ID 020C: Hardware-in-Loop: System Testing Without the System

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ID 020C Hardware-in-Loop System Testing Without
the System
Applied Dynamics International
Marcella Haghgooie
Sr. Field Applications Engineer
13 October 2010
Version 1.2
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Marcella HaghgooieSr. Field Applications
Engineer, Applied Dynamics International

• Over 30 years experience in Systems Engineering
  for applied physics applications of real-time
  hardware-in-loop simulation supplying robust
  development and test facility tools to aerospace,
  automotive, power, and medical industries.
• MSEE from Northeastern University,
• BS Physics from Brandeis University

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Renesas Technology and Solution Portfolio
Microcontrollers Microprocessors1 Market
shareworldwide
SolutionsforInnovation
Analog andPower Devices1 Market sharein
low-voltageMOSFET
ASIC, ASSP MemoryAdvanced and proven
technologies
MCU 31 revenue basis from Gartner
"Semiconductor Applications Worldwide Annual
Market Share Database" 25 March 2010 Power
MOSFET 17.1 on unit basis from Marketing Eye
2009 (17.1 on unit basis).
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Renesas Technology and Solution Portfolio
Microcontrollers Microprocessors1 Market
shareworldwide
SolutionsforInnovation
Analog andPower Devices1 Market sharein
low-voltageMOSFET
ASIC, ASSP MemoryAdvanced and proven
technologies
MCU 31 revenue basis from Gartner
"Semiconductor Applications Worldwide Annual
Market Share Database" 25 March 2010 Power
MOSFET 17.1 on unit basis from Marketing Eye
2009 (17.1 on unit basis).
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Microcontroller and Microprocessor Line-up

• Up to 1200 DMIPS, 45, 65 90nm process
• Video and audio processing on Linux
• Server, Industrial Automotive

Superscalar, MMU, Multimedia

• Up to 500 DMIPS, 150 90nm process
• 600uA/MHz, 1.5 uA standby
• Medical, Automotive Industrial

High Performance CPU, Low Power

• Up to 165 DMIPS, 90nm process
• 500uA/MHz, 2.5 uA standby
• Ethernet, CAN, USB, Motor Control, TFT Display

High Performance CPU, FPU, DSC

• Legacy Cores
• Next-generation migration to RX

R32C
M16C
H8S
H8SX
General Purpose
Embedded Security
Ultra Low Power

• Up to 10 DMIPS, 130nm process
• 350 uA/MHz, 1uA standby
• Capacitive touch

• Up to 25 DMIPS, 150nm process
• 190 uA/MHz, 0.3uA standby
• Application-specific integration

• Up to 25 DMIPS, 180, 90nm process
• 1mA/MHz, 100uA standby
• Crypto engine, Hardware security

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Microcontroller and Microprocessor Line-up

• Up to 1200 DMIPS, 45, 65 90nm process
• Video and audio processing on Linux
• Server, Industrial Automotive

Superscalar, MMU, Multimedia
All Of Them!

• Up to 500 DMIPS, 150 90nm process
• 600uA/MHz, 1.5 uA standby
• Medical, Automotive Industrial

High Performance CPU, Low Power

• Up to 165 DMIPS, 90nm process
• 500uA/MHz, 2.5 uA standby
• Ethernet, CAN, USB, Motor Control, TFT Display

High Performance CPU, FPU, DSC

• Legacy Cores
• Next-generation migration to RX

R32C
M16C
H8S
H8SX
General Purpose
Embedded Security
Ultra Low Power

• Up to 10 DMIPS, 130nm process
• 350 uA/MHz, 1uA standby
• Capacitive touch

• Up to 25 DMIPS, 150nm process
• 190 uA/MHz, 0.3uA standby
• Application-specific integration

• Up to 25 DMIPS, 180, 90nm process
• 1mA/MHz, 100uA standby
• Crypto engine, Hardware security

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Innovation
Embedded Control Systems need Hardware-in-Loop
Simulation
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Innovation using HIL Simulation

• Simulation Architecture must include
• real-time simulation components
• pseudo real-time environments and displays
• global time stamping for synchronization
• Improved hardware capabilities
• compute power
• communication bandwidth

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Hardware-In-Loop with Renesas and ADI

• Renesas provides the MCU families to integrate
  easily into your products and your
  Hardware-In-Loop (HIL) test facilities.

Applied Dynamics International (ADI) has over 50
years experience supplying tools for
Hardware-In-Loop (HIL) Systems.
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The Need

• Renesas MCU

• ADIs HIL Simulators

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Agenda

• What is HIL?
• Virtual Systems integrated with HIL Simulation
  Systems
• Process Improvements using HIL
• Real-time HIL as Risk Reduction Platform
• From Model-based Development to HIL-based System
  Testing
• QA

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Key Takeaways

• Understand how Hardware-in-Loop (HIL) simulation
  and testing can be useful in your product
  development process
• Identify systems development where HIL is
  beneficial
• List tool characteristics that enable HIL
  integration and test
• Highlights of the HIL demo in Lab Session 020L
  SH2A Model Based Design
  (MBD), Virtualization Hardware in the Loop
  (HIL) Lab

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What is HIL?

• Simulation uses technology to provide an
  experience within an environment that is
  representative of the real thing.
• Hardware-in-Loop (HIL) uses simulation and real
  hardware components to provide an identical
  experience to the real thing.

NASA Ames Vertical Motion Simulator
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Real-time HIL Simulation ApplicationsTest and
Rapid-Prototyping
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System Test BenchSystem Testing without the
System

• The system test bench starts with model-based
  simulation. Models can consist of
• Physics-based plant models
• Control algorithms
• Experimental data
• Mathematical Function data
• Subsystem implementations
• Communication Databus
• Interface documents describe model I/O

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System Test BenchSystem Testing without the
System

• The system test bench includes the Embedded
  Control System
• Emulated or virtual system (model-based)
• Actual software (hand-coded or auto-coded)
• Actual hardware (prototype or production)
• Supports Test case development
• Supports Revision Control

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System Test Bench Benefits System Testing
without the System

• The system test bench provides the platform for
• Co-simulation of Models and Embedded Software
• Interface document verification (model I/O
  validation)
• Defining hardware interface requirements
• Designing the graphical tester interfaces
• Generating test cases and script for test
  automation
• And the benefits
• Co-simulation assets flow through product life
  cycle
• Quick turn-around on design changes
• Managed product development and testing

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System Test Bench HIL System Testing without the
System

• The virtual system test bench integrates with the
  HIL Simulation System by reusing the assets from
  the Model-based development.

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System Test Bench HIL System Testing without the
System

• HIL brings process improvement by adding
• Physical plant and/or human in the loop
• Embedded processor (or emulated processor) in the
  loop
• Prototypes and production controllers and
  subsystems in the loop

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Process Improvements using HIL Simulation

• HIL Simulation provides the bottom-line process
  improvements to testing and life-cycle support
• Faster development/deployment of embedded systems
• Validated and repeatable testing span life cycle
• Early fault detection minimizes late process
  high-cost changes

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Real-time HIL as Risk Reduction Platform

• Risk reduction facilities where software and
  hardware can be developed, integrated, tested and
  evaluated prior to being fielded
• Subsystem stand alone functionality
• Systems interoperability
• Supports highly coordinated systems integration

Distributed HIL uses subsystems at varying stages
to create an early system integration lab
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Boeing Satellite Development Center

• 100 Successful 1ST Missions
• Standard Validation Platform
• Fly Spacecraft on the Ground
• Satellite Emulator

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Gulfstream Aerospace

• 75 Test Time Reduction
• ITF and ARDL

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BAE Systems

• NLOS-C, NLOS-M
• Future Combat Systems

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Real-time HIL as Risk Reduction Platform

• Proven cases where HIL Simulation provide
  industry with identifiable risk reduction
• Safe Testing outside the box (what if
  requirements are exceeded?)
• Fault detection and insertion test cases are easy
  to do (without damaging costly equipment)
• Put your product through the paces without having
  to work in extreme environments (using simulated
  terrain and temperatures instead of extremes of
  desert or mountains).

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HIL Modular Simulation

• ADI delivers modern, open architecture, scalable
  tools for the development and test of embedded
  controls electronics that
• Correctly match capability and cost with the
  development and testing task
• Allow a common tools approach throughout various
  stages of development
• Allow the tools to grow and expand as the users
  requirements and capabilities change

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HIL Modular Simulation

• Real-time simulation models and tools for device
  emulation
• Requirements for real-time simulation plant
  models
• Emulated embedded processor transitions to actual
  processor in the loop
• Example SimuQuest Engine model, Renesas Control
  Processor

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HIL Modular Simulation

• Signal conditioning for actuators and sensors
• Easy integration of the embedded processor
  toolset
• Integrated data acquisition and performance
  estimates
• HIL is safe, low cost platform to perform
  experiments

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HIL Modular Simulation - PCI-Engine

• PCI-Engine is an innovative tool for the design,
  development and acceptance testing of engine
  control units (ECU). PCI-Engine emulates an
  8-cylinder engine with signal measurement and
  generation that is crank-based and time-based.

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I/O Considerations

• ADIs PCI-Engine is a specialized PCI solution
  providing engine signal emulation including the
  hall effect sensors

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Engine Emulation
HIL Demonstration
Emulated Engine Closed-loop with ECU
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HIL Demonstration
rtX HIL System
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ECU Testing with Emulated Engine

• Test ECUs recognition of an event and the
  appropriateness of the ECU response
• Simple as a set of potentiometers and switches
• ECU response is measured to determine that it is
  within tolerance
• Multiple input events to ECU may be generated
  simultaneously

Open-Loop Stimulate Monitor
ECU
Closed-Loop
ECU

• Test
• ECU control algorithm effectiveness
• Response time and control stability
• Adaptive capability of controller

Real-Time Engine Model
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HIL Modular Simulation - PCI-Engine

• ADIs sensor emulation technology developed for
  HIL applications includes sensors and emulated
  devices
• Ratiometric sensors,
• Thermistor and Thermocouple emulation,
• Encoder measurement/emulation

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HIL Modular Simulation - PCI-Engine

• PCI-Engine was integrated with the Renesas
  Controller and the SimuQuest Engine Model for HIL
  automated testing

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HIL Summary

• Hardware-in-the-Loop Simulation
• Model-based development and testing of a single
  subsystem
• System Integration
• Model-based integration testing of stand-alone
  functionality and subsystem interoperability

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Innovation
Embedded Control Systems need Hardware-in-Loop
Simulation
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Questions?
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Feedback Form

• Please fill out the feedback form!
• If you do not have one, please raise your hand

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Thank You!
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