced
and professional
project management and global operations
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
LABCAR offers powerful real-time fault insertion unit
Value added
 Customer can generate reproducible electrical
faults in real-time
(fault is set within 200µs)
 Very low resistance between in- and outputs:
25mOhm
 Many different types of faults possible (open
load, short circuit to +/- UBatt A/B, Pin-to-Pin
resistance, Leakage current to +/- Ubatt A/B,
Inline resistance, loose contact)
 Open API for operation with different HiL
system/automation tools. A lot of competitor
simulators are equipped with the ETAS original
ES4440 box
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
LABCAR enables true White-Box Testing of ECUs
Value added
 Customers can make use of an ETK interface
on the ECU and access ECU internal data in
real-time from within the simulator. Thus, test
depth and test efficiency are highly increased
 Customers are able to perform precise actioreaction tests and response time tests with
the HiL simulator.
 If INCA is used at the customer, no
other HiL Simulator has a fast and time
synchronous access to INCA
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
Customer Benefit
Value added
 ETAS is a comprehensive HiL supplier:
 People to guide through procurement process
 People to support installation, training,
commissioning
 Resident engineers to work with your teams to
boot strap knowledge
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Benefits of ETAS LABCAR
ETAS offers Consultancy Services to increase
our customers processes, efficiency and improve operation
ETAS invests in
− Process consulting services
− Test consulting services
− Embedded software consulting
services
− Calibration consulting services
to complete our verification and validation
portfolio and offer a complete solution to our
customers
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Agenda
Content
36
1
ECU testing methods
2
Need for HiL
3
Tests on ETAS LABCAR
4
Components of ETAS LABCAR
5
Portfolio of ETAS LABCAR
6
Benefits of ETAS LABCAR
7
Customer references
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS Webinar: LABCAR - Scalable HiL Solution
Customer reference : GM - Versatile resource
LABCAR can be re-configured in a matter of minutes
• RealTimes 1-2007: Customer reports 15 minutes to reconfigure the test bench for
another ECU
• Increased utilization of the test bench
• Share test bench among multiple ECU programs
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ETAS Webinar: LABCAR - Scalable HiL Solution
Customer reference : Consumer Electronics OEM – Generic systems
Washing Machine
Control Panel
38
Washing Machine
Simulation Model
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editing, distribution, as well as in the event of applications for industrial property rights.
ETAS LABCAR Test
Hardware
ETAS Webinar: LABCAR - Scalable HiL Solution
Customer reference : Consumer Electronics OEM – Generic systems
Challenge
− High effort to manually test all variations of long running wash cycles
− Low availability of washing machine prototypes
− Incomplete testing done today due to large number of variants
ETAS Solution
− Closed loop Mini LABCAR plus signal conditioning for 230V AC
− ETAS Variant Management System to manage complexity
− Fully automated test scripts with LABCAR Automation
− Resident engineer to ensure quick introduction of LABWASH into testing process
Customer Benefits
− Fast and completely automated test execution to reduce time to market
− Flexibility to reconfigure the system for different washing machines / dishwashers
− Reduced dependency on hardware prototypes
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ETAS Webinar: LABCAR - Scalable HiL Solution
Customer reference : MAN – Complex systems
Application Areas:
• Powertrain
• Chassis Systems
Applications:
• Testing of 1500+ electrical failure
scenarios in a interconnected ECU
environment.
• ECU system test
• Release/Validation test
• Engine application
Number of LabCar Systems:
Central
Board
Computer
Engine
Controller
Instrument CAN
Engine CAN
Drivetrain CAN
Vehicle
Management
Brake
Controller
Transmission
Controller
Air Pressure
Monitor
Trailer CAN
• 2 x LabTruck System ( 5 individual
single LabCar systems per LabTruck)
• 2 X LabCar PT
40
Instrument
Cluster
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Retarder
Controller
ETAS Webinar: LABCAR - Scalable HiL Solution
Customer reference : BOSCH – Robust systems
BOSCH presentation February 2011
 Development of Gasoline and Diesel ECUs
 Several hundred Simulation Models
and variants
 >200 identical ETAS PT LABCARs
 10 locations globally
 Regression testing of all variants
 Release testing of all new software
 Endurance testing (tests run over 6 weeks)
 Using the entire LABCAR tool chain
 Seamless integration of LABCAR AUTOMATION
in the development process
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ETAS Webinar: LABCAR - Scalable HiL Solution
Customer reference : Japanese OEM – Automation
Challenge:
• Customer requested a automated, scalable test system
for
• Network integration tests incl. ext. fault simulation
with up to 8 ECUs
• Operating different simulation models (3rd-party
and original)
• Using 3rd-party developed scenarios and test
cases
Solutions:
• Customized 4-rack ETAS LC system supporting connection
• Operation of up to eight ECUs and automated fault
simulation
• 1.stage: network (Rack A and loadbox)
• 2.stage: network,engine (Rack A,B and loadbox)
• 3.stage: network,engine, brake,ESP,ABS,AMT…
(Rack A,B,C and loadbox)
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Network Integration with LABCAR
© ETAS GmbH 2009. All rights
reserved. The names and designations
used in this document are trademarks
or brands belonging to their respective
owners.
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ETAS Webinar: LABCAR - Scalable HiL Solution
Customer references – Indian OEM: complete solution providers
Indian OEM using LABCAR as vehicle simulator with body, chassis and
powertrain controller
Challenge:
To integrate ECUs from different vendors and verify algorithms, communication and
diagnostics
Solution:
Complete vehicle simulator LABCAR HiL with the possibility:
− Connection of real and virtual loads
− Fault insertion for all inputs and outputs for diagnostics testing
− Test of full fledged body control module integrated with instrument cluster
− Virtual vehicle dynamics simulation environment
Customer benefit:
− Early verification of algorithms, communication and diagnostics
− Reduced dependency on vehicle prototypes
− Automation testing and report generation
− HiL also was re-used for individual ECU test
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ETAS Webinar: LABCAR - Scalable HiL Solution
Questions
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Public | ETIN/STI3 | 2014-02-27 | © ETAS GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.

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