CarSim/TruckSim/BikeSim

Real-Time Hardware In the Loop

Mechanical Simulation Corporation
www.carsim.com
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
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)
Example Applications
n Brake Testing
l Test prototype and production ECUs
l Hydraulic lines and calipers
l Environmental chamber
l Applications temperature and EMI reliability, brake dyno control

n Active Damper System

l Physical dampers difficult to model
l Complex suite of test conditions (roads and maneuvers)
l Applications 7 post rig, stability control, ride optimization

n Driving Simulator for Active Safety

l Human in the Loop
l Drive vehicle through complex traffic scenarios
l Freeform testing
l Visual sensor representations
l Applications active cruise control, crash mitigation, lane departure
Case Study Braking ROI
Evaluation of Physical Testing vs. HIL

Physical Testing CarSim HIL

One Time Costs One Time Costs
Instrumentation $50k Lab construction $120K

Recurring Costs Recurring Costs

Mule Car w/installation $40k Energy $2k
Transportation $20k Installation $5k
Fuel $8k Labor $20k
Staff $180k

Uptime less than 80% Uptime 99%

Uptime issues Uptime issues

Weather, driver availability, fueling, non- Test component failure
productive driving, vehicle component
failure, remote locations, driver
accuracy, driver safety
CarSim/TruckSim/BikeSim supported RT System

RT-Lab Target dSPACE Target Linux RT Based Target LabVIEW RT Target

(LabCar, A&D, Fujitsu-Ten)
CarSim/TruckSim/BikeSim supported RT System
n Opal-RT: RT-Lab
RT-Lab Target Settings
 Simulink Model for RT-Lab System
Run on Host
Subsystem

Run on Target
Subsystem

Output to ECU

Input from ECU

CarSim/TruckSim/BikeSim supported RT System
n dSPACE
l 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)
dSPACE Target Settings
Simulink Model for dSPACE System

DS2211 IO Card

Runs on DS1006 Board

CarSim/TruckSim/BikeSim supported RT System
n ETAS LabCar
Linux RT Based Target Settings
Simulink Model for ETAS LabCar

LabCar IO Ports
CarSim/TruckSim/BikeSim supported RT System
n LabVIEW RT
Target Monitor (option)

LabVIEW RT Target
Real-Time Animator (option)
Host PC ESC Controller
LabVIEW-RT Target Settings
 LabVIEW Model for LabVIEW-RT System

LabVIEW Background Connection

Timed Loop. dT= 1 ms

LabVIEW Front Panel
Inputs from ECU

Initialize CarSim Vehicle Solver.

Outputs to ECU

CarSim Vehicle Solver. Terminate CarSim

Update each time step Vehicle Solver.
HIL+Human In the Loop: Driving Simulators

Engineering Tool CarSim/TruckSim Inside

Drive on your proving ground Integrate the CarSim/TruckSim
Instantaneous A/B/C/D/ math models with other
comparison of vehicle components technologies
Drive a road before it is built Advanced vehicle controls
HIL testing of ECUs or complete Driver training
chassis systems Entertainment
Thank
You