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1
Seminar
Modeling and Simulation of Dynamical Systems
Presented by the IEEE Control Systems Society
Santa Clara Valley
Sunnyvale, 5 February 2011
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2YOUR LOGO
HERE
Program
Welcome 08:45 – 09:10am Coffee and bagels, Seminar kickoff at 9:00am
Session 1 09:10 – 10:00am Mathematical models of dynamical systemsDr. P.K. Menon, Optimal Synthesis
Session 2 10:10 – 11:00am System Identification - Theory and PracticeDr. Mark B. Tischler, Ames Research Center
Session 3 11:10 – 12:00am Visualization and Virtual EnvironmentsDr. Hadi Aggoune, Cogswell Polytech. College
Lunch 12:00 – 12:40pm Sandwiches, sodas, discussions and product demos
Session 4 12:40 – 01:30pm Applications of Hardware-in-the-Loop SimulatorsChristoph Wimmer, National Instruments
Session 5 01:40 – 2:30pm Simulation with Software ToolsElliot English, Dr. Martin Aalund, Dr. Karl Mathia
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3YOUR LOGO
HERE
Session 4
Applications of Hardware-in-the-Loop Simulators
Christoph Wimmer, National Instruments
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4YOUR LOGO
HERE
Agenda
Reason for HIL Components of a HIL System
Hardware Software
Summary
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5YOUR LOGO
HERE
Increasing Software Content…
Reality• Software Growth• SW enables Functionality
•http://www.nasa.gov/pdf/418878main_FSWC_Final_Report.pdf
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6YOUR LOGO
HERE
Impact
Complexity Risk, Damage Time to Market
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7YOUR LOGO
HERE
Complexity
BMW 7 Series: 70 ECUsLexus 460: 100 ECUs
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8YOUR LOGO
HERE
Embedded Software Development Process
Requirementsgathering
Simulation and rapid prototyping
Code generation and ECU flashing
Hardware-in-the-loop testing
(HIL)
Physical testing
Test cells
Field test
Calibration
+-
Controller PlantPlantController
Manage complexity by…
Tying modeling, RCP, and HIL results to requirements
Maximizing system simulation early
Reusing models and tests between stages
+-
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9YOUR LOGO
HERE
HIL Definition – Dynamic Test
HIL System
I/OProcessor
Host PC
HIL didn’t exist 20-25 years agoRoots in aviation
Controller
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10YOUR LOGO
HERE
Components of a HIL System
A real-time target computer(s) with I/O. A host PC with communications link to target computer and
diagnostic link to ECU. A Graphical User Interface (GUI) application to download and
control the real-time process. A test automation application to automate all aspects of the test. A math model of the plant (i.e. engine or vehicle model). Sensor models Real or simulated loads Fault insertion relay matrix
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11YOUR LOGO
HERE
Aircraft Arrestor System
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12YOUR LOGO
HERE
Hydraulic Control System Testing
“The out-of-the-box capabilities of NI VeriStand made it practical for us to develop an HIL test system, reducing our total testing cost by more than $500,000.”
– Greg Sussman, CLA, Process Automation
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13YOUR LOGO
HERE
HIL I/O Components
AI (force), DI (stop), DO (limits) Loads (brake motors) Power Supplies Buses: fiber (ARINC, CAN, …) Sensor Simulation (Encoder, TC, LVDT, …) Fault Insertion Unit
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14YOUR LOGO
HERE
LabVIEW FPGA VHDL~4000 lines
FPGA Sensor Simulation
LVDT Simulation
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15YOUR LOGO
HERE
Fault Insertion Unit (FIU)
•Ch0 •DUT0
•Fault Insertion Unit
•Channel 0
•Channel 1•Ch1 •DUT1
•Fault Bus A•Fault Bus B
+12VGND
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16YOUR LOGO
HERE
The Challenge: Testing Your Multi-Domain System
•16
•Mechanical •Electrical
•Control•Software
•Control•Circuits
•Electro-Mechanical
•Sensors &
Actuators
•Digital Control
•Micro-controllers
•Multi-technology: ThermalMagneticMechanical Hydraulic
•Analog, Digital, & Mixed-Signal circuits
•Transfer functions
•Embedded Control or Supervisory
Systemvision
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•© 2009 ITI GmbH | www.simulationx.com
SimulationX Model Libraries
•17SimulationX Concept | System Simulation
•Domain •SimulationX Model Elements (Samples)
•Signal Blocks
•Mechanics
•Powertrain
•Electro-•Mechanics
•Magnetics
•Pneumatics•Hydraulics
•Thermo
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18YOUR LOGO
HERE
Open Platform
•Simulink is a registered trademark of The MathWorks, Inc®.
The MathWorks, Inc. Simulink®
software NI LabVIEW C/C++ MapleSim models from Maplesoft SimulationX from ITI Tesis DYNA models NI MATRIXx SystemBuild
Esterel SCADE Suite C/C++
CarSim from Mech Sim Corp. GT-POWER engine models from
Gamma Technologies Inc. AMESim models from LMS VI-grade
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19YOUR LOGO
HERE
Distribute test system tasks across cores to increase system bandwidth
Execute models in parallel on multiple cores to improve performance
Real-time Multicore Simulation
www.ni.com/multicore
Efficiently harness the data and task parallelism provided by the latest processor technologies
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20YOUR LOGO
HERE
Multi Chassis Simulation
Engine
Transmission
Chassis
Data exchange Synchronization
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21YOUR LOGO
HERE
Demo: Helicopter Controller Test System
Position Feedback[ENCODER]
Position Set Point[PWM]
Motor Commands[PWM]
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22YOUR LOGO
HERE
Demo: Helicopter Controller HIL Test System
NI VeriStand
Stimulus
Helicopter System Model
Motor Commands[PWM]
Position Set Point[PWM]
Position Feedback[ENCODER]
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23YOUR LOGO
HERE
Helicopter Model
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24YOUR LOGO
HERE
Helicopter Controller
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25YOUR LOGO
HERE
Driver-in-the-loop Test Platform for EHB System Using NI PXI
The Challenge: The key to develop an EHB (Electro-Hydraulic-Brake) controller is to know the performance of actuator through extensive testing experiments, reduce the difficulties caused by real road test through effective parameter simulation and software simulation, and use virtual reality technology to develop a hybrid simulation platform where the actual manipulation of the driver in different virtual environment can perform functional verification of EHB rapid prototyping controller and demonstration of product properties.
The Solution: Develop a wheel cylinder pressure measurement and control system with LabVIEW to control the high-speed switching electromagnetic valve of EHB system. Implement data acquisition (DAQ) and communication of steering wheel, electronic throttle, brake pedal and wheel cylinder pressure in HIL test. Integrate the real-time vehicle model generated with DYNAwaresoftware to VeriStand software platform
Products: NI VeriStand, PXI-6289, LabVIEW, PXI-8196 RT, FPGA Module, Real-Time Module, PXI-1042Q, PXI-7851R, PXI-8464/2, PID and Fuzzy Logic
"Using NI software and hardware, we successfully developed a test platform for EHB hybrid simulation.“
He Huang - Hefei University of Technology
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26YOUR LOGO
HERE
•NI CompactRIO•RT PXI •RT PC •NI Single-Board RIO•Industrial Controller
•NEW*
• Single-point I/O
• Calculated channels
• Stimulus generation
• Test Automation
• Data logging
• Alarming
• Run-time editable user interface
• User management
• Multi-chassis synchronization
• Deterministic model execution
•* 128MB DRAM or great required
HIL Software Real-Time Testing and Simulation Software
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27YOUR LOGO
HERE
NI VeriStand Framework
WORKSPACE
User Interface
FPGA I/O
I/OChannel ForcingModel DLL ExecutionParameter Updates
Calc Ch ProcessingStimulus GenerationAlarm / Procedure Exec Custom Devices
NI VERISTAND ENGINE
I/O Drivers
Server Communication
NI VeriStand Host Server
I/O
Host PC
Real-time System
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28YOUR LOGO
HERE
Demo 2: Helicopter Controller HIL Test System
NI VeriStand
Stimulus
Helicopter System Model
Motor Commands[PWM]
Position Set Point[PWM]
Position Feedback[ENCODER]
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29YOUR LOGO
HERE
High Power
DC-AC InverterHigh / Low Voltage DC-DC ConverterBattery Monitor
Battery Charger
Integrated Power ModuleHigh Voltage Power Distribution CenterCharge Cord Set
Manual Service Disconnect
High Power
DC-AC InverterHigh / Low Voltage DC-DC ConverterBattery Monitor
Battery Charger
Integrated Power ModuleHigh Voltage Power Distribution CenterCharge Cord Set
Manual Service Disconnect
DC-AC InverterHigh / Low Voltage DC-DC ConverterBattery Monitor
Battery Charger
Integrated Power ModuleHigh Voltage Power Distribution CenterCharge Cord Set
Manual Service Disconnect
Remote Start / Keyless Entry SystemsCar2UTM:
- 2Way RKE System- Universal Garage Door OpenerPassive Entry & StartIntelliTire – Tire Pressure Monitoring SystemVehicle Immobilizer
Wireless Control Module
Wireless
Remote Start / Keyless Entry SystemsCar2UTM:
- 2Way RKE System- Universal Garage Door OpenerPassive Entry & StartIntelliTire – Tire Pressure Monitoring SystemVehicle Immobilizer
Wireless Control Module
Wireless
Core Body Control Modules
Gateway Modules
Smart Trailer Tow Module
Door Zone Modules
Seat Heat Modules
Seat Memory Modules
Body Electronics
Core Body Control Modules
Gateway Modules
Smart Trailer Tow Module
Door Zone Modules
Seat Heat Modules
Seat Memory Modules
Body ElectronicsBody Electronics
Infotainment
Sound System Tuning
Amplifiers – Medium, Premium and Advanced Levels
TV Tuner
Infotainment
Sound System Tuning
Amplifiers – Medium, Premium and Advanced Levels
TV Tuner
Low / High Voltage Wire Harnesses
Alternative Wire Technology
Flex Fold Wire
Signal to High Power Terminals & Connectors
Wiring
Low / High Voltage Wire Harnesses
Alternative Wire Technology
Flex Fold Wire
Signal to High Power Terminals & Connectors
WiringWiring
Complete European Terminal & Connector SystemsSignal to High Power Application SystemsIn-line and Board Edge SystemsSealed and Unsealed Systems
Flat Cable Systems
Terminals & Connectors
Complete European Terminal & Connector SystemsSignal to High Power Application SystemsIn-line and Board Edge SystemsSealed and Unsealed Systems
Flat Cable Systems
Terminals & Connectors
Complete European Terminal & Connector SystemsSignal to High Power Application SystemsIn-line and Board Edge SystemsSealed and Unsealed Systems
Flat Cable Systems
Terminals & ConnectorsTerminals & Connectors
Lear is among the global leaders in electrical distribution and has strong market positions in key electronics products totaling $1.9B in sales.
•Passive Junction Box
•Smart Junction Box
•Solid State Smart Junction •Box (S•3•JB•TM•)
•Power Distribution Centers
•Pre•- •Fuse Boxes
•Fuse Systems
•Power •Distribution
•Passive Junction Box
•Smart Junction Box
•Solid State Smart Junction •Box (S•3•JB•TM•)
•Power Distribution Centers
•Pre•- •Fuse Boxes
•Fuse Systems
•Power •Distribution
Lear Electronics
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30YOUR LOGO
HERE
Lear Reduces Embedded Software Issues Using the NI HIL Platform
The Challenge: Maintaining quality and reliability standards amidst the growing complexity of our embedded electronics products while meeting budget and schedule targets.
The Solution: Adopting a new hardware-in-the-loop (HIL) test platform based on NI VeriStand real-time testing software and PXI hardware that provide the flexibility, efficiency, and intuitiveness necessary to address our current requirements with the ability to scale to future needs as we continue to expand our products.
Products: Reconfigurable I/O Devices, NI PXI-8512 CAN/HS1, NI VeriStand Full Development System
Learn more at ni.com
"NI VeriStand has played a significant role in achieving the quality and reliability standards that have helped us win new automotive business.“--Jason G. Bauman - Lear Corporation
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31YOUR LOGO
HERE
Testing Efficiencies
Test cycle time cut in half
Test resources reduced by 80% per validation cycle
Lear Systems Validation Results
Manual Testing
HIL Testing
Test Time Test Cost (man-weeks)
100%
50%
100%
20%
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32YOUR LOGO
HERE
Locations as Part of the Process
Technical Design Center
Regional Design Center Test Cell Field Test Manufacturing
Test
Software validation using HIL
+ -
Controller Plant
Simulation and rapid prototyping
In-vehicle and automated test
+-
PlantController
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33YOUR LOGO
HERE
HIL System Requirements
Open hardware & software platform
Great variety, value, & availability of commercial off-the-shelf (COTS) products
Easily integratable I/O & FPGAs & processing platforms
Multicore, Multisystem support
Test platform that extends beyond HIL testing
Global services, support, & partner expertise
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34YOUR LOGO
HERE
Session 5: HIL Simulators
Q & A
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35YOUR LOGO
HERE
Additional Slides
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36YOUR LOGO
HERE
NI Profile
Leaders in computer-based measurement and automation
Long-term track record of growth and profitability
More than 5,000 employees; operations in 40+ countries
Fortune’s “100 Best Companies to Work For” 11th
consecutive year
More than 500 alliance members worldwide
16% of revenue invested in R&D
40% ($50M) of R&D in real-time and embedded products
•Net Revenue in M
illions
•Revenue of $872 Million in 2010
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37YOUR LOGO
HERE
Reflective Memory
2Gb/s data rate
Fiber optic128/256MB
Deterministic400-500ns transfer
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38YOUR LOGO
HERE
References
[West 2001] Adam West. NASA Study on Flight Software Complexity, http://www.nasa.gov/pdf/418878main_FSWC_Final_Report.pdf, accessed Feb. 2011[Navet 2009] Nicolas Navet, In-Vehicle Networking: a Survey and Look Forward,
http://www.slideshare.net/REALTIMEATWORK/invehicle-networking-a-survey-and-look-forward accessed Feb. 2011
[Wikipedia] Hardwar-in-the-loop simulation, http://en.wikipedia.org/wiki/Hardware-in-the-loop_simulation accessed Feb. 2011
[Gomez 2001] Martin Gomez, Hardware-in-the-loop simulation, http://www.eetimes.com/design/embedded/4024865/Hardware-in-the-Loop-Simulation, EE Times accessed Feb. 2011
[Bico 2009] Samir Bico, Siemens Wind Power Develops a Hardware-in-the-Loop Simulator for Wind Turbine Control System Software Testing, http://sine.ni.com/cs/app/doc/p/id/cs-12344, accessed Feb. 2011