Standard Tools for

Hardware-in-the-Loop
(HIL) Modeling and
Simulation
2008 Mathworks Aerospace and Defense Symposium

April 2, 2008

Robert McNeal and Dr. Mohamed Belkhayat

Technology Development Engineers
Northrop Grumman Corporation

4/17/2008 2:20 PM

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Copyright 2006 Northrop Grumman Corporation

HIL Modeling and Simulation

Hardware-in-the-Loop (HIL) Simulations involve the
integration of validated system simulations and
prototype hardware.
Areas of Integration
Communication between Hardware and Computer
models
computer models simulate system dynamics and
inputs into the hardware
Hardware outputs response signal back to the
computer model
Simulation synchronization
Real-Time Simulation
1

4/17/2008 2:20 PM

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Copyright 2006 Northrop Grumman Corporation

Hardware SEL 300G Protection Relay

Hardware in the Loop:
Schweitzer Engineering Laboratories (SEL) 300G
Generator Protection Relay
Provides power protection
Detects 3- or 4- wire potentials, and 3 phase
current
Voltage Input Range: + 10V
The generator computer model was wired directly
into the processing module via a low level
interface.

4/17/2008 2:20 PM

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Data Acquisition Sound Card

Integrated Sound Card Analog I/O
2 Channels Input, 2 Channels Output (Stereo)
Sample Rate: 48 kS/s
Voltage Output Range: + 2V
Frequency Range: 10 20000 Hz
PCI Sound Card Analog I/O
2 Channels Input, 5 Channels Output (Stereo)
Sample Rate: 50 kS/s (approximately)
Voltage Output Range: + 14V
Frequency Range: 10 50000 Hz

4/17/2008 2:20 PM

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System Configuration w/ Sound Card

4/17/2008 2:20 PM

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Computer Model w/ Sound Card

Configure Output

A
B
C

Input Speed

Voltage
Current

m
-C-

-C-

Pm
A

Vf_
C

Output Signal

Three-Phase Breaker
com

Synchronous Machine
pu Fundamental

80 MW Load
Analog Input

From Wave
Device

Vabc
Iabc

C
Internal
Voltage

4/17/2008 2:20 PM

To Wave
Device

100 MW Load

pow ergui
Discrete,
Ts = 0.0001 s.

Breaker Command

Breaker Control

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Breaker

Fault

Breaker
Feedback

com
A
B
C

Three-Phase Fault

Copyright 2006 Northrop Grumman Corporation

Relay Data w/ Sound Card

Simulation Time
Step: 1ms
Bolted Fault @
0.25s ~ 10 cycles
Clears fault in
25ms
Inconsistent
reaction time
Relay needs three
phases or very
large overcurrent
(100 pu)
6

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Copyright 2006 Northrop Grumman Corporation

Sound Card Interface

Pro
Availability Standard in Computers
Inexpensive
Con
Limited I/O ports Two Channels (Stereo)
Limited Data Type Analog only
Limited fidelity 16 bit data
Simple Standardized Tool for I/O interface

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Data Acquisition Dedicated I/O Card

National Instruments Data Acquisition (NIDAQ) Card
NI PCI-6733
Analog Output (No Input)
8 Channels
Voltage Range: + 10V
Update Rate: 1MS/s
Digital I/O
8 Channels, TTL Logic
Voltage Range: + 5V

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System Configuration w/ NI DAQ Card

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HIL Timing Diagram

Simulink
Simulation

Time

HIL
Relay
Relay is Initialized

Simulation Begins
(Steady State)

Fault Condition
Exists

Relay Receives
Data from
Simulation

Relay Detects Fault

Fault Cleared

Contact Closes
Contact Bouncing
Virtual
Breaker
Opens

Relay Receives
Data from
Simulation

Breaker Closes
Simulation Returns
To Steady State

10

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Relay Receives
Data from
Simulation

Copyright 2006 Northrop Grumman Corporation

Computer Model w/ NI DAQ Card

100 MW Load
A

pow ergui
Discrete,
Ts = 0.0001 s.

Machine
Mearsurments

Input Speed
m
-C-

Internal
Voltage

E
C

Simplified Synchronous
Machine pu Units

Digital Input

Digital Input

Breaker Control

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Analog Output
Analog
Output

Output Signal

Three-Phase Breaker
com

Breaker Command

National Instruments
PCI-6733 [auto]

4/17/2008 2:20 PM

Vabc
Iabc

Digital
Input

11

Current

Configure Output
Voltage

Pm

SSM
-C-

B
C

National Instruments
PCI-6733 [auto]

Breaker

80 MW Load

Fault

Breaker
Feedback

com
A
B
C

Three-Phase Fault

Copyright 2006 Northrop Grumman Corporation

Computer Model Data w/ NI DAQ Card

6
4
Current (A)

Simulation Time
Step: 10 s
Bolted Fault @
0.25s ~ 10 cycles

Current

2
0
-2
-4
-6
0.22

0.23

0.24

0.25

0.26

0.27
time

0.28

0.29

0.3

0.31

0.32

0.28

0.29

0.3

0.31

0.32

Voltage
1

0.5
Voltage (V)

Clears fault
immediately
Closes Breaker in
25ms later

-0.5

-1
0.22

0.23

0.24

0.25

0.26

0.27
time
Trip Signal

Trip
Fault

Switch bouncing
can be seen
Detects fault at
1.5pu overcurrent
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4/17/2008 2:20 PM

Trip

0.8
0.6
0.4
0.2
0
0.22

0.23

0.24

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0.25

0.26

0.27
time

0.28

0.29

0.3

0.31

0.32

Copyright 2006 Northrop Grumman Corporation

Relay Data w/ NI DAQ Card

Three
Phase
Voltages

Three
Phase
Currents
Fault
Detection
Signals
13

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Copyright 2006 Northrop Grumman Corporation

Interface w/ NI DAQ Card

Pro

Numerous I/O ports

Analog and Digital Data support
High Fidelity rate (1Mb/s or better)
Current controlled I/O ports available

Con
Expensive
Not standard in Computers Add-on PCI Card
Multi-port Interface for Control Simulation

14

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Conclusion
The relay in the HIL environment was able to receive
Voltage and Current analog signals from the power
system simulation running in a Simulink real-time
environment.
The relay acted on the signals as if the relay had
been installed in an actual power system.
The relay was able to communicate back to the
Simulink simulation. (Closing the Loop)
The simulation used the relay feedback information
to control a virtual breaker and clear a fault.
15

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Conclusions, Cont.
For very simple HIL interface needs, a computer sound card
can be used as a data acquisition tool.
For multiple signals, multiple sound cards could be used.
For more complex HIL interface needs, a dedicated I/O card
should be chosen.
Windows Real-Time Target simulation environment is
necessary for this HIL testing.
Next stage is to use xPC target, as it is completely independent
of windows.
HIL provides a cost effective method of testing prototype
hardware with standard tools.
Simulink/MATLAB real-time environment
Desktop Computer/PC
Data Acquisition Card
Sound Card
Dedicated I/O Card National Instruments DAQ

16

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Questions

17

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