Modular HIL Simulator

 

CHALLENGE

 

DISTek was tasked by a large OEM to create a modular, full system Hardware-in-the-Loop (HIL) simulator system.

SOLUTION

The engineers at DISTek put its 25 years in the Off-Highway software industry to work and together with the OEM developed a solution using a combination of off-the-shelf hardware, custom components, and a custom software application. DISTek decided to leverage its experience as a National Instruments integrator and focused on using NI hardware and software components in the system.

System Hardware:

  • Real Time Controller – Used to run high speed stimulus, deterministic messaging, and six degree of freedom vehicle models
  • MXI Rio and PXI – Used for FPGA, vehicle communications simulation, and hardware IO interface to the vehicle controllers
  • Standard PC – Used to run Graphical User Interface(GUI) and interact with the rest of the system
  • Vehicle controller(s) and display(s)

System Software

  • Simulink – Used for vehicle plant models including six degree of freedom models
  • LabVIEW – Used to code GUI as well as all simulation software including the FPGA
  • VeriStand – Used for convenience to interface between NI hardware and software components while also managing the loops on the real time controller

A modular system was developed to allow for maximum reuse of hardware. The National Instruments hardware and Windows PC were housed in a rack that connects to a removable controller component. This allows the changing of vehicle profiles without a need to fully reconfigure the rest of the hardware for the system.

RESULTS

Coupling DISTek’s years of experience with the customer’s vision of a modular system has proven to be a great success. These modular HIL systems are now being used to represent dozens of different vehicle platforms with minimal hardware purchase required for each new system.

The HIL solution developed for these systems is now running thousands of hours of tests each year, many of them having been automated so they are run without the need for an operator. This shift to HIL results in huge savings for software testing due to the reduced machine requirements, fuel usage, and operator time. Utilizing these systems also creates free time for on-vehicle operators to test unique corner conditions and perform exploratory testing rather than base level regression tests.

 

To view more DISTek case studies, click here.

For more information or a consultation, contact DISTek.

 

 

Featured DISTek Expert

Name:

Joe

Title

Senior Software Engineer

Technical Strengths:

C, CAN, SAE J1939, ISOBUS, MATLAB, Simulink, PREEvision, AUTOSAR, Perl & Python, HTML/CSS/Javascript, Linux.

Past Experience

Custom embedded operating system development and maintenance. Reusable drivers for PWM, ISOBUS, & fault management. Building reusable AUTOSAR software components. ISOBUS-compatible application development. Previously a Scrum Alliance Certified Scrum Product Owner.

DISTek Employee Since:

2006

What I love about my job:

The best thing about my job at DISTek is the quality of the people I get to work with. We are home to some of the most intelligent, professional, open-minded and tenacious software engineers in the industry. Working with these people every day helps to stretch me and make me into a better engineer!

Click HERE to become a DISTek EXPERT!