HIL-Family NovaSim: simulation and automation in the component test

Author(s):
O. Ragonesi - MICRONOVA ELECTRONICA

Industry:
Industrial Controls/ Devices/ Systems, Automotive

Products:
Real-Time Module, LabVIEW, PXI/CompactPCI, FPGA Module

The Challenge:
Developing a compact, high accuracy and flexible scalable HIL-Simulator System for use in HIL environment.

The Solution:
Integration of powerful modules based on NI PXI-components ( Controller, I/O- and FPGA-Boards) and NI software (LabVIEW, LabVIEW Real-Time, LabVIEW FPGA) into NovaSim and modeling within a complete HIL-Simulator.

MicroNova produces turnkey information systems for test bench automation (Hardware in the Loop Simulation) in the automotive segments body, infotainment, chassis and powertrain ECU testing.
In this context, MicroNova's HIL-family NovaSim is a novelty. From the simple test stimulant via a compact system for mobile use up to distributed simulators in the functional fields of convenience, infotainment and drive, NovaSim-systems can be combined by following the same pattern.

PXI components by National Instruments represent important elements within the NovaSim Family. In this context, the engine-HIL-board by MicroNova is of special significance. It is used in engine-HIL-simulators and on account of the high demands on the signals it is based on the advanced FPGA-Technology by National Instruments.

Compact-HIL and Fullsize-HIL
MicroNova’s two HIL-concepts were designed for the complex and multiple tasks initially outlined. The Compact-HIL- system (see illustration on the lower left) is a simulator with a high scale of packing density based on NovaSim RT.

It is suitable for mobile testing allowing the analysis of faults found during test rides right on the spot.
The Fullsize-HIL-system (see illustration on the lower right) also is based on NovaSim RT and is designed for stationary use in the development of vehicles and their components. Compared to the Compact-HIL, it is additionally equipped with extended functions for fault feedforward, closed-circuit measurement as well as controllable power supply and load box for the simulation of loads. This high-end-system delivers an ideal performance rate for test modeling and automation. Both systems can be perfectly matched to suit the specific requirements and/or test projects and, as a result, may execute extensive electronic tests at low cost.

The utilization of equal test procedures in development and production saves time and reduces the fault rate.
Larger test coverage and test proficiency generate an increase of quality at shorter project terms, they increase the production speed and the safety of the products.

Advantages of the HIL-Systems
 High test proficiency through test automation
 Reproducibility of tests
 Simulation of hazardous and/or costly test cases

The illustration below shows the clear modular design of both HIL-systems. The major advantage of the scalability becomes evident. With the same NovaSim-technology you may react dynamically to the most diverse request profiles.

The individual components in detail:

Real Time Computer
Standard PXI-CPUs are used as real-time computers. These are available with high computing performance (currently 2.5 GHz Pentium Mobile). Employing standard components, the user always benefits from applying the latest advancements.
Analog-/Digital-I/O and Special Signals Standard PXI boards are used for analog-/ digital boards. Any special signals such as busses can be implemented simply by making use of the FPGA technology.
In such a way, proprietary serial busses were successfully implemented in the past.

HIL-Boards
For particular applications such as the creation of engine signals, MicroNova offers special boards. On these multi-purpose boards the functionality requested by the user is provided with high performance and flexibility.

Bus Interfaces
NovaSim supports the following interfaces:
 CAN-Bus-Interfaces (standard: two High-Speed-CANs, optional four CANs)
 LIN-Bus-Interface
 FlexRay-Interface CARDBUS-Board (in preparation)
 MOST-Interface

Signal Conditioning
In the field of signal conditioning the whole arena of the automotive signals is available. You have a choice of expansion plug-in cards from current measurement via PWM signals up to simple analog- and digital signals. By means of a prototype board, special requests can be met easily and at the same time cost effectively.

Relay Matrix
For the fault simulation interacting with regressionable test automation, a CAN-controlled relay matrix is optional for NovaSim. Typical faults such as cable cut-offs and short circuits can be simulated. By simulation of these faults the diagnostic functionality of controllers is tested.

Power Supply
Power supply units are available at different power levels. In addition to the highest possible power output of 0-20V with 0-60A (1.2kW power level) existing at the moment, there are smaller systems (e.g. 1kW) according to the power needed. For more sophisticated simulations such as those of swift signals, even external power supplies can be connected via corresponding plug-in connectors.

Real Loads
All real loads such as throttle valve, ignition coil and stepping motors are supplied by the customer and connected via clamping bars.

Load Box
Loads can be simulated via combined resistive, inductive and capacitive dummy loads. The load box is able to absorb up to 2 kW load energy.

Connection Panel
The activation of the customized ECUs occurs via the connection panel. NovaSim employs standardized connectors to hook-up the controllers. The connection panel is customized and tailored to the customer's needs.

Wiring
The wiring concept has been optimized in view of the best possible reuse of existing components. The slide-in computer with signal conditioning is based on MicroNova's own and purchased standard components. The wiring of the I/O-hardware with signal conditioning is accomplished via standard cables and so is the connection panel with the slide-in computer. The application-specific adjustment to the controllers is made in the connection panel.

Conclusion
The HIL family NovaSim flexibly accommodates the needs of the car manufacturers and their suppliers. With NovaSim, electronic components and their hardware specifications can be added fast and smoothly into a priority generic overall test concept. This automation step reduces both redundant expenditures and fault-proneness and cuts the necessary project terms for the development of controllers. With the different characteristics of MicroNova's high-performance HIL-systems - Compact-HIL and Fullsize-HIL - for stationary and mobile use, test coverage and test proficiency are guaranteed to meet the necessary quality criteria for modern vehicles.

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