Modular HiL Testing System for Automotive Electronic Control Units

Functions at a Glance

• Compact real-time testing system for automotive Embedded Control Units (ECUs)
• Open, modular system architecture for simulation models, software, hardware, test automation, and time-synchronous ECU access
• PC-based simulation with extensive possibilities (Dual-Core, Quad-Core, etc.)
• Excellent price/performance ratio

LABCAR’s main differentiator is its open, modular architecture, which allows the testing system to be easily adapted and functionally extended to suit future requirements. The strict separation of the system-specific hardware and the PC-based computing engine provides a high degree of investment protection. This facilitates the dedicated replacement or addition of individual hardware modules without the need for additional capital investment.

By way of illustration, the LABCAR architecture can be divided into five system components (see Figure 1).

Real-Time Simulation Target
The PC based simulation target calculates the models in real time
More information on LABCAR-RTPC

Models Configuration Prior to Actual ECU testing
Of particular interest in the long-term use of a HiL system is its openness to simulation models from different sources – containing the central know-how. LABCAR is open to the integration of numerous types and versions of modeling tools. In this way, it is possible to integrate, besides MATLAB®/Simulink®-based models (such as TESIS DYNAware), virtually any of the C code-based models supplied by third party vendors (e.g., SIMPACK, GT-Power, AMESim, CarSim). The execution of LABCAR experiments does not require a Simulink® license.

Hardware (Signal I/O)
The LABCAR specific hardware can be assembled according to the customer’s demands.
I/O Components
The I/O components are cards that can be placed in different housings.
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Stand-Alone Extensions
The stand-alone extensions contain compact, independent modules. The following are available:
ES4408 – Load Module for simulation of electrical loads
ES4440 – Failure Simulation Module for simulation of electrical failures

Electrical Operator Interface for Control During a Test
LABCAR comes with a breakout box, with 300 standardized jumpers and 50 additional jumpers for high-current signals. The breakout box also functions as a clearly structured interface for external measuring equipment, and physical real-world components, plus external access to experiments.
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Operating Software
The LABCAR operationg software serves as the user interface not only for the pre-configuration procedures and automation but also for experiment design and execution.
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PT-LABCAR
PT-LABCAR is specifically designed for powertrain applications. The basic configuration is designed for testing ECUs that control up to 8-cylinder gasoline engines or 12-cylinder diesel engines (car or truck). It is possible to upgrade the system up to 16-cylinder engines for all engine management units.