Ecu Testing PDF

Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.
de 2005
74
ECU Testing
ECU Testing with
dSPACE Simulator
Real-1ime IhIer!ace
CohIrolDesk /
AuIomaIiohDesk / MoIiohDesk
Modular Hardware
SimulaIor-
Speci!ic
Hardware
MA1LA8
/ Simulihk
/ SIaIe!low
OIhers
eaI-Time Hardvare
ImpIemenIaIion 5ofIvare ExperimenI 5ofIvare
eaI-Time ModeIs
CohIroller / LCU
Cutting-edge systems
for ECU/controller testing
Original equipment manufacturers (OEMs) today face pressures on multiple fronts.
The time to market is shrinking while the content and complexity of the vehicle
electronics is rapidly increasing. Almost every automotive innovation effects the
electronics in the vehicle.
Test drives in test vehicles can scarcely cope with the volume of systematic testing
needed, especially close to start of production. The growing number of recalls is a
clear indication of this. It is little wonder that testing and error nding have become
key tasks in the development process.
Systematic and Reproducible
Testing in Hardware-in-the-loop (HIL) simulation is a viable alternative, allowing new
electronic control units (ECUs) and software to be tested largely in a virtual environ-
ment, without real vehicles or prototypes. Such tests are very systematic and also
completely safe, even when critical thresholds are exceeded, while allowing ECU
errors to be reproduced whenever and however required.
Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de
2005
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Improving ECU Software Quality

HIL simulation improves quality even at an early
stage. A major Japanese automobile manufacturer
states that HIL simulation nds 90% of ECU er-
rors, and almost all the errors that it is possible
to nd before the calibration phase. Recall cam-
paigns and associated damage to the companys
image are minimized. The investments made in
HIL systems and in developing tests have usually
paid off after only a few months. Just a few of
the reasons:
Hardware-in-the-loop simulation
avoids recall campaigns and
loss of corporate image
Fewer prototypes, fewer test drives,
lower costs
More comprehensive and more systematic tests in a shorter time
Higher quality, lower risks
Start of production on schedule using fewer resources
dSPACE Simulator Introduction
Key Features of dSPACE Simulator Your Benets
Full integration of MATLAB/Simulink,
the worlds leading design and
modeling tool
State-of-the-art modeling and
maximum compatibility with existing
models or third-party models
Full integration into
the dSPACE tool chain
Maximum reusability of models, test
scripts, layouts and knowledge
Solution-oriented products and
powerful test automation
Savings in time and money
Greatly improved software quality
Easy access to the real-time model,
states and parameters,
even during run time
Fast, graphical programming
via drag & drop
Homogeneous and efcient
user interfaces
Steep learning curves
Fast iterations
Competitive advantage
Product maturity as the worlds most
used HIL simulator:
1,100 in operation worldwide
Best options for
networking and expandability
dSPACEs extensive experience in
the elds of hardware-in-the-loop
simulation and test automation
Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.de 2005
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ECU Testing
Test Scenarios with dSPACE Simulator
The complexity and multilayered architecture of modern ECU software means that
the same ECU has to be tested from all perspectives. dSPACE Simulator covers every
conceivable test scenario. dSPACE Simulator is not only used in the classical domains
of engine, powertrain, and chassis. The systems exibility allows virtually any adapta-
tion: cruise control, body electronics, and especially ECU network tests.
Verifying Control Algorithms
The ECUs are tested against the specication in normal operation. This is done by
running virtual test runs simulating all the necessary vehicle and component variants,
either manually or in automated form. Slalom tests and lane change maneuvers for
vehicle dynamics control units and standard drive cycles, such as FTP75 for testing
engine controls, are examples of this.
dSPACE Simulator offers you a perfect environment for such tests. The ECUs diag-
nostics functions are tested under closed-loop conditions, for example, you have to
check the plausibility of safety-critical sensors such as steering wheel sensors and
yaw rate sensors. Sensor failures (for example, a wheel speed sensor failure at high
speed and during control operation) and CAN bus failures can also be simulated,
and the new controller has to react to them correctly.
ECU Calibration
This can be carried out at a very early stage by means of modern simulators. This is
important because the fast-growing number of ECU parameters and their mutual
effects are making it more and more difcult to get the nal vehicle right. Using
realistic vehicle models, it is possible to carry out or even automate the adaptation
of ECUs, which can later reduce the cost involved in the calibration process.
Vehicle Dynamics
Bosch ESP 5.3, 5.7, 8.0
ContiTeves ESP
TRM ESP
Otto
4-16 cylinders
Manifold injection
Direct injection
Turbocharger
Diesel
4-12 cylinders
Turbocharger
Common rail unit injection
Passenger car and
heavy-duty trucks
Transmission
Continuously variable transmission
Automatic transmission
Automated manual transmission
Double-clutch transmission
Others
Body electronics
Comfort
Air-conditioning control systems
Vehicle Types
From passenger cars to
light and heavy-duty
trucks to Formula One
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Integration Tests on ECU Networks

The main concern is to test problem-free interaction of all the ECUs that are com-
municating, e.g., via CAN and LIN. Network tests have become necessary mainly
because of the growing number of ECUs from different manufacturers that perform
their overall function only when networked.
ECU Network Tests
In an ECU network test with dSPACE Simulator, ECUs that are not yet available can
be simulated and replaced by their real counterparts later on (restbus simulation).
Depending on the application, you will have to test networked ECUs (for example,
ECUs in powertrain or body electronics systems which together provide superior
functionality). Because dSPACE Simulator is so exible, it can easily have several
ECUs connected to it.
CAN heIwork

CAN heIwork

... or a simulator network. ECUs that are
not yet available can be simulated (software
ECUs) and gradually replaced by their
real counterparts (restbus simulation). All
simulators can be operated from a single PC.
Networked ECUs can be tested
using a single simulator ...
In other cases, it is desirable to rst test each ECU separately with different dSPACE
Simulators. After successful tests, it is no problem to connect the dSPACE Simula-
tors, in order to work with a networked simulator setup. The modularity of dSPACE
Simulator makes virtually all test scenarios possible. For example, you can run all the
simulators in a network or separately as single simulators. Missing ECUs can even
be replaced by simulation models, without rebuilding any code.
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ECU Testing
Testing Diagnostic Functions
To test diagnostic functions (e.g., OBDII and EOBD), the ECU behavior when faults
occur is tested. The vehicle is simulated in a closed-loop environment and systemati-
cally drives through all the dened operating points. This allows the diagnostics to
be tested systematically. Typical diagnostic tests relate to the plausibility of signals or
defective electrical connections. It is important for diagnostic tests to be run com-
pletely automatically, as release tests often have to be performed within an extremely
short time. dSPACE Simulator exibly creates different scenarios for different ECUs,
allowing a great diversity of versions to be handled. In the near future, Automa-
tionDesk (p. 140) offers a powerful and convenient test automation environment
to make systematic testing even more efcient.
The Benets of dSPACE Simulator
dSPACE A Competent HIL Partner
dSPACE is your partner in selecting the right system and installing and
conguring your dSPACE Simulator.
Delivery on schedule (approx. 3 months for a single Simulator Full-Size,
approx. 6 months for simulator networks for over 30 ECUs)
Professional project management and fast commissioning
Our ofces can help you get the most out of your dSPACE Simulator by
offering additional services such as training sessions and on-site support.
Technical Lead
dSPACE Simulator is the worlds leading system for the systematic testing of
electronics and software. There are currently more than 1,100 simulators with
dSPACE technology in use worldwide, nearly all of them at major automotive
companies such as Audi, BMW, DaimlerChrysler, DENSO, Ford, Magneti Marelli,
Nissan, Opel, Renault, Toyota, Volkswagen and several Formula One teams.
Broad range of experience: diesel, spark ignition and direct injection
engines, transmission, vehicle dynamics, and vehicle interior systems
Support of networked ECUs (example: 36 ECUs, more than 7,000 signals
on 4 CAN busses and 10 LIN busses, plus 2,000 further I/O signals) and
even the complete vehicle electronics system
Battery network management (sleep, wake-up) tested by precise
measurement of sleep-mode current and operation current from
1 A to over 100 A
Exemplary hardware and software tools for error-nding and test
automation
Applications: cars, light and heavy-duty trucks, racing (Formula One, rally),
aerospace
dSPACE Simulator offers everything you need to perform your tests: Tight
integration of dSPACE software and the modeling tool MATLAB/Simulink from
The MathWorks provides a powerful development environment. And the powerful
and robust dSPACE hardware always sets the standards for HIL technology.
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Test Efciency
dSPACE Simulators graphical user interfaces provide a convenient and
exible environment. Simulated driving cycles, data acquisition, instrumentation,
monitoring, test automation and all other tasks are executed graphically within
dSPACE Simulator.
dSPACE software gives you the greatest possible test efciency and ease of
use.
Signal Generation and Measurement
These are just a few of the automotive signals that can be generated and
measured by dSPACE Simulator
Algorithm- and waveform-based signal generation
(e.g., crankshaft, camshaft, knocking signals)
Generation of PWM sensor signals and Hall sensor signals
(e.g., wheel speed, fuel level)
Generation of resistance-based sensor signals (e.g., temperature)
Generation and measurement of analog and digital sensor signals
(e.g., throttle, switches, lamps, relays)
Simulation of linear lambda probes
Angle-based measurement of injection and ignition pulses
Measurement of PWM actuator signals (e.g., solenoid valves)
Connection to CAN, LIN, FlexRay and serial interfaces
Example: Compensation of potential gradients caused by...
Cable resistance
The ECUs varying power consumption in different operating conditions
...and our solutions in dSPACE Simulator:
Differential analog inputs and outputs
Potential-free resistance outputs
Output transformers for all fast analog outputs
dSPACE Simulator Components
For details on dSPACE Simulators modular concept, please see the following
pages.
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ECU Testing
Implementation Software
The code for dSPACE Simulators real-time hardware is generated automatically,
directly from MATLAB/Simulink. Your MATLAB/Simulink model is connected to the
real-time hardware via drag & drop. Powerful software tools are available for this:
Real-Time Interface for implementing Simulink and Stateow models on
dSPACE Simulator
Optional extensions to Real-Time Interface
Real-Time Interface (RTI)
dSPACEs Real-Time Interface completely integrates MATLAB/Simulink and offers
additional blocks to connect models and our I/O hardware. For example, there are
comprehensive libraries for the DS2211 HIL I/O Board, our most powerful I/O board
for HIL applications. RTIs graphical user interface reduces the work involved in
supplementary model changes and I/O adjustments to a minimum.
Real-Time Interface (p. 108)
Graphical programming and connection to
I/O, CAN bus or LIN bus: everything is done
graphically in Simulink with our Real-Time
Interface.
Conguring CAN and LIN Bus Communication
Conguring your CAN bus communication graphically from Simulink is no problem
with the additional RTI CAN Blockset.
With our new RTI CAN MultiMessage Blockset, you can congure and control a large
number of CAN messages (more than 200) from one single Simulink block.
To simulate communication in a LIN network, we also provide the RTI LIN Blockset
for effortless conguration of LIN master and slave nodes simulated on the DS4330
LIN Interface Board.
Real-Time Interface CAN Blockset (p. 116)
Real-Time Interface CAN MultiMessage Blockset (p. 118)
Real-Time Interface LIN Blockset (p. 120)
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Experiment Software:
ControlDesk for Experiment Management
dSPACE Simulator gives you complete control of your experiments. ControlDesk is
a graphical front-end tool that forms the interactive experiment and visualization
interface of dSPACE Simulator.
Graphical user interface for experiment and platform management
Generation of virtual instrument panels
Precongured layouts for HIL applications
Design of user-specic layouts
ControlDesk offers powerful analysis tools, such as instruments to set up virtual
instrument panels.
With the integrated experiment and test environment and ControlDesks Simu-
link interface, you can monitor your experiments in Simulink and later in real-time
simulation, using the same tools and the same user interfaces.
ControlDesk (p. 128)
dSPACE Simulator Software
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ECU Testing
ControlDesk Failure Simulation
Using ControlDesk Failure Simulation, you can simulate failures in the wiring of
an electronic control unit (ECU). For example, you can simulate that an ECU pin is
short-circuited to ground or the battery voltage, or that an ECU pin is not connected
(cable break).
Extension of ControlDesk Standard
Remote control of the failure insertion unit in dSPACE Simulator
Mid-Size or Full-Size
Import of ECU pin description les
Central Failure Management
ControlDesk Failure Simulation is software for driving the electrical failure simula-
tion in the ECU cable harness. The failure simulation hardware, failure patterns, and
ECU signal channels are all handled centrally via software. Electrical failures are also
activated and deactivated centrally. When networked ECUs are tested, each ECU is
displayed separately with its signal channels. ControlDesk Failure Simulation runs on
existing dSPACE Simulators Mid-Size (p. 88) and Full-Size (p. 90). It also works hand
in hand with AutomationDesk, our test automation software (p. 140).
Handling Failure Simulation Hardware
The Failure Simulation Navigator provides access to the failure simulation system:
Access to all connected ECU signal channels enabled for
electrical failure simulation
Administration of failure patterns (failures to be simulated at the same time)
Handling Failure Patterns
The Failure Pattern window visualizes failure patterns and the status of the failure
simulation hardware, and allows the failure patterns to be edited and saved.
ControlDesk Failure Simulation (p. 139)
The Failure Simulation Navigator
in ControlDesk Failure Simulation:
Central handling of failure simulation
hardware, failure patterns and
all ECU channels.
Failure Pattern window: Every failure
pattern is shown in a layout.
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Test Software:
AutomationDesk
AutomationDesk facilitates the task of developing and managing tests.
Automated testing in HIL simulation
Graphical user interface for managing test projects
Graphical editor for describing automation sequences
AutomationDesk is ideal for automating hardware-in-the-loop tests. AutomationDesk
offers a convenient test automation environment, which supports the development
and handling of large test projects and test sequences. With AutomationDesk, the sys-
tematic structure, reusability, and reproducibility of test sequences are unequalled.
AutomationDesk (p. 140)
Typical Automation Tasks Executed with AutomationDesk
Setting up operating point ECU initialization (e.g., failure memory
reset) and simulator environment
Stimulus signal generation (to switch
short circuit failures or to input
reference trajectories)
Access to real-time variables during
run time
Measurement Access to ECU internal variables via
diagnostic or calibration interfaces
Data capturing of simulator variables
Evaluation and test reporting Access to MATLABs mathematical
test validation capabilities or direct
calculations in Python
Automated report generation based
on XML with standard style sheets for
HTML and PDF
Data management Organization and storage of
test sequences, parameter sets,
measurement data and test reports
dSPACE Simulator Software
84
ECU Testing
3-D Online Animation with MotionDesk
MotionDesk provides 3-D animation of mechanical systems in a virtual world.
3-D online animation of HIL simulation in real time
Graphical user interface similar to other dSPACE tools
Graphical interactive scene design
Scalable number of MotionDesk PCs for multichannel visualization,
e.g., for interactive test drives
Time-stamping and AVI le generation
Simulation comparison: for example, transparent or shadow vehicles
In vehicle dynamics simulation, maneuvers and critical behaviors are particularly hard
to detect by conventional methods such as time histories and display instruments.
A much better impression of what is happening with the vehicle is given by 3-D
online animation.
MotionDesk performs such 3-D animation for all objects simulated on dSPACE
Simulator in real time. With MotionDesk, the results of any action in the simulation
that is running become visible on your PC immediately.
MotionDesk (p. 154)
Full-brake simulation or braking on different surfaces: MotionDesk makes the
cars behavior visible.
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dSPACE Simulator Hardware Concepts

Different Systems for Different Tasks
The hardware requirements might vary immensely depending on your hardware-in-
the-loop application. For example, function tests are executed with simulators that
have a clear set of I/O. In contrast, acceptance tests call for modular, expandable
simulator hardware that allows I/O and processing power to be scalable.
dSPACE Simulator therefore comes in different hardware types, which are the basis
for expansion to your specic task.
dSPACE Simulator Mid-Size
dSPACE Simulator Mid-Size is a standardized, off-the-shelf HIL simulator. Its hardware
is based on two boards from our modular hardware, a processor board and the
DS2211 HIL I/O Board. Other I/O boards can be added if required.
dSPACE Simulator Mid-Size (p. 88)
dSPACE Simulator Full-Size
dSPACE Simulator Full-Size is a modular simulator concept that is assembled with
off-the-shelf components according to your needs. This results in high quality at
attractive prices. dSPACE Simulator Full-Size gives you a high-quality, tailored sys-
tem with enormous extension capabilities. If you need to expand or modify your
simulator, dSPACE has a wide variety of components that can be integrated into
your dSPACE Simulator Full-Size.
dSPACE Simulator Full-Size (p. 90)
Simulator Networks
Several dSPACE Simulators (of any hardware type) can be connected to set up a
networked simulator environment (p. 77).
dSPACE Simulator Hardware
dSPACE Simulator Types:
Mid-Size and Full-Size
86
ECU Testing
Hardware Summary
dSPACE Simulator
Mid-Size (p. 88)
dSPACE Simulator
Full-Size (p. 90)
Form factor 19 desktop rack 19 cabinet 17 37 HU
Vertical modules
Processor hardware DS1005 PPC Board or
DS1006 Processor Board
DS1005 PPC Board or
I/O hardware DS2211 HIL I/O Board Any number and type of
dSPACE I/O boards
Further I/O hardware
Signal conditioning
Substitute loads
Real-load connector
Failure insertion unit
Integration of simulator-
specic hardware
(p. 74)

Integration of third-party
hardware, e.g., load panels

ECU connectors Three 90-pin connectors
Additional connectors
for additional I/O
optional
One or more 90-pin
connectors for each ECU
(standardized)
optional
Break-out box
OBDII diagnostic
connector /
connection to
diagnostic tools
Sub-D connector with
optional CARB adapter
CAN connector
Standard 16-pin CARB
connector
Diagnostic connectors
(CAN, K-line)
Others on request
Truck applications-capable
(24 V/36 V)

42 V-capable
Power supply
(remote controlled)

Included
Available on demand
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Failure Simulation Summary

Failure simulation can be performed with both dSPACE Simulator Mid-Size and
dSPACE Simulator Full-Size. Powerful failure simulation hardware further boosts
their functionality.
dSPACE Simulator
Mid-Size
Standard Hardware Extension
Failure insertion units 5 x DS749 FIU Module
(each features 10 channels)
Optional: replaced with
5 x DS792 Fuse Cards
n x DS793/DS794 Sensor
FIU Cards (up to 2 cards,
each 81 channels with
CMOS switches)
Possible failure types On ECU outputs:
Cable break
Short circuit to ground
Short circuit to
battery voltage
Short circuit to another
ECU pin via two fail planes
On ECU inputs:
Cable break (open line)
Short circuit to ground
Short circuit to
battery voltage
ECU pin via two fail planes
dSPACE Simulator
Full-Size
Failure Simulation Variant 1 Failure Simulation Variant 2
Failure insertion units n x DS291 FIU Module
(each features 10 channels)
n x DS281 Load Module
1 x DS293 Central FIU
Module
n x DS282 Load Module
(10 channels)
1 x DS289 Rsim Module
(simulates a resistance in
the range 1 ...131 k
in steps of 1 )
Possible failure types On ECU inputs and outputs:
Open circuit
Short circuit to ground or
minus pole of the battery
(KL31) with connected/
disconnected load (an ECU
input is disconnected from
a dSPACE output channel)
Short circuit to plus pole
of the battery (KL30) with
connected/disconnected
load (an ECU input is
disconnected from a
dSPACE output channel)
ECU pin with or without
load (via common rail)
On ECU inputs and outputs:
Open circuit with or
without additional
hardware (Rsim, MEAS or
SOURCE) in series
ECU pin directly or via
additional hardware
Short circuit to 5 reference
points (potential 04)
directly or via additional
hardware
dSPACE Simulator Hardware
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ECU Testing
dSPACE Simulator Mid-Size:
Hardware Details
The hardware of dSPACE Simulator Mid-Size is mounted in a 19 desktop rack (height:
6 9 HU). The simulation model runs on the processor board. dSPACE Simulator
Mid-Size generates and measures I/O signals via the DS2211 HIL I/O Board, which
also performs the signal conditioning. Additional I/O and signal conditioning can
be added on request.
Hardware summary (p. 86)
Failure insertion units,
load cards, external
connection of real loads
Spare slot
Modular hardware:
processor board and
I/O board with signal
conditioning
OBDII connector
via adapter
ECU connectors
Remote-controlled
power supply
(battery simulation)
Connection to Host PC
All dSPACE software (p. 106) for experiment setup and control runs on your PC or
notebook. The dSPACE Simulator hardware is connected to your PC via link boards
(ISA, PCMCIA, or PCI, p. 322).
Typical Fields of Application
Engine, transmission and vehicle dynamics HIL
Realistic software system tests/unit tests
Function integration tests
Open-loop or closed-loop environment
Automated testing of diagnostic functions that check the ECU outputs
Hardware Components
Installation in 19 desktop rack (see table)
Integrated signal conditioning for all DS2211 signals
Enclosure Variants
Standard variant,
2-voltage system optional
Small variant,
1-voltage system
DS1005 PPC Board or

DS2211 HIL I/O Board
Failure insertion units
Load cards
Power supply
Second power supply
Free ISA slots for expansion 1 (PX5 version, only for
DS1005 PPC Board)
5 (PX10 version)
1 (PX5 version, only
for DS1005 PPC
Board)
Height units 9 6
Included
Optional
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Signal Conditioning
On-board for DS2211 HIL I/O Board signals
Two spare slots for additional signal conditioning (e.g., current measurement
for diesel and stratied injection applications, lambda probe simulation or
signal conditioning for additional I/O boards)
Failure Insertion Units
A standard dSPACE Simulator Mid-Size supports electrical failure simulation on all
ECU output pins connected to the DS2211. A hardware extension allows electrical
failures to be simulated on ECU inputs as well. The host PC controls both types of
failure simulation via an RS232 interface. See p. 67 for further information.
ECU outputs: Five failure insertion units (FIUs) with 10 channels, connected to
all 50 actuator channels; Optional: replaced with 5 x DS792 Fuse Cards
ECU inputs: optional, via hardware extension (p. 67)
Remote-controlled with ControlDesk Failure Simulation and (on request)
automated with AutomationDesk
Simulation of shorts: shorts from ECU pins to ground or battery voltage
Cable break simulation (open wire)
Simulation of cross-wired short circuits via two fail planes
Simultaneous activation of multiple failures (latch mode)
Load Capabilities
Five load cards, 10 single-ended loads or 5 double-ended loads each
2 W maximum continuous power per load (substitute loads)
8 A maximum load current per pin (real loads)
LED indicators displaying current load states (display mode selectable)
Front connector for measurement or connection of real loads
VBat Jacks
Provides power voltage of both power supplies for external devices
(e.g., external test or diagnostic devices)
4 mm sockets
Power Supply
Programmable switched-mode power supplies (remote-controlled, 2 power
supplies required for simulation of vehicle batteries in 2-voltage systems)
Support of 24-V systems with the rst system
Support of 42-V systems with the second system
Three switched battery rails for each battery voltage,
e.g., main relay, ECU-controlled high rail
16 A maximum current for each rail of rst battery voltage
7.5 A maximum current for each rail of second battery voltage
Other Hardware Components
Break-out box (optional)
Expandability
Expansion with further DS2211 HIL I/O Boards (cascadable),
ECU Interface or CAN Interface boards
Inclusion of real loads, additional, or customer-specic signal conditioning
(e.g., current measurement for diesel or stratied injection applications) or
signal conditioning for an additional I/O board
Customer-specic modications/extensions possible
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ECU Testing
dSPACE Simulator Full-Size:
Hardware Details
dSPACE Simulator Full-Size is mounted in a 19 cabinet whose height depends on
your requirements. The dSPACE boards are mounted in a standard PX20 Expansion
Box (p. 321). The PX20 Expansion Box provides 20 ISA slots for dSPACE boards,
and an additional Expansion Box can be integrated, so you never face restrictions
on expandability.
Open Hardware Concept
The simulation model runs on the processor hardware (single-processor or multi-
processor systems, based on processor boards).
dSPACE Simulator generates and measures I/O signals via the integrated dSPACE
I/O boards. The signal conditioning, loads, failure insertion units and power supply
are also mounted in the 19 cabinet. The number of components, and their types,
depend on your requirements and are congured to t your application.
(e.g., CARB, OBD)
Power supply
Break-out box ECU connector
Connector for
external loads
Loads and failure
simulation
(remote-controlled)
Signal conditioning
Modular hardware:
processor boards
and I/O boards
Connection to Host PC
All dSPACE software for setting up and controlling experiments runs on your PC or
notebook. The dSPACE Simulator hardware is connected to your PC via Link Boards
(ISA, PCMCIA, or PCI, p. 322).
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dSPACE Simulator Full-Size

Typical Fields of Application
Engine, powertrain, and vehicle dynamics HIL
Comprehensive closed-loop tests on ECUs, release/acceptance tests
Networked ECUs
Special requirements, e.g., with high system exibility
Truck applications
Racing applications (Formula One, rally)
Hardware Components
Installation in 19 cabinet
Single-processor or multiprocessor systems, based on processor boards
PX20 Expansion Box for modular dSPACE hardware
Freely expandable by any dSPACE I/O board (see Modular Hardware, p. 224),
according to your requirements
Expandable, e.g., with hardware for signal conditioning,
failure insertion and load simulation
Signal Conditioning
Signal conditioning for all dSPACE I/O boards
Modular signal conditioning concept (off-the-shelf components,
customer-specic conguration)
Supports almost any signal type: e.g., digital in, digital out, analog in,
analog out, relay simulation, current sink/source, LVDT simulation,
resistance simulation
Further modules on demand
Failure Insertion Units
Failure insertion unit (FIU) for ECU inputs and outputs
Modular FIU concept (customer-specic conguration)
Remote-controlled with ControlDesk Failure Simulation
(and optionally with AutomationDesk)
Simulation of shorts: shorts from ECU pins to ground,
battery voltage, or switched rail
Cable break simulation (open wire)
Simulation of cross-wired short circuits
Simultaneous activation of multiple failures (latch mode)
Failure Simulation Variant 1
Our standard variant for failure simulation on dSPACE Simulator Full-Size supports
failure simulation on all ECU input and output pins. All digital and analog I/O boards
from dSPACE are supported by failure simulation. The relay boards (DS291) for failure
simulation can be used on their own or in conjunction with load boards (DS281).
Failure relays are controlled via a serial RS232.
Failure Simulation Variant 1 (p. 87)
Failure Simulation Variant 2
Our second failure simulation variant uses a central relay switching matrix (DS293)
for failure simulation on ECU inputs and outputs. Signal channels can be switched
in on three different rails via load modules (DS282). Further devices that can be
connected include 5 different system potentials (for example, KL30, KL31, KL15),
various measurement devices, and Rsim modules (DS289 for simulating real
substitute loads). See p. 87 for further information. Failure simulation is controlled
via a CAN interface.
Failure Simulation Variant 2 (p. 87)
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ECU Testing
Load Capabilities
Modular load concept (customer-specic conguration)
Support of single-ended and double-ended loads
Resistive loads or other kinds of equivalent loads
Connection of electrically equivalent loads or low-power resistive loads
Connection of real loads, can be integrated in the cabinet
Integration of customers load panels
Power Supply
Simulation of car battery
Programmable switched-mode power supply
Remote-controlled
42 V and truck-capable: 0 50 V voltage range
Other Hardware Components
Break-out box (optional, integrated in cabinet or external)
Optional inclusion of third-party hardware;
e.g., load panels, signal routing units, GPIB instruments
Power switch modules (p. 94)
Expandability
Maximum exibility through modular concept
Minimum hardware modication when requirements change
Supersets with spare signals, allowing tests on several ECU variants,
even after ECU pinout changes
All signals accessible on terminal strips for additional measurement tasks
Clear and transparent system architecture
Multirack systems possible
2005
93
CohIroller/LCU Modular Hardware

5imuIaIor Hardvare
IhIer!ace Io DiaghosIic
ahd CalibraIioh Hardware
Real SysIem CompohehIs
8reak-OuI 8oxes
Relay ahd Failure UhiIs
Programmable Power Supply
Power SwiIch Modules
Sighal CohdiIiohihg
CAN CaIeway
OIhers
Simulator-Specic Hardware
If you need to expand or modify your simulator, dSPACE has a wide variety of off-the
shelf components that can be integrated into your dSPACE Simulator.
dSPACE Simulator Full-Size can be equipped with simulator-specic hardware for
optimum tailoring to your specic needs. dSPACE Simulator Mid-Size can also be
similarly equipped to a certain extent.
The simulator-specic hardware includes real system components and signal con-
ditioning, as well as measurement and diagnostic tools. The components and tools
can be built and integrated by dSPACE, third-party suppliers, or you yourself.
The setup shown in the illustration is typical of many application areas, and you can
also add or remove as many components as you like.
94
ECU Testing
Examples of Simulator-Specic Hardware
Interface to Diagnostic and Calibration Hardware
Many companies already have their own diagnostic and calibration hardware to
perform tasks such as reading out internal ECU variables from the failure memory.
If you do not intend to run this functionality on dSPACE Simulator, the hardware is
connected to dSPACE Simulator via appropriate interfaces, which might in some cases
need a little engineering. You can connect any kind of measuring device, digital scope,
and diagnostic device you like with special protocols such as GPIB or RS232.
Real System Components
In some cases, the real system components (such as injection valves, hydraulic com-
ponents, and sensors) have to be integrated into dSPACE Simulator. This is necessary,
for example, if ECUs and related components come from different suppliers and
have to be checked within the simulated environment. Moreover, not every vehicle
component can be simulated with a justiable amount of time and money, and many
ECUs require real loads at their outputs in order to function at all.
Break-Out Boxes
An optional break-out box makes all ECU pins directly accessible. This simplies the
measurement and input of signals. The break-out boxes can be integrated into dSPACE
Simulator, or take the form of external desktop boxes. Third-party break-out adapters
can also be included (available for dSPACE Simulator Mid-Size and Full-Size).
Relay and Failure Insertion Units
Any number and type of open circuits and short circuits can be simulated by using
relay and failure boxes. Besides our failure insertion unit, it is also possible to integrate
customer-specic and third-party solutions.
Programmable Power Supply
The programmable power unit supplies the components to be tested and enables the
simulation of real voltages such as the battery voltage of a vehicle during start-up.
The power supply unit is remote-controlled from within the real-time model.
Power Switch Module
ECUs consume power even when the vehicle is parked. Many modern ECUs have
a sleep mode to avoid draining the vehicles electrical system unnecessarily. Some
ECUs therefore contain a CAN transceiver capable of sleep mode, which allows the
ECU to run only if it is needed and switches it off otherwise. Power switch modules
provide network management for such systems to be tested, e.g., with sleep mode
and wake-up functions.
Moreover, systems with networked ECUs often require different power supply voltage
levels. Each power switch module therefore handles two power supplies to simulate
different vehicle electrical systems within dSPACE Simulator. Even the sequence when
a vehicle is starting up can be simulated.
A measurement unit allows the precise current measurement of each ECU in different
current ranges, even in the microampere range. For example, current consumption
during ECU sleep mode can be compared with normal operation mode behavior.
The module is controlled by software via a CAN interface.
2005
95
Signal Conditioning
Real components usually cannot be connected directly to the real-time hardware.
The signal level of the ECU and other connected components must rst be adapted
to the I/O interfaces of the real-time hardware. The signal conditioning necessary
for adaptation is an important part of dSPACE Simulator and includes protection
circuits, signal preparation, etc., in addition to level adaptations.
CAN Gateway
In large-scale CAN networks, the testing of bus communication plays a key role.
Engineers need to test the behavior of ECUs and distributed functions when an
expected CAN message fails to arrive or contains unexpected signals.
To simulate errors, a CAN gateway is inserted into the CAN network (see graphic).
Each ECU can be connected individually to one of the two CAN controllers. Signal
manipulation by software allows you to manipulate any CAN messages from any
ECU, with a predened effect on the other ECUs in the CAN network. The CAN
software (RTI CAN MultiMessage Blockset) generates error situations right up to
message or individual signal level.
CAN gateway for simulating errors in large ECU networks.
Simulation of Linear Lambda Probes
LSU is a new signal conditioning module for dSPACE Simulator Full-Size and
Mid-Size that simulates the behavior of linear lambda probes. These probes mea-
sure the air-fuel ratio in a cars catalytic converter. The engine ECU reacts continu-
ously to this information so that the catalytic converter can operate at an optimal
performance rate.
The LSU module allows Nernst cell voltage to be generated on two independent
channels, according to pump current and Nernst cell inner resistance. The module
functions as a linear probe or as a jump probe. Parameters such as maximum/
minimum Nernst cell voltage can be adjusted.
Signal manipulalion
CAN gaIeway so!Iware
Signal
manipulalion
Px Px Tx Tx
CAN -
cohIroller 1
CAN -
cohIroller 2
LCU 1 LCU 2
LCU h
CAN gaIeway hardware
96
ECU Testing
Real-Time Models for dSPACE Simulator
Models from MATLAB/Simulink/Stateow
For hardware-in-the-loop simulation, you need real-time models to simulate the real
environment. dSPACE Simulator is optimally equipped for integrating simulation
models from MATLAB/Simulink/Stateow. Thanks to years of cooperation between
The MathWorks and dSPACE, the tools from these two companies are perfectly
tailored to each other. This way, you can can use your own real-time models or
third-party models. For example, our partner TESIS DYNAware, Munich, Germany,
offers Simulink-based simulation models for HIL simulators that really make your
dSPACE Simulator come alive.
Model-Based Development
After you develop your simulation model, you can test it with Simulink and
ControlDesks Simulink interface and then in real time on dSPACE Simulator with
the same layouts, test scripts and parameter sets.
Services for Real-Time Models
Based on years of know-how in hardware-in-the-loop simulation, dSPACE also offers
modeling services such as
Integration of models into dSPACE Simulator
Parameterization of models based on customer data
Model interfaces
Integration of different modeling tools (Dymola, AmeSim, C-Code, others)
Adaptation of customer models
2005
97
Conguration Examples
O!!-Ihe-shel! hardware
lailure lnserlion Unils
Load Cards
Oll-lhe-shell hardware
Load Cards
PC
dSPACL SimulaIor Mid-Size
Modeling sollware
lmplemenlalion sollware
Lxperimenl sollware
LCU
Modular hardware
(o!!-Ihe-shel!)
DS!005
DS22!!
Power supplies
Peal-Time model
(execuled by DS!005)
Conguration Example:
dSPACE Simulator for Testing Single ECUs
dSPACE Simulator Mid-Size is the perfect choice for testing single ECUs or for test
projects with xed ECU wiring.
Possible ECU Testing Tasks for This Conguration
Functional tests for single ECUs
Integration tests for single ECUs
Acceptance tests for single ECUs
Release tests for single ECUs
Virtual vehicles (when networked with other dSPACE Simulators)
Possible Test Areas for This Conguration
Gasoline engine
Diesel engine
Transmission
Vehicle dynamics
Climate control
Comfort functions
12 42 V applications
Components (Example)
Third-Party Components Further Details
PC
Modeling software MATLAB / Simulink /
Stateow from The
MathWorks
p. 35
Real-time model Real-time models for
dSPACE Simulator
p. 96
Real-time code generation Real-Time Workshop p. 36
Software Components Further Details
Implementation software Real-Time Interface p. 108
PowerPC compiler p. 127
Experiment software ControlDesk p. 128
ControlDesk Failure
Simulation
p. 139
AutomationDesk p. 140
98
ECU Testing
O!!-Ihe-shel! hardware
Load Cards
Signal condilioning
Olhers
PC
d5PACE 5imuIaIor fuII-5ize
Modeling sollware
lmplemenlalion sollware
Lxperimenl sollware
ECUs
Modular hardware
(o!!-Ihe-shel!)
Processor boards
l/O boards
Power supplies
Real-1ime model
(execuled by processor boards)
Hardware Components Further Details
Modular hardware Processor Board:
DS1005 PPC Board
p. 230
I/O boards:
DS2211 HIL I/O Board
p. 254
Off-the-shelf hardware Failure insertion units p. 87
Load boards p. 87
One or two power
supplies (two for
2-voltage system
simulation)
p. 94
Others
Conguration Example:
dSPACE Simulator for Testing Networked ECUs
dSPACE Simulator Full-Size is perfect for projects with higher I/O requirements. The
hardware is expandable and exible, and can be quickly adapted, for example, for
system tests with changing ECU wiring.
Possible ECU Testing Tasks for This Conguration
Function tests for single or networked ECUs
Integration tests for single or networked ECUs
Acceptance tests for single or networked ECUs
Release tests for single or networked ECUs
Virtual vehicles with greatest possible exibility
Possible Test Areas for this Conguration
Gasoline engine
Diesel engine
Transmission
Vehicle dynamics
Climate control
Comfort function
Tests with high currents
12 42 V applications
Power consumption test (airport test)
Very complex real-time models (multiprocessing or networked simulators)

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Catalog 2005 dSPACE Technologiepark 25 33100 Paderborn Germany info@dspace.de www.dspace.

Improving ECU Software Quality

Integration Tests on ECU Networks

dSPACE Simulator Introduction

dSPACE Simulator Hardware Concepts

Failure Simulation Summary

dSPACE Simulator Mid-Size

dSPACE Simulator Full-Size

CohIroller/LCU Modular Hardware

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