PSA Peugeot Citroën Simulates Automotive Environments with NI LabWindows™/CVI and PXI for Validating Electronic Designs

Author(s):
Stéphane Legrand - PSA Peugeot Citroën
Hakim Bensalah - PSA Peugeot Citroën

Industry:
Automotive, Transportation, Electromechanics/ Electrotechnics

Products:
PXI-8461/2 Series 2, LabVIEW, PXI-6624, LabWindows/CVI, PXI-6602, FPGA Module, PXI-6704, Data Acquisition, PXI-6527, PXI-6040E, Signal Conditioning, PXI-6713, Real-Time Module

The Challenge:
Performing functional validations without a prototype vehicle, but with similar electronic topology.

The Solution:
Designing a low-cost, high-performance, and simple modular system using PXI hardware and National Instruments LabWindows/CVI application development environment.

During new vehicle development, PSA Peugeot Citroën (PSA) engineers perform numerous tests soon after completing the design phase. The quantity and sophistication of these tests dramatically increased with electronic circuits’ growth in the automotive industry, leading to an increased workload. Ideally, these tests are performed on prototype vehicles, but this method is costly. Therefore, it is essential to work upstream at the laboratory level and simulate the engine control unit (ECU) environment.

To validate various ECU electronic functions, PSA required a modular, low-cost simulation solution that was durable and easy to maintain and that eliminated existing traditional instrumentation such as function generators, variable resistances, decade boxes, and other equipment. These traditional instruments made synchronization difficult and did not offer the performance our industry required. With the very short time allocated to develop new vehicles, automating validations seemed obvious. Finally, the system had to rely on a “popular” software platform.

We had to quickly implement the validation tools with an industry-standard programming software that was easy to maintain and had a flexible configuration. It was also necessary to find simple, low-cost, high-performance tools.

Modular, Low-Cost, and Easy-to-Maintain System

National Instruments hardware and the LabWindows/CVI environment best met our requirements due to its low cost, simplicity, and durability compared to the existing PSA group technologies.

We chose a modular PXI system, which included an 8-slot chassis connected to isolated and conditioned signals to protect the NI modules. The chassis, which can be driven by an external PC via the National Instruments PXI-8330 or embedded in an NI PXI-8187 controller, contains a PXI-6040 multifunction data acquisition module; the PXI-6713 and PXI-6704 analog output modules; the PXI-6602, PXI-6624, and PXI-6527/28 digital I/O modules; and two PXI-8461 CAN interface modules. In some configurations, the application handles up to 18 analog inputs, 32 analog outputs, 24 digital inputs, 24 digital outputs, 10 counter inputs, and 4 counter outputs.

We replicated the system, designed by the MPVI teams in the Belchamp and Velizy technical centers, for multiple vehicle projects from subcompact cars to minivans and utility vehicles. The modular PXI system is as close as it gets to an actual in-car test system; it saves time and improves performance. For example, a function test and validation takes less than half the time as traditional instruments. In addition, we can go much more in-depth in the simulation of the ECU environment. Finally, we significantly improved the work station ergonomics.

We are planning to upgrade the system for a more real-time approach, using our simplified models designed in The MathWorks, Inc. MATLAB^® and Simulink^® software environments. To achieve this, we will integrate real-time embedded PXI controllers and use National Instruments LabVIEW Real-Time software. We are even considering using the NI LabVIEW FPGA Module to further improve performance and customization. The goal is to make tests more reliable with sufficient determinism to validate ECUs with optimal efficiency. Embedded controllers will help the user separate the user interface (on a PC) from the acquisition/processing (within PXI chassis) sections via/through a TCP/IP link. With this more real-time approach, we expect to significantly speed up the development phases needed to adapt to new engines. Today, a new engine introduction implies a 25-day development period to integrate the new parameters into the system. By using an approach based on National Instruments LabVIEW software, integrating our simulation models with real-world I/O, we cut development time nearly in half, to 14 days. This is a key element to consider when reducing vehicle time-to-market.

For more information, contact:

Hakim Bensalah

PSA Peugeot Citroen

Direction Technique Industrielle

DTI/DPMO/CSEO/CSIV SVBP

Centre Technique de Belchamp

hakim.bensalah@mpsa.com

 

Stéphane Legrand

PSA Peugeot Citroen

Direction Technique Industrielle

DTI/DPMO/CSEO/CSIV SVVV

Centre Technique de Vélizy

stephane.legrand@mpsa.com

 

MATLAB^® and Simulink^® are registered trademarks of The MathWorks, Inc.

 

Author Information:
For more information on this Case Study, contact:
Hakim Bensalah
PSA Peugeot Citroën
Tel: NA
hakim.bensalah@mpsa.com

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