Implementing Hardware-in-the Loop HIL Test Systems Christian Hahn

Implementing Hardware-in-the. Loop (HIL) Test Systems Christian Hahn National Instruments

Closed-Loop Control Disturbance Desired Speed Motor Controller Motor Command Measured Speed DC Motor 2

Closed-Loop Control Engine Control Navigation Control Flight Control Steam Turbine Control Dryer Cycle Control Print Head Control Medical Device Control 3

Example…the automobile 3 ECUs 15 to 70 ECUs in 10 years 4

Embedded Control System Challenges • Increasing application complexity Test Challenges • Increasing reliability requirements • Decreasing time-to-market Test Resources • Reduce development cost Are these mutually exclusive? 5

Testing Embedded Control Systems System Level Testing Test System Test Profile Logging/ Analysis UUT Disturbance Desired Speed Motor Controller Measured Speed Motor Command DC Motor 6

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 Measured Speed Motor Command DC Motor 7

Testing Embedded Control Systems Component Level Testing Test System Test Profile Logging/ Analysis UUT Disturbance Desired Speed Motor Command Controller Measured Speed 8

What is HIL Simulation? • Types of Test § § § Functional Parametric Validation (V&V) Durability (HALT/HAST) End-of-line … • Test Methods § § § Temperature/power variation Salt/sand spray EM radiation Mechanical loading/resistance HIL Simulation … 9

Virtual Reality for your UUT What does your UUT know about the world around it? UUT Voltage Desired Speed TCP Motor Controller ENCODER Motor Command Current PWM Impedance Measured Speed Timing 10

Testing Embedded Control Systems Virtual System Level Testing Test System Test Profile Logging/ Analysis MODEL UUT Desired Speed Motor Command Controller Measured Speed Stimulus = MODEL(test profile, UUT response) 11

Testing Embedded Control Systems Virtual System Level Testing Test System Test Profile Logging/ Analysis MODEL UUT Desired Speed Motor Command Controller Measured Speed Stimulus = MODEL(test profile, UUT response) 12

What is a Model? m k c 13

Dynamic System Models NI Lab. VIEW Maple. Soft Maple. Sim The Math. Works, Inc. Simulink® Software Esterel SCADE Simulink® is a registered trademark of The Math. Works, Inc. All other trademarks are the property of their respective owners. 14 ANSI C NI MATRIXx System. Build

You Need a Model… Test System Test Profile Logging/ Analysis MODEL UUT Desired Speed Motor Command Controller Measured Speed Stimulus = MODEL(test profile, UUT response) 15

Control Design Process Modeling and Design System Testing Rapid Prototyping Hardwarein-the-Loop Testing Targeting 16

Modeling and Design Setpoint Error Kc Controller Control Output Kp Feedback Plant Modeling and Design Produce Controller and Plant Models 17

Modeling and Design Software Tools • NI Lab. VIEW Simulation Module • NI MATRIXx • The Math. Works Inc. , Simulink® Application Software • MSC Car. Sim • Hand-coded models (C, Fortran, etc. ) Simulink® is a registered trademark of The Math. Works, Inc. 18

Rapid Control Prototyping Setpoint Error Kc Controller Control Output Kp Plant Creating a Functional Prototype of the Controller 19 Feedback

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

HIL System Architecture Host PC Loads / Power Real-Time Fault Insertion Simulator Unit (FIU) 21 ECU

Loads, Power, and Faults Simulated & Real Loads Physical loads that would be seen by the ECU Break-out Panel Simulated and Real Loads Power Supplies 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 Fault Insertion Unit (FIU) 22

HIL Functional Architecture Host User Interface Model Manager Data Manager Test Sequence Analysis & Reporting Simulator Interface IO RT Simulator Datalogging IO Interfaces Sequencer/Profiler Plant Model Simulated Fault Insertion RT IO Interfaces DMM/ FPGA IO AIO/DIO RF / Cal / Diag Vision Scope Sig. Con GPIB Interfaces Fault Insertion Unit (Switching) Power Supply Bus IO Break-out ECU Loads 23

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 Lab. VIEW Real-Time § Modular PXI hardware platform § NI DAQ I/O modules § • Saved 44 weeks of development time and reduced cost by 6 x 24

Lockheed Martin Simulator (PXI, Lab. VIEW 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 Lab. VIEW and NI hardware provide future flexibility § NI helped create an interface to a third-party synchronous serial interface using NI-VISA § 25