Implementing HardwareintheLoop HIL Test Systems

1
Implementing Hardware-in-the-Loop (HIL) Test
Systems

• Christian Hahn
• National Instruments

2
Closed-Loop Control
Disturbance
Motor Command
DC Motor
3
Closed-Loop Control
Engine Control
Navigation Control
Flight Control
Steam Turbine Control
Print Head Control
Dryer Cycle Control
Medical Device Control
4
Examplethe automobile

• 3 ECUs ? 15 to 70 ECUs in 10 years

5
Embedded Control System Challenges
Test Challenges

• Increasing application complexity
• Increasing reliability requirements
• Decreasing time-to-market
• Reduce development cost

Are these mutually exclusive?
6
Testing Embedded Control SystemsSystem Level
Testing
Test System
Test Profile
Logging/ Analysis
UUT
Disturbance
Measured Speed
Motor Command
DC Motor
7
Testing Embedded Control SystemsSystem 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?

8
Testing Embedded Control SystemsComponent Level
Testing
Test System
Test Profile
Logging/ Analysis
UUT
Disturbance
Desired Speed
Motor Command
Motor Controller
Measured Speed
9
What is HIL Simulation?

• Types of Test
• Functional
• Parametric
• Validation (VV)
• Durability (HALT/HAST)
• End-of-line

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

10
Virtual Reality for your UUT

• What does your UUT know about the world around it?

UUT
Voltage
Current
Desired Speed
Motor Command
Motor Controller
Impedance
PWM
TCP
Measured Speed
Timing
ENCODER
11
Testing Embedded Control Systems Virtual System
Level Testing
Test System
Test Profile
Logging/ Analysis
MODEL
UUT
Desired Speed
Motor Command
Motor Controller
Measured Speed

• Stimulus
• MODEL(test profile, UUT response)

12
Testing Embedded Control SystemsVirtual System
Level Testing
Test System
Test Profile
Logging/ Analysis
MODEL
UUT
Desired Speed
Motor Command
Motor Controller
Measured Speed

• Stimulus
• MODEL(test profile, UUT response)

13
What is a Model?
14
Dynamic System Models
NI LabVIEW
ANSI C
MapleSoft MapleSim
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.
15
You Need a Model
Test System
Test Profile
Logging/ Analysis
MODEL
UUT
Desired Speed
Motor Command
Motor Controller
Measured Speed

• Stimulus
• MODEL(test profile, UUT response)

16
Control Design Process
17
Modeling and Design
Control Output
Kc Controller
Kp Plant
Error
Feedback
Setpoint

• Modeling and Design Produce Controller and Plant
  Models

18
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.
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Rapid Control Prototyping
Control Output
Kc Controller
Kp Plant
Error
Feedback
Setpoint

• Creating a Functional Prototype of the Controller

20
Hardware-in-the-Loop Simulation
Control Output
Kc Controller
Kp Plant
Error
Feedback
Setpoint

• Testing Production Controller with Simulated Plant

21
HIL System Architecture
22
Loads, Power, and Faults
Simulated Real Loads Physical loads that would
be seen by the ECU Break-out Power
Supplies Panel for manual fault insertion and
custom loads Fault Insertion Unit Programmatic
fault insertion of open, short to Vbatt, short to
GND, ch-to-ch
Break-out Panel Power Supplies
Simulated and Real Loads
23
HIL Functional Architecture
User Interface
Data Manager
Analysis Reporting
Model Manager
Test Sequence
Host
IO Interfaces
Simulator Interface
Sequencer/Profiler
Datalogging
RT Simulator
Plant Model
Simulated Fault Insertion
RT IO Interfaces
Power Supply
FPGA IO
AIO/DIO
RF / GPIB
Cal / Diag Interfaces
Bus IO
DMM/ Scope
Vision
IO
SigCon
Fault Insertion Unit (Switching)
ECU
Loads
Break-out
24
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

25
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
• Key points
• LabVIEW and NI hardware provide future
  flexibility
• NI helped create an interface to a third-party
  synchronous serial interface using NI-VISA