dspace Prototyping Systems

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1 Function Prototyping dspace Prototyping Systems Accelerated function prototyping for controller development Key Features Control design development and optimization without manual programming Optimum scalability and flexibility of dspace hardware with high performance and extensive I/O MATLAB /Simulink models implemented on dspace hardware automatically with dspace Real-Time Interface Whole controller replaced by a dspace prototyping system, or new functions developed via bypassing Flexible adaptation of sensor and actuator signals with RapidPro Hardware Introduction dspace prototyping systems are flexible development systems that let you develop and optimize your control designs for the real plant without manual programming. Design faults are found immediately and corrections can be carried out on-the-spot. No special expertise is necessary for implementation on the prototyping system. We offer numerous input/output interfaces to connect the prototyping system to sensors and actuators. These can be configured graphically in the block diagram, without any programming. dspace has a wide range of software and hardware components for building your own tailored prototyping system. You can also take advantage of our engineering service to make customer-specific extensions. Two Ways of Function Prototyping There are two basic approaches to rapid control prototyping (RCP): fullpass and bypass. With fullpass, the prototyping system completely replaces the production ECU. All sensors and actuators are connected to this real-time hardware, and it has full authority to control the plant. In bypassing (see also p.50), the prototyping system may be connected to some extra sensors and actuators, and parts of the control task are done by a production controller. For example, specific software functions that are under development are offloaded from the production controller to the controller prototyping unit connected to it Catalog 2006 dspace Technologiepark Paderborn Germany

2 dspace Prototyping Systems Application Areas Automotive Industry The flexible development systems let you go on optimizing your function designs in the vehicle until you have them just right. Design faults are found immediately, and corrections can be carried out on the spot. Whatever the ECU will be used for engine, transmission, vehicle dynamics, airbags, comfort systems or any other type of application the prototyping system handles it. Aerospace Industry The prototyping systems provide all you need for prototyping the software for your production controllers and can be used for applications such as: Helicopter blade control for noise reduction Realistic simulation of flight maneuvers Control of combustion pressure oscillations Turbine development Other Industries The prototyping systems have been used for many different applications, such as: Control of a modular rail system for passenger and freight transport Control of a telescope Control system for a wrist simulator Control of the dragline cycle in open cut mining Catalog 2006 dspace Technologiepark Paderborn Germany

3 Function Prototyping Technology Issues Bypassing in General Integrating New Functions in Existing Controllers In contrast to fullpass applications, where the ECU is completely replaced by the prototyping system, with the external bypass approach only individual parts of the controller code are shifted to the prototyping system, and the calibration load is limited. The bypass method is an efficient approach, especially to developing new functions and optimizing existing controller strategies. The original controller executes all functions that remain unchanged, while new algorithms are executed on the prototyping hardware. Using the external bypass approach gives you great flexibility, since you are scarcely limited during the design phase by resource constraints such as RAM, ROM, processor performance, or I/O channels. Real-time behavior is guaranteed even with complex bypass functions. In addition, autoboot options of the prototyping systems allow you to validate the behavior of the new function in realistic scenarios, for example, during test drives. External bypassing: New functions run on the prototyping system, while existing code stays on the ECU Catalog 2006 dspace Technologiepark Paderborn Germany

4 dspace Prototyping Systems External Bypass Methods and Interfaces Matrix To divert the flow of data from the ECU to the prototyping system and back, dspace supports several methods and interfaces. Bypass Interfaces Bypassing methods available ECU hardware requirements Synchronization between controller and prototyping system Max. number of service calls (bypass hooks) in controller code Max. number of functions to be bypassed concurrently DPMEM Plug-On Device (POD) Address-based bypassing (code patch) Service-based bypassing (dspace Calibration and Bypassing Service Access to microcontroller bus, mechanical integration in or on controller Address-based bypassing: via 16 interrupts Service-based bypassing: via 128 interrupts On-Chip Debugging Interfaces (e.g., Nexus, NBD, AUD, JTAG/OCDS) Address-based bypassing (code patch) Service-based bypassing (dspace Calibration and Bypassing Service Debug connector (e.g., DCI-GSI1, p.430), mechanical integration in or on controller Address-based bypassing: via 128 interrupts Service-based bypassing: via 128 interrupts XCP on CAN Service-based bypassing (dspace XCP Service) One (exclusively) available CAN channel Service-based bypassing: via 128 interrupts Address-based bypassing: 16 Address-based bypassing: 128 Service-based bypassing: 128 Service-based bypassing: 128 Service-based bypassing: 128 Bypassing Interfaces. Catalog 2006 dspace Technologiepark Paderborn Germany

5 Function Prototyping Address-Based Bypassing Address-based bypassing is one method of transmitting specific sections of ECU code to a prototyping system for function optimization and development. It can be applied in combination with a dual-port memory (DPMEM) or an on-chip debug interface. The method involves integrating customer-specific code patches into the ECU code. If the input and output variables of functions change, the ECU code typically also needs to be modified. Address-based bypassing provides very fast execution times and minimum latencies in data transmission. For example, using a dspace address-based bypass system with a DPMEM plug-on device (POD), the latency for 20 bytes to be sent from the ECU to the prototyping system and back again is only 2 x 8.5 µsec. A typical address-based bypass scenario via DPMEM: The input data U for the new function is written to the DPMEM. When all the values have been written, the ECU generates an interrupt to the prototyping system, which reads the data from the DPMEM and executes the new function Y =f (U ). The result values Y are written back to the DPMEM, and the ECU reads them for further processing. Dual-Port Memory (DPMEM) Plug-on Device (POD) On-Chip Debug Interface A dual-port memory allows read and write access by two systems (processors) independently of one another, so that they can exchange data. Each of the two ports has its own address, control and data channels. DPMEMs are used in bypassing to transmit data between the ECU and the prototyping system via their shared memory with the smallest possible latencies. Plug-on devices are additional components mounted on an ECU to connect it to the prototyping hardware (for example, the DS4121 ECU Interface Board). PODs contain a dual-port memory (DPMEM) which is connected directly to the address and data bus of the microcontroller, and signal-conditioning tailored to the specific ECU. To provide cost-efficient and powerful interfaces for modern 32-bit microcontrollers, manufacturers are integrating on-chip debug controllers directly into processors. On-chip debug controllers allow actions such as reading and writing memory cells at run time. These options are particularly important in measurement, calibration, and bypassing if serial interfaces such as CAN do not provide enough bandwidth or if an external data/address bus is not (exclusively) available. Interfaces in widespread use include AUD, NBD, JTAG/SDI, JTAG/OCDS, and Nexus Catalog 2006 dspace Technologiepark Paderborn Germany

6 dspace Prototyping Systems Debug Interface AUD NBD JTAG/SDI JTAG/OCDS Description Advanced User Debugger interface (for example, for SH2 processors from Renesas) Non-Break Debug (debug interface, for example, for NEC V85x or Renesas M32R processors) Scalable Debug Interface (debug interface, for example, for Renesas M32R processors) Debug interface for Infineon TriCore processors Nexus The Nexus 5001 Forum standard IEEE-ISTO is an open standard for a multipurpose interface for software development and is particularly suited to debugging on embedded processors. The Freescale MPC56x and MPC55xx processors are examples. Normally, preparation of the ECU code for bypassing is carried out only once by the ECU supplier. With service-based bypassing as supported by dspace, more than 100 functions in the ECU code can be prepared for bypassing by means of service calls (bypass hooks). Afterwards, there is no need to modify the ECU code again. Service calls in the ECU code can be described in a variable description file (ASAP2 file) and evaluated by the RTI Bypass Blockset, so you can flexibly select the functions to be bypassed later on in the model environment. Moreover, service-based bypassing is a generic solution which can be applied independently of the processor type, the coding method (direct or indirect variable access), and the compiler. The function interfaces can be adjusted with respect to a guaranteed interrupt behavior. dspace provides ECU services for DPMEM PODs, for XCP on CAN, and for the DCI-GSI (p. 430). These services can be used for measurement, for calibration, and for bypassing. They are available in C code and have to be compiled and linked to the ECU code only once. Service-Based Bypassing A typical service-based bypass scenario via DPMEM or via XCP on CAN: The new function is executed by the prototyping system, and the results are written back for further processing by the ECU. Catalog 2006 dspace Technologiepark Paderborn Germany

7 Function Prototyping Via DPMEM The address tables and the data buffer are located in the DPMEM of the plug-on device (POD). The connection between the ECU and the prototyping system is implemented via LVDS. Via XCP on CAN The address tables and the data buffer are located in the ECU RAM.The connection between the ECU and the prototyping system is implemented via the CAN bus. Examples of Service Configuration Options Double buffer mechanism Wait mechanism Failure checking mechanism Alive and version information mechanism Subinterrupt handling mechanism To transfer consistent data blocks from the prototyping system to the ECU and vice versa Used in the read service call to wait for a valid response from the prototyping system, when the double buffer mechanism is enabled Checks for valid communication between the prototyping system and the ECU and switches to ECU internal default values if the failure counter has exceeded a given limit. Checks if the prototyping system is connected to the ECU and running. Synchronizes the execution of functions on the ECU and on the prototyping system. XCP on CAN XCP, the Universal Measurement and Calibration Protocol, is standardized by ASAM e.v. (Association for Standardisation of Automation- and Measuring Systems). XCP technology is independent of the transport layer, so XCP can be used with different physical layers, such as CAN and USB. XCP on CAN is a member of the XCP protocol family, and the successor to the CAN Calibration Protocol (CCP) Version 2.1. dspace provides an XCP on CAN service implementation fully compatible with the ASAM standard for various processor platforms. Apart from basic features such as measurement, calibration, page switching, and ECU flash programming, the dspace XCP implementation also supports function bypassing Catalog 2006 dspace Technologiepark Paderborn Germany

8 dspace Prototyping Systems System Components Overview Once you have created your function models, you can automatically implement them on the prototyping hardware with the help of Real-Time Interface without any programming effort at all. You can even configure complex I/O interfaces directly in the block diagram. And you can immediately try out new ideas as soon as you insert them in your model design all without writing a single line of code. It is also no problem to implement C-coded models. Implementation Software (p. 120) Implementation Software Catalog 2006 dspace Technologiepark Paderborn Germany

9 Function Prototyping Real-Time Hardware Typically, prototyping hardware is several times more powerful with regard to processor performance and RAM/ROM resources than the controller itself, to keep you free of hardware restrictions in the design phase. The hardware of dspace prototyping systems consists of high-performance processors which can calculate your controller models in microseconds. Connection to the outside world is established by a broad range of I/O interfaces. There are numerous hardware options for the prototyping system: single-board hardware, MicroAutoBox hardware, RapidPro hardware, and modular hardware. Single-Board Hardware With single-board hardware, you have everything on one card. The boards contain a comprehensive selection of I/O interfaces that meet the requirements typical of the prototyping field. Our single-board hardware typically runs diretcly in the PC and is ideally suited to cost-sensitive applications, from rapid control prototyping to applications that place high demands on performance and I/O. Single-Board Hardware (p. 248) Modular Hardware Modular hardware gives you optimum scalability and flexibility. You can choose from our wide range of boards to put together exactly the prototyping hardware you need for your project. Modular Hardware (p. 266) MicroAutoBox Hardware The MicroAutoBox hardware is the ideal prototyping hardware if you have fixed requirements for your I/O interfaces. The special strength of the MicroAutoBox hardware is its unique combination of high-performance, comprehensive automotive I/O, and an extremely compact and robust design. It is specifically designed for invehicle usage and makes for easy integration of all major automotive bus systems CAN, LIN and FlexRay into in-vehicle function prototyping. Since a MicroAutoBox is hardly larger than an electronic control unit, it can be placed virtually anywhere in the vehicle. MicroAutoBox Hardware (p. 378) Catalog 2006 dspace Technologiepark Paderborn Germany

10 dspace Prototyping Systems RapidPro Hardware The RapidPro hardware consists of three different unit types: the RapidPro SC Unit (signal conditioning unit), the RapidPro Power Unit (power stage unit), and the RapidPro Control Units (intelligent I/O subsystem for dspace prototyping systems as well as stand-alone prototyping ECU). Off-theshelf signal conditioning and power stage modules can be mounted on the RapidPro units to set up individual systems that optimally fit the needs of a particular application. Customer-specific modules are available on request. The modular concept, using modules that are hardware- and softwareconfigurable, means that all components can be reused, reconfigured, or extended, for example in later projects or if requirements change with a minimum of effort. RapidPro can be used for various use cases, such as: Signal conditioning and power stages Intelligent I/O subsystem Stand-alone prototyping ECU RapidPro Hardware (p. 388) To guide you through your function development process, we offer you a sophisticated experiment tool: ControlDesk. For access to the prototyping software from within MATLAB, we offer you MLIB/MTRACE. Test and Experiment Software ControlDesk ControlDesk is a comprehensive, virtual instrument-oriented experiment environment that lets you intuitively manage, control, and automate your experiments. It is ideally suited to simulating your controller models offline, for rapid control prototyping, and for hardware-in-the-loop simulation (HIL). ControlDesk is your convenient user interface for changing parameters online during an experiment, loading look-up tables, and recording data. ControlDesk (p. 140) Catalog 2006 dspace Technologiepark Paderborn Germany

11 Function Prototyping MLIB/MTRACE MLIB/MTRACE, the MATLAB-dSPACE Interface Library, gives you access to the prototyping hardware from within MATLAB. MLIB/MTRACE (p. 178) Measurement and Calibration Software CalDesk CalDesk is a universal tool for measurement, calibration, and diagnostics. It is ideal for rapid prototyping, ECU calibration, and data analysis tasks. It is possible to interface dspace prototyping systems, various kinds of ECUs, measurement modules,and the vehicle bus in parallel and to correlate all measurement data. CalDesk can be operated completely via keyboard shortcuts. A high-contrast mode for visualization and audible signals for trigger and threshold conditions help to make in-vehicle work easier. A COM interface allows CalDesk to be remote-controlled, for example, by MATLAB, in order to automate parameter optimization and measurement tasks. CalDesk (p. 208) Engineering Services for Function Prototyping dspace offers numerous services to assist you with your function prototyping activities. Whatever you would like to do with dspace prototyping systems, you can be sure that we are ready to support you with: Consulting and engineering for special bypassing, signal conditioning, and power stage issues Engineering for RCP tool introduction and process adaption (application scenarios, consulting,pilot projects, specific training and coaching) Customer-specific hardware development and integration of thirdparty products Maintenance services (extension of interfaces, hardware modification) Engineering Services (p. 442) Catalog 2006 dspace Technologiepark Paderborn Germany

12 dspace Prototyping Systems Configuration Example: Stationary Single-Board Solution This example shows how even a cost-efficient prototyping system based on our single-board hardware in this case the DS1103 PPC Controller Board can form a powerful, multipurpose prototyping system. The versatile DS1103, which is installed in a PX4 Expansion Box in our example, is suitable for demanding tasks in rapid control prototyping such as robotics applications, servohydraulics, drives applications, and automotive controllers (for example, ABS or steering). The DS1103 is fully programmable from the Simulink block diagram environment, which makes it possible to implement control functions fast and easily. For easy access to all the signals, you can combine the board with an off-the-shelf connector panel or a connector/led combi panel. The sophisticated experiment software ControlDesk offers a comprehensive, virtual instrument oriented environment that lets you intuitively manage, control, and automate your experiments. Third-Party Components PC Modeling software Real-time code generation from Simulink block diagrams and Stateflow systems MATLAB/Simulink/Stateflow from The MathWorks Real-Time Workshop and Stateflow Coder from The MathWorks Description Required Components (Example) Software Components Implementation software Real-Time Interface (RTI) p. 120 Test and Experiment software Hardware Components RTI CAN Blockset p. 128 PowerPC Compiler p. 139 ControlDesk p. 140 MLIB/MTRACE p. 178 Single-board hardware DS1103 PPC Controller Board p. 250 Accessories PX4 Expansion Box with PCMCIA Link p. 368 CLP1103 Connector Panel p. 260 Catalog 2006 dspace Technologiepark Paderborn Germany

13 Function Prototyping Configuration Example: Stationary Modular Solution Description This prototyping system is a typical example of a laboratory or test-bench-based, automotive fullpass application. In stationary test environments, a local area network (LAN) is often used to exchange data between a host PC and (prototyping) systems here we used an Ethernet TCP/IP link for this purpose. To enable the Ethernet connection, the prototyping system (a DS1005 system in a PX10 Expansion Box) is equipped with a slot-cpu board including an Ethernet interface. The PX10 also contains a choice of modular hardware boards. The ideal choice depends on the specific application, so the boards shown here are only examples. An option in many applications is to use the RapidPro hardware for signal conditioning and power stages Catalog 2006 dspace Technologiepark Paderborn Germany

14 dspace Prototyping Systems Third-Party Components PC with Ethernet interface Modeling software Real-time code generation from Simulink block diagrams and Stateflow systems MATLAB/Simulink/Stateflow from The MathWorks Real-Time Workshop and Stateflow Coder from The MathWorks Required Components (Example) Software Components Implementation software Real-Time Interface (RTI) p. 120 Test and Experiment software RTI CAN Blockset p. 128 PowerPC Compiler p. 139 ControlDesk p. 140 MLIB/MTRACE p. 178 Hardware Components Modular hardware DS1005 PPC Board p. 268 DS2003 Multi-Channel A/D Board p. 278 DS2103 Multi-Channel D/A Board p. 287 DS4002 Timing and Digital I/O Board p. 318 DS4302 CAN Interface Board p. 332 RapidPro hardware RapidPro Hardware p. 388 Accessories PX10 Expansion Box with Ethernet interface (via slot-cpu board) p. 368 Catalog 2006 dspace Technologiepark Paderborn Germany

15 Function Prototyping Configuration Example: Distributed In-Vehicle Solution Description A dspace prototyping system is not limited to only one prototyping unit. This prototyping system (containing one AutoBox and two MicroAutoBoxes all three are perfectly suited to in-vehicle use) shows how separate application components (each for single-processing) can work within a network and be controlled with one notebook as the host. All the prototyping units can be connected to the notebook via the DS830 MultiLink Panel. They communicate with the notebook via a highspeed serial link. The AutoBox used here contains a choice of modular hardware boards. The ideal choice depends on the specific application, so the boards shown here are only examples. In some applications,it might be necessary to establish an additional bus connection so that the prototyping units can communicate with each other directly. This has been realized with a CAN bus here. For signal conditioning and power stages, an option in many applications is to use the RapidPro hardware. Basic signal conditioning is included in the MicroAutoBox. Configurations like the system shown in this example are applicable to many automotive prototyping applications Catalog 2006 dspace Technologiepark Paderborn Germany

16 dspace Prototyping Systems Third-Party Components PC Modeling software Real-time code generation from Simulink block diagrams and Stateflow systems MATLAB/Simulink/Stateflow from The MathWorks Real-Time Workshop and Stateflow Coder from The MathWorks Required Components (Example) Software Components Implementation software Real-Time Interface (RTI) p. 120 Test and Experiment software RTI CAN Blockset p. 128 PowerPC Compiler p. 139 ControlDesk p. 140 MLIB/MTRACE p. 178 Hardware Components MicroAutoBox hardware MicroAutoBox p. 378 Modular hardware DS1005 PPC Board p. 268 DS2003 Multi-Channel A/D Board p. 278 DS4002 Timing and Digital I/O Board p. 318 DS4302 CAN Interface Board p. 332 RapidPro hardware RapidPro Hardware p. 388 Accessories AutoBox with PCMCIA Link p. 372 DS830 MultiLink Panel p. 376 Catalog 2006 dspace Technologiepark Paderborn Germany

17 Function Prototyping Configuration Example: Bypass Solution Description Bypassing (p. 50) means that new functions are moved to the prototyping system, while existing code continues to run on the ECU. An example of service-based bypassing via the ECU s on-chip debug port is shown here. It is possible to read from and to write to any ECU memory address synchronously to ECU code execution at run time by this method. You can use the DCI-GSI1 (p. 430), which supports a range of debug ports, as an interface between MicroAutoBox and the ECU. The debug interface actually used for service-based bypassing depends on the ECU s processor type. Here it is a JTAG/Nexus debug interface, which is suited to processors of the Freescale MPC55xx family. The RTI Bypass Blockset allows you to configure the bypass interface and the bypass functions Catalog 2006 dspace Technologiepark Paderborn Germany

18 dspace Prototyping Systems Third-Party Components PC Modeling software Real-time code generation from Simulink block diagrams and Stateflow systems MATLAB/Simulink/Stateflow from The MathWorks Real-Time Workshop and Stateflow Coder from The MathWorks Required Components (Example) Software Components Implementation software Real-Time Interface (RTI) p. 120 Test and Experiment software Measurement and Calibration software Bypassing services RTI Bypass Blockset (add-on installation for DCI-GSI1) p. 136 PowerPC Compiler p. 139 ControlDesk p. 140 MLIB/MTRACE p. 178 CalDesk p. 208 dspace Calibration & Bypassing Service p. 231 (service-based bypassing) Hardware Components MicroAutoBox hardware MicroAutoBox with PCMCIA Link p. 378 Calibration hardware DCI-GSI1 p. 430 Catalog 2006 dspace Technologiepark Paderborn Germany

19 Function Prototyping Configuration Example: Bypass Solution with Additional I/O Description If bypassed functions require additional I/O functionalities, these can also be provided by a dspace prototyping system, as shown in this example. The prototyping system itself is an AutoBox containing a choice of modular hardware boards. A processor board and the ECU interface board are essential for bypassing, and you can equip the AutoBox with the necessary I/O boards if additional I/O functionalities are needed. The signal conditioning and power stages can be provided by our new RapidPro hardware. With the prototyping system shown, you can perform address-based bypassing via DPMEM. Bypassing methods and interfaces are described on p. 50 p Catalog 2006 dspace Technologiepark Paderborn Germany

20 dspace Prototyping Systems Third-Party Components PC Modeling software Real-time code generation from Simulink block diagrams and Stateflow systems MATLAB/Simulink/Stateflow from The MathWorks Real-Time Workshop and Stateflow Coder from The MathWorks Code patches for bypassing Customer-specific code patches p. 52 (address-based bypassing) Please inquire. Required Components (Example) Software Components Implementation software Real-Time Interface (RTI) p. 120 Test and Experiment software Measurement and Calibration software PowerPC Compiler p. 139 ControlDesk p. 140 MLIB/MTRACE p. 178 CalDesk p. 208 Hardware Components Modular hardware DS1005 PPC Board p. 268 DS2003 Multi-Channel A/D Board p. 278 DS4121 ECU Interface Board p. 324 DS4302CAN Interface Board p. 332 RapidPro hardware RapidPro hardware p. 388 Accessories AutoBox with PCMCIA Link ECU-specific plug-on device (POD) p. 372 Please inquire. Catalog 2006 dspace Technologiepark Paderborn Germany

21 Function Prototyping Configuration Example: Bypass Solution via XCP on CAN Description A prime objective in function development using the external bypass approach is often to employ existing ECU-network interfaces, such as CAN. Against the background of cost savings and long-term investment protection, this requires standardized protocols like XCP tailored not only to today s but also to future in-vehicle communication standards. Apart from basic features such as measurement, calibration, and ECU flash programming, the dspace XCP service (p. 230) also supports function bypassing. In connection with a dspace prototyping system, the XCP service guarantees minimal communication latencies via the CAN bus and real-time behavior even with complex bypass models. Flexible configuration options make it possible to tailor the implementation of the service with regard to functionality and resource consumption in the ECU. The XCP service implementation can be used simultaneously for bypass, measurement, and calibration tasks. In this example of service-based bypassing, the MicroAutoBox (p. 378) is used as a real-time prototyping platform calculating the bypass model. Bypass communication with the ECU runs via the CAN bus using the XCP protocol. The dspace XCP service is implemented on the ECU itself. CalDesk (p. 208) serves as an experiment environment for the MicroAutoBox and optionally for measuring and calibrating ECU variables via the USB-to-CAN converter DCI-CAN1 (p. 424). Measurement data from the MicroAutoBox and the ECU can be correlated and parameters on both platforms tuned in parallel in CalDesk Catalog 2006 dspace Technologiepark Paderborn Germany

22 dspace Prototyping Systems Third-Party Components Notebook Modeling software Real-time code generation from Simulink block diagrams and Stateflow systems MATLAB/Simulink/Stateflow from The MathWorks Real-Time Workshop and Stateflow Coder from The MathWorks Software Components Implementation software Real-Time Interface (RTI) p. 120 Test and Experiment software Measurement and Calibration software RTI Bypass Blockset p. 136 PowerPC Compiler p. 139 MLIB/MTRACE p. 178 CalDesk p. 208 Bypassing services dspace XCP Service p. 230 (service-based bypassing) Hardware Components MicroAutoBox hardware MicroAutoBox p. 378 Calibration hardware DCI-CAN1 p. 424 Catalog 2006 dspace Technologiepark Paderborn Germany

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