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Increasingly, the exchanges of data in complex ECM (Electronic Control Module) systems rely on multiple communication networks across various physical and network layers. This has greatly increased system flexibility and provided an excellent medium to create well-defined exchangeable interfaces between components; however this added flexibility comes with increased network complexity. A system-level approach allows for the optimization of data exchange and network configuration as well as the development of a comprehensive network failure strategy. Many current ECM systems utilize complex multi-network communication strategies to exchange and control data to components. Recently, Caterpillar implemented an HIL (Hardware-In-the-Loop) test system that provides an approach for developing and testing a comprehensive ECM network strategy.

Electric powertrains are quiet, efficient, and provide a better controllability over their conventional counterparts. There are also many other areas in off-highway and commercial vehicles that are beginning to apply Electric Drive technology. The heart of these systems is the Electric Drive control technology being done on ECUs. Due to the complexity of the systems and need for demanding control applications, these ECU systems require a level of closed-loop testing that previous standard bench test-methods cannot supply. The common approach to testing these systems is using Hardware-in-the-loop (HIL) systems designed for electric drive. This paper describes a typical HIL simulation platform for testing control systems for electric powertrain. The scope of this paper covers the standard practices in HIL simulation of electric drives, giving a general overview of the necessary interfaces and simulation technology.

This paper discusses our experiences on the implementation and benefits of using the Hardware-In-the-Loop (HIL) systems for Powertrain control system software verification and validation. The Visteon HIL system integrated with several off-the-shelf diagnostics and calibration tools is briefly explained. Further, discussions on test automation sequence control and failure insertion are outlined The capabilities and advantages of using HIL for unit level software testing, open loop and closed-loop system testing, fault insertion and test automation are described. HIL also facilitates Software and Hardware Interface validation testing with low-level driver and platform software. This paper attempts to show the experiences with and capabilities of these HIL systems.

Currently, Hardware-In-the-Loop (HIL) testing is the defacto standard for ECU verification and validation at the majority of the Commercial Vehicle OEMs and Tier1 suppliers. HIL Testing is used to shorten development and testing time for both engine and machine control systems. In order to use this process, many of these companies have to develop and maintain expertise in the area of Model-based development (MBD). This paper introduces an approach which allows for the effective use of HIL systems without having to directly work in a MBD environment. Many HIL tests can be done with stimulus and response analysis of the ECUs, given core knowledge of the expected behavior of its control software and I/O subsystems. For hardware interface and diagnostics validation, this open-loop testing of the controller may suffice. It is important to provide the tester with capabilities to easily modify these stimuli and evaluate the responses.

Hardware-in-the-loop (HIL) testing is an indispensable tool in the software development process for electronic control units (ECUs) and Logical Replaceable Units (LRUs) and is an integral part of the software validation process for many organizations. HIL simulation is regarded as the tried-and-tested method for function, component, integration and network tests for the entire system. Using the Model based design approach has further enabled improved and faster HIL implementations in recent years. This paper describes the changing requirements for HIL simulation, and how they need to be addressed by HIL technology. It also addresses the challenges faced while setting up a successful HIL system: namely the division of tasks, the total cost of ownership, budget constraints and tough competition and the adaptability of a HIL simulator to new demands. These requirements are discussed using a dSPACE HIL system architecture that was designed from the ground-up to address these needs.

Currently, hybrid and electric drive control systems are being developed for many types of platforms in the aerospace, automotive, and commercial vehicle industries. These systems also entail the use of Battery Management Systems (BMS) to handle their demanding power needs. However, the development of these technologies brings increased system complexity, evident in the platform variants and even more so in the control algorithms of various electronic control units (ECUs). There is also a greater need to handle system-level control strategies, via communication networks and command software. This increased system complexity poses new challenges for software design and ECU system validation, mandating the need for simulation tools that can easily handle the inherent system complexity, while providing cost-effective, industry-proven verification tools and processes.

The Aerospace and Defense industry is currently challenged in multiple ways - cost cutting and sequestration on the defense side, and spurt of growth on the commercial aviation side of business. While these are opposing trends, both will impose severe challenges to the management of product development process for both the Air framers and the suppliers. The challenge becomes severe as the innovation expectations become rapid with increases in embedded software content in avionics and the advent of a new category of autonomous ground, marine, and air systems. Clearly, the industry need is to have a product development process that allows for reducing costs, while increasing embedded software quality and thereby product quality even in an iterative development process.

This paper explores how to enhance your autonomous system (AS) testing capabilities and quality assurance using a completely automated hardware-in-the-loop (HIL) test environment that interfaces to or simulates autonomous sensor technology, such as cameras, radar, LIDAR, and other key technologies, such as GNSS/maps and V2X communication. The key to performing such real-time testing is the ability to stimulate the various electronic control units (ECUs)/sensors through closed-loop simulation of the vehicle, its environment, traffic, surroundings, etc., along with playback of captured sensor data and its synchronization with key vehicle bus and application data. The latest technologies are introduced, which allow for direct sensor data injection to ECUs/line replaceable units (LRUs) for test interaction and stimulus, in addition to dynamic, on-the-fly modification of sensor data streams. It will be shown how these techniques are integrated with current HIL systems.