Laboratory Course Industrial Automation. Experiment Nr. 6. Introduction to the FlexRay bus system. Brief User Guide IAS Demonstrator Go-Cart

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1 Universität Stuttgart Institut für Automatisierungs- und Softwaretechnik Prof. Dr.-Ing. M. Weyrich Laboratory Course Industrial Automation Experiment Nr. 6 Introduction to the FlexRay bus system Brief User Guide IAS Demonstrator Go-Cart Room 1.126

2 Kurzanleitung IAS Demonstrator Gokart V Table of contents TABLE OF CONTENS IAS DEMONSTRATOR GO-CART INTRODUCTION BUS TOPOLOGY Driving mode CANoe simulation / testing mode SETTING UP THE DEMONSTRATOR Wiring Wheel position Power supply Checking the status indicators PROBLEMS HARDWARE FLEXDEVEL VN STEERING WHEEL CONTROL UNIT WHEEL CONTROL UNIT PIN ASSIGNMENT D-SUB D-SUB HIRSCHMANN G 4 A 5 M FLEXRAY- PIN ASSIGNMENT FLEXRAY CABLE FLEXRAY FRAMES SIGNALS DATA PACKETS PDUS LITERATURE... 19

3 Kurzanleitung IAS Demonstrator Gokart V IAS demonstrator go-cart 1.1 Introduction Figure 1.1 IAS demonstrator go-kart At the institute of industrial automation and software engineering, a go-cart has been implemented in a diploma thesis [Marx10]. It is used to illustrate the capabilities of a steerby-wire system, utilizing the FlexRay bus system. The demonstrator consists of four fault tolerant control units, two at the sensor (steering wheel) and two at the actuator (servo motor / steering mechanics), which communicate using both channels of the FlexRay bus. 1.2 Bus topology Driving mode Figure 1.2 Topology Driving mode In Figure 1.2, the bus topology of the IAS demonstrator is shown. If the configuration is changed, the external terminator resistors have to be adjusted.

4 Kurzanleitung IAS Demonstrator Gokart V CANoe simulation / testing mode Figure 1.3 Topology CANoe simulation 1.3 Setting up the demonstrator Prior of using the IAS demonstrator, the following steps have to be taken: Wiring Depending on the set up, it is necessary to check if the terminators of the FlexRay cables, the topology (see Figure 1.2 / Figure 1.3 Topology CANoe simulation), the FlexRay A/B channels, and the sensors are properly connected to the ECUs Wheel position To avoid sudden movement of the wheels when powering the demonstrator, the wheels should be in the same orientation as the steering wheel Power supply If the wiring and the wheel position have been checked, the IAS demonstrator can be powered up using the switch shown in Figure 4.1. The power can be supplied by an accumulator or an external power supply, depending on the mode of operation. Driving mode self-sustaining power supply 1 Verify the go-cart is switched off 2 Connect the accumulators 3 Verify steering wheel position 4 Power up the demonstrator Testing mode external power supply 1 Verify the go-cart is switched off 2 Verify the selected voltage on the power supply unit 3 Connect the power supply unit 4 Verify steering wheel position 5 Power up the demonstrator

5 Kurzanleitung IAS Demonstrator Gokart V Checking the status indicators After powering up the IAS demonstrator, the status indicators of the steering wheel control unit (Figure 3.1), the wheel control unit (Figure 4.1) and the system diagnostic interface (Figure 3.3) should indicate as follows to ensure correct operation. Steering wheel control unit: - A/B: red LEDs off - Sync: green LEDs illuminate - Active: green LEDs blink Wheel control unit: - A/B: red LEDs off - Sync: green LEDs illuminate - Active: green LEDs blink System control unit: - green LED illuminates - text on display: Betriebsbereit 1.4 Problems CANoe terminates the simulation right after starting it - Active and simulated nodes connected at the same time - FlexRay cable of channels A/B are switched - Incorrect termination of the FlexRay bus - Reset VN3600 (disconnect and reconnect USB cable) - Reset go-cart (switch off and on) FlexRay node is unable to synchronize - Incorrect termination of the FlexRay bus - FlexRay cable of channels A/B are switched - Reset go-cart (switch off and on)

6 Kurzanleitung IAS Demonstrator Gokart V Hardware 2.1 FlexDevel The ECUs of the steer-by-wire demonstrator have been implemented using the FlexDevel Evaluation Board (see Figure 2.1) by Eberspächer Electronics. This board can be used to implement FlexRay, CAN and LIN systems in a laboratory environment. The hardware configuration of the implemented FlexRay network can be found in the diploma thesis Realisierung eines Steer-by-Wire Demonstrators als Beispiel für den Einsatz des FlexRay-Bussystems (Implementation of a steer-by-wire demonstrator as an example for the use of the FlexRay bus system)[marx10]. Figure 2.1 FlexDevel Evaluation Platform [Eber08] The FlexDevel Evaluation Platform has the following characteristics [Eber11]: Freescale µc: MPC Bit, 120MHz Memory: 2M Flash 80k RAM The hardware provides various communication interfaces [Eber11]: 1 Ethernet 1 FlexRay 2 CAN 1 LIN 1 RS232 2 SPI Digital I/O 8 Input 8 Output 8 PWM 8 A/D Wandler 2 (5A) Motor H-bridge 8 user accessible LEDs 2 user accessible switches

7 Kurzanleitung IAS Demonstrator Gokart V slot for a LCD module Figure 2.2 FlexDevil block diagram [Eber08] An overview of the interfaces and components can be found in Figure 2.2. A description of the single components is available in FlexDevel Instructions for Use [Eber08]. 2.2 VN3600 The FlexRay interface VN3600 by Vector Informatik GmbH (see figure 2.3) is used as an interface connecting the simulation PC and the FlexRay cluster. figure 2.3 FlexRay-Interface VN3600 [Vect11] This USB interface can be used with CANoe or CANalyzer to analyze, stimulate and simulate of FlexRay networks. It can also be used to test single ECUs. The interface can take the role of a coldstart node, and therefore is able to start up the cluster.

8 Kurzanleitung IAS Demonstrator Gokart V Steering wheel control unit Figure 3.1 Front panel Connectors steering wheel control unit Ttable 3.1 Front panel Connectors steering wheel control unit Connector Pin Signal Function FSU 1 RS232 2 SCI_A_Tx_out FlexRay node FSU1 RS232 interface 3 SCI_A_Rx_out 5 GND FSU 1 A 2 BM FlexRay node FSU1 Connector channel A 3 GND 7 BP FSU 1 B 2 BM FlexRay node FSU1 Connector channel B 3 GND 7 BP FSU 2 RS232 2 SCI_A_Tx_out FlexRay node FSU2 RS232 interface 3 SCI_A_Rx_out 5 GND FSU 2 A 2 BM FlexRay node FSU2 Connector channel A 3 GND 7 BP FSU 2 B 2 BM FlexRay node FSU2 Connector channel B 3 GND 7 BP Lenkradwinkel Sensor (steering wheel sensor) 3 +5V 1 GND Connector for the steering wheel sensor 2 SteerWheelAngle (SWhAng)

9 Kurzanleitung IAS Demonstrator Gokart V Figure 3.2 Back panel Connectors steering wheel control unit Table 3.2 Back panel Connectors steering wheel control unit Connector Pin Signal Function Messsignal 1 UMeasCell1 measurement signal of the power supply Energieversorgung 2 UMeasCell2 (measurement signal 3 UMeasNodePwr Power supply) 4 UMeasSMPwr 5 UMeasDigital 9 AGND Spannungsversorgung 1 +12V Power supply for the steering wheel (power supply) 2 GND control unit 3 +5V Systemzustandsanzeige 1 HIDLedOk Connector for the system diagnostic (system diagnostic 2 HIDLedFail interface interface) 3 HIDLedError 4 HIDBuzzer 5 HIDBtUp 6 HIDBtDown 7 HIDBtEnter 8 +5V 9 GND LCD Display 25

10 Kurzanleitung IAS Demonstrator Gokart V Figure 3.3 LC display: System diagnostic interface The system diagnostic interface provides information on the status of the system. Figure 3.3 shows the frontal view of the component. The switches can be used to change the output of the display. Table 3.3 System diagnostic interface - LEDs LED State Description Green Ready System Ok. All FlexRay nodes are active and synchronized. All sensors are connected. Yellow System failure Complete or partial failure of a FlexRay node, or power level of the accumulator is low Red System failure Failure of at least two FlexRay nodes, of a sensor, or a FlexRay channel. Table 3.4 Decision table for the system status [Marx10] FR_FSU1 OK SF OK OK OK OK OK SF OK OK FR_FSU3 OK OK OK SF OK FR_FSU4 OK OK OK OK SF SF at 2 FSUs or 1 DF DF at 2 FSUs System status OK SF SF SF SF SF DF Status LEDs Green Yellow Yellow Yellow Yellow Yellow Red Audio signal Off Off Off Off Off On On DF: SF: Dual failure. No signals of the component can be received. Single failure. The components sends its signals via one channel only.

11 Kurzanleitung IAS Demonstrator Gokart V Wheel control unit Figure 4.1 Back panel Connectors wheel control unit

12 Kurzanleitung IAS Demonstrator Gokart V table 4.1 Back panel Connectors wheel control unit Connector Pin Signal Function FSU 3 RS232 2 SCI_A_Tx_out FlexRay node FSU3 RS232 interface 3 SCI_A_Rx_out 5 GND FSU 3 A 2 BM FlexRay node FSU3 Connector channel A 3 GND 7 BP FSU 3 B 2 BM FlexRay node FSU3 Connector channel B 3 GND 7 BP FSU 4 RS232 2 SCI_A_Tx_out FlexRay node FSU4 RS232 interface 3 SCI_A_Rx_out 5 GND FSU 4 A 2 BM FlexRay node FSU4 Connector channel A 3 GND 7 BP FSU 4 B 2 BM FlexRay node FSU4 Connector channel B 3 GND 7 BP Radwinkel Sensor (wheel angle Sensor) 3 +5V Tachogenerator und Endschalter Servomotor 1 GND Connector for wheel angle sensor 2 WheelAngle (WhAng) 1 LimitSwitchPwr +12V Connector for the speed indicator of the servo motor and the limit switches 2 LeftLimitSwitch 4 Speedometer + (speed indicator 5 Speedometer and limit switch) 6 RightLimitSwitch Servomotor 1 Motor + Power supply for the servo motor 2 Motor + (servo motor) 3 Motor 4 Motor Lenkrad 1 +12V Power supply for the steering wheel control 2 GND (steering wheel) 3 +5V N.C. unit Not connected (former connector for the charging device)

13 Kurzanleitung IAS Demonstrator Gokart V Pin assignment 5.1 D-Sub 9 male female Figure 5.1 D-Sub 9 Pin assignment 5.2 D-Sub 26 male female Figure 5.2 D-Sub 26 Pin assignment 5.3 Hirschmann G 4 A 5 M male female Figure 5.3 Hirschmann G 4 A 5 M Pin assignment [Beld11]

14 Kurzanleitung IAS Demonstrator Gokart V FlexRay- Pin assignment male female Figure 5.4 FlexRay Pin assignment 6 FlexRay cable Table 6.1 FlexRay cable Cable Description Blue cable Connection between the FlexRay interface VN3600 and the FlexRay network. The FlexRay channels are separated. Grey cable Extension cable and branch line for a FlexRay channel. D Sub 9 male D Sub 9 female

15 Kurzanleitung IAS Demonstrator Gokart V FlexRay 7.1 Name convention: <Name_Tx_node>Fr<Frame_name>_<Slot><Channels> Table 7.1 FlexRay frames [Marx10] Descriptor of the frame Segment Slots Startup/Sync Channel Cycle Length [Bytes] FR_FSU3FrWheelAngle_001AB static 1 Yes AB 16 FR_FSU4FrWheelAngle_002AB static 2 Yes AB 16 FR_FSU3FrLimitSwitch_003078A static 3; 78 No A 16 FR_FSU3FrLimitSwitch_003078B static 3; 78 No B 16 FR_FSU4FrLimitSwitch_004079A static 4; 79 No A 16 FR_FSU4FrLimitSwitch_004079B static 4; 79 No B 16 FR_FSU1FrSMRefSpeed_005AB static 5 Yes AB 16 FrSMRefSpeed_006AB static 6 Yes AB 16 FR_FSU1FrSteerWheelAngle_007AB static 7 No AB 16 FrSteerWheelAngle_008AB static 8 No AB 16 FR_FSU3FrWheelAngle_076AB static 76 No AB 16 FR_FSU4FrWheelAngle_077AB static 77 No AB 16 FR_FSU1FrSMRefSpeed_080AB static 80 No AB 16 FrSMRefSpeed_081AB static 81 No AB 16 FR_FSU1FrSteerWheelAngle_082AB static 82 No AB 16 FrSteerWheelAngle_083AB static 83 No AB 16 FR_FSU1FrNMMessage_095A dynamic 95 A 1 8 FR_FSU1FrNMMessage_095B dynamic 95 B 1 8 FrNMMessage_095A dynamic 95 A 2 8 FrNMMessage_095B dynamic 95 B 2 8 FR_FSU3FrNMMessage_095A dynamic 95 A 3 8 FR_FSU3FrNMMessage_095B dynamic 95 B 3 8 FR_FSU4FrNMMessage_095A dynamic 95 A 4 8 FR_FSU4FrNMMessage_095B dynamic 95 B 4 8 FR_FSU1FrDiagRequest_096A dynamic 96 A 254 FR_FSU1FrDiagResponse_097A dynamic 97 A 254 FrDiagRequest_098A dynamic 98 A 254 FrDiagResponse_099A dynamic 99 A 254 FR_FSU3FrDiagRequest_100A dynamic 100 A 254 FR_FSU3FrDiagResponse_101A dynamic 101 A 254 FR_FSU4FrDiagRequest_102A dynamic 102 A 254 FR_FSU4FrDiagResponse_103A dynamic 103 A 254 FR_FSUFrDiagRequest_104A dynamic 104 A 254

16 Kurzanleitung IAS Demonstrator Gokart V Table 7.2 FlexRay signals [Marx10] Signal name Data type T A Tx ECU Rx ECU FR_FSU1SteerWheelAngle Int16 2,5ms FR_FSU1 FR_FSU1SMRefSpeed Int16 2,5ms FR_FSU1 FR_FSU3 FR_FSU4 SteerWheelAngle Int16 2,5ms FR_FSU1 SMRefSpeed Int16 2,5ms FR_FSU3 FR_FSU4 FR_FSU3WheelAngle Int16 2,5ms FR_FSU3 FR_FSU1 FR_FSU3LeftLimitSwitchA Uint8 2,5ms FR_FSU3 FR_FSU1 FR_FSU3RightLimitSwitchA Uint8 2,5ms FR_FSU3 FR_FSU1 FR_FSU3LeftLimitSwitchB Uint8 2,5ms FR_FSU3 FR_FSU1 FR_FSU3RightLimitSwitchB Uint8 2,5ms FR_FSU3 FR_FSU1 FR_FSU4WheelAngle Int16 2,5ms FR_FSU4 FR_FSU1 FR_FSU4LeftLimitSwitchA Uint8 2,5ms FR_FSU4 FR_FSU1 FR_FSU4RightLimitSwitchA Uint8 2,5ms FR_FSU4 FR_FSU1 FR_FSU4LeftLimitSwitchB Uint8 2,5ms FR_FSU4 FR_FSU1 FR_FSU4RightLimitSwitchB Uint8 2,5ms FR_FSU4 FR_FSU1

17 Kurzanleitung IAS Demonstrator Gokart V Data packets PDUs Table 7.3 FlexRay data packets (PDUs) [Marx10] FR_FSU1PduSteerWheelAngle FR_FSU1FrSteerWheelAngle_007AB FR_FSU1FrSteerWheelAngle_082AB FR_FSU1SteerWheelAngle FR_FSU1PduSMRefSpeed FR_FSU1FrSMRefSpeed_005AB FR_FSU1FrSMRefSpeed_080AB FR_FSU1SMRefSpeed PduSteerWheelAngle FrSteerWheelAngle_008AB FrSteerWheelAngle_083AB SteerWheelAngle PduSMRefSpeed FrSMRefSpeed_006AB FrSMRefSpeed_081AB SMRefSpeed FR_FSU3PduWheelAngle FR_FSU3FrWheelAngle_001AB FR_FSU3FrWheelAngle_076AB FR_FSU3WheelAngle FR_FSU3PduLimitSwitchA FR_FSU3FrLimitSwitch_003078A FR_FSU3LeftLimitSwitchA FR_FSU3RightLimitSwitchA

18 Kurzanleitung IAS Demonstrator Gokart V FR_FSU3PduLimitSwitchB FR_FSU3FrLimitSwitch_003078B FR_FSU3LeftLimitSwitchB FR_FSU3RightLimitSwitchB FR_FSU4PduWheelAngle FR_FSU4FrWheelAngle_002AB FR_FSU4FrWheelAngle_077AB FR_FSU4WheelAngle FR_FSU4PduLimitSwitchA FR_FSU4FrLimitSwitch_004079A FR_FSU4LeftLimitSwitchA FR_FSU4RightLimitSwitchA FR_FSU4PduLimitSwitchB FR_FSU4FrLimitSwitch_004079B FR_FSU4LeftLimitSwitchB FR_FSU4RightLimitSwitchB

19 Kurzanleitung IAS Demonstrator Gokart V Literature [Beld11] Belden Electronics GmbH: Stand 06/2011 [Eber08] Eberspächer Elecronics: FlexDevel Instructions for Use, 2009 [Eber11] Eberspächer Elecronics: FlexDevel Produktbeschriebung, In: 02/2009 [Marx10] Marx, P.: Realisierung eines Steer-by-Wire Demonstrators als Beispiel für den Einsatz des FlexRay-Bussystems, Uni Stuttgart, DA Nr. 2340, 2010 [Vect11] Vector Informatik GmbH: Stand 02/2011

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