CarSim/TruckSim/BikeSim Real-Time Hardware In the Loop Mechanical Simulation Corporation

Transcription

1 CarSim/TruckSim/BikeSim Real-Time Hardware In the Loop Mechanical Simulation Corporation

2 What is Hardware In the Loop (HIL)? Pure Simulation Software In the Loop (SIL) Plant Model Simulation with/without sub models. There is no timing control and runs as fast as possible. The integration time step can be continuous. Pure Real Time Simulation Run SIL on the computer with Real Time Operation System (RTOS). There is an accurate timing control. The integration time step must be fixed. Hardware In the Loop Simulation Pure Real Time simulation + real components (ECUs and actuators). Vehicle Plant Model SIL HIL External Controller

3 Why do we need Hardware In the Loop? Verify model - can it run in hard real time? Verify hardware controllers Some parts are difficult to simulate (non-linear behavior, environmental variances) Components laboratory testing (reliability, vibration, temperature, EMF) Save cost to test real vehicles Save development time Easily reproduce/repeat test conditions Safe for testing for some dangerous conditions (rollover, pre-crash)

4 Example Applications Brake Testing Test prototype and production ECUs Hydraulic lines and calipers Environmental chamber Applications temperature and EMI reliability, brake dyno control Active Damper System Physical dampers difficult to model Complex suite of test conditions (roads and maneuvers) Applications 7 post rig, stability control, ride optimization Driving Simulator for Active Safety Human in the Loop Drive vehicle through complex traffic scenarios Freeform testing Visual sensor representations Applications active cruise control, crash mitigation, lane departure

5 Case Study Braking ROI Evaluation of Physical Testing vs. HIL Physical Testing One Time Costs Instrumentation $50k Recurring Costs Mule Car w/installation $40k Transportation $20k Fuel $8k Staff $180k CarSim HIL One Time Costs Lab construction $120K Recurring Costs Energy $2k Installation $5k Labor $20k Uptime less than 80% Uptime 99% Uptime issues Weather, driver availability, fueling, nonproductive driving, vehicle component failure, remote locations, driver accuracy, driver safety Uptime issues Test component failure

6 CarSim/TruckSim/BikeSim supported RT System RT-Lab Target dspace Target Linux RT Based Target LabVIEW RT Target (LabCar, A&D, Fujitsu-Ten)

7 CarSim/TruckSim/BikeSim supported RT System Opal-RT: RT-Lab

8 RT-Lab Target Settings

9 Simulink Model for RT-Lab System Run on Host Subsystem Run on Target Subsystem Output to ECU Input from ECU

10 CarSim/TruckSim/BikeSim supported RT System dspace DS1006, DS1005 (PPC 800+ MHz), DS1103 (PPC 800+ MHz), MicroAutobox (PPC 800 MHz) ABS controller runs on dspace MicroAutobox CarSim vehicle model runs on compact dspace chassis with DS1006 and DS2211(IO)

11 dspace Target Settings

12 Simulink Model for dspace System DS2211 IO Card Runs on DS1006 Board

13 CarSim/TruckSim/BikeSim supported RT System ETAS LabCar

14 Linux RT Based Target Settings

15 Simulink Model for ETAS LabCar LabCar IO Ports

16 CarSim/TruckSim/BikeSim supported RT System LabVIEW RT Real-Time Animator (option) Target Monitor (option) Host PC LabVIEW RT Target ESC Controller

17 LabVIEW-RT Target Settings

18 LabVIEW Model for LabVIEW-RT System LabVIEW Background Connection LabVIEW Front Panel Timed Loop. dt= 1 ms Inputs from ECU Initialize CarSim Vehicle Solver. Outputs to ECU CarSim Vehicle Solver. Update each time step Terminate CarSim Vehicle Solver.

19 HIL+Human In the Loop: Driving Simulators Engineering Tool Drive on your proving ground Instantaneous A/B/C/D/ comparison of vehicle components Drive a road before it is built HIL testing of ECUs or complete chassis systems CarSim/TruckSim Inside Integrate the CarSim/TruckSim math models with other technologies Advanced vehicle controls Driver training Entertainment

20 Thank You