Body Subsystems Test Automation using the dspace Hardware-in-the-Loop setup

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1 dspace User Conference Body Subsystems Test Automation using the dspace Hardware-in-the-Loop setup Venkata RK Pinnelli Suresh H Mohammed Haneefa Kolari 14-Sep-2012

2 General Motors Testing Environments Test Environments: Requirements (Vehicle) Vehicle level Validation Vehicle Validation Vehicle Level Validation Requirements (System) ) System level SW Verification System SW Verification dspace HIL Benches Requirements ( SubSystem Subsystem ) Subsystem level SW Subsystem Verification SW Verification Subsystem SW Verification System Level Validation Subsystem Level Software Verification Requirements Component Requirements Component (Component) Component level SW Verification (Component) SW Verification SW Verification SW Verification SubSystem Level Validation Component Level Validation

3 Subsystems within Body Domain Passive Entry and Passive Start Exterior and Interior Lighting Power Windows Wash/Wipe Seat Supervised movements Power Sunroof Power Mirrors Seat Memory & Heating/Cooling

4 Tools Used Simulation and Automation Plant Model Tools: Matlab / Simulink ToolBoxes GM Internal Tool for Real-Time Simulation of GMLAN dspace Experiment Tools: dspace ControlDesk Design of Simulator Boxes Tools: Microsoft Visio Diagnostics Intrepid / Vector tools Test Automation GM Internal Tool

5 HIL Test Environment Development Process for Subsystems Software Verification Subsystem Requirements Analysis Requirements Hardware Requirements Analysis Bench Setup as per requirements Requirement / Software / Hardware modification Plant Model Development Verification Report dspace ControlDesk Experiment Development Manual Software Verification Automated Test Procedure Develolpment Testing Environment Development Validation Automated Software Verification

6 Host PC Test Environment Setup Plant Model Development dspace SW (ControlDesk etc.,) Compiled Model Compiled Script HIL I/O Cards Internal GM SW Tool Suite Test Report HIL Simulator Test Bench

7 Hardware Test setup The Test bench setup is a functional reproduction of a vehicle s electrical system

8 HIL Test Setup Progression for Software Verification Vehicle Level Test Bench Subsystem Level (e.g. Body Electronics) Component Level Test Bench All ECUs applicable to a Vehicle are present on the bench All ECUs applicable to a Subsystem (e.g. Entry Controls) are present on the bench Component Under Test is present on the bench

9 Vehicle Parts on Body Subsystem Test Bench Vehicle parts on Body Subsystem test bench include: Electronic Control Units applicable to every subsystem Actuators, and Loads (e.g. Wiper motor, Head Lamps, Steering columns, Pedals, Window Regulators, Latches) Switches (e.g. Ignition, Wiper, Memory, Mirror, Seat, Windows ) Over 100 Vehicle parts

10 Simulation Environment for Body Subsystem Test Bench Relays to simulate/control switches for fault creation Signal conditioning circuits to have the required voltage and signal levels for dspace I/O Simulation of sensors and actuators Fault Insertion circuits for short to Battery / GND and Open scenarios Instrumentation of the actual vehicle parts for controlling through dspace Hardware fixtures to obtain the feedback from the vehicle parts to dspace Communication panels for High speed CAN, Low speed CAN and LIN along with standard Diagnostic tools

11 Body Subsystem Test Bench Control and Feedback Mechanisms Instrumented switches for operation and control by dspace String Potentiometers for position calculations Encoders for speed calculations High resolution camera for image capturing General purpose linear actuators for creating obstructions, moving vehicle parts, operating switches. Monitoring the actuator control lines from ECUs through dspace Monitoring sensor feedback signals to the ECUs through dspace Enables complete test automation for a given subsystem

12 Bench Setup Overview ECU HIL Breakout Panel Loads Relays / Fuses Communication panels Other Modules

13 Wash/Wipe Subsystem - Modules Wiper Modules Front and Rear Wiper motors are controlled by the Body Control Module (BCM). Front Wiper motor can operate at Low Speed, High Speed and Intermittent modes based on the switch inputs, where as rear motor has one speed. Stalk Switch Hardware Switch inputs are connected to the BCM. Switches are also simulated in plant model to support automation. Rain Sensor Module Rain Sensor Module senses the intensity of the rain. It sends this information to BCM. The module is simulated in the plant model. Front and Rear Wash Pump: BCM controls wash motors for both Front and Rear.

14 Wash/Wipe Subsystem Bench Setup Host PC Activation status, position, speed feedback Front Wiper Control signal monitor Front Wiper Fixture Rain Sensor Module Simulated Stalk switch LIN Rain Sensor Signals Other Simulated Inputs Other Feedback signals Stalk Switch Input BCM Front Wiper Control Rear Wiper Control HIL Simulator Rear Wiper Control signal monitor Activation status, position, speed feedback Rear Wiper Fixture

15 Wash/Wipe Subsystem Automation Setup Software for Wash/Wipe Subsystem is verified for Front and Rear modules Switches are simulated in the plant model Rain Sensor module is simulated in the plant model Activation status, Speed and Position feedbacks are monitored Wiper position Wiper position feedback is monitored using the dspace setup. A position sensor is used for measuring the position Wiper speed A speed sensor is used to measure the speed of the motor and the feedback is monitored using the dspace setup

16 Software Verification Wash/Wipe Subsystem

17 Acknowledgements Mina Khoee-Fard Engineering Group Manager, General Motors Tarek Lahdhiri Engineering Specialist, General Motors Shubha Channappa Sr. Engineering Manager, General Motors

18 Thank You

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