PT-LABCAR is an open and scalable Hardware-in-the-Loop (HiL) system. It is designed for open- and closed-loop testing of ECUs specifically in the powertrain application domain. The system can be used to run automated regression tests for the release of software variants as well as for the validation of control and diagnostic functions in early phases of ECU development. PT-LABCAR systems can also be used for ECU pre-calibration in the lab.
PT-LABCAR –
LABCAR System Components
PT-LABCAR
A typical PT-LABCAR system configuration is designed for testing ECUs that control up to 8-cylinder gasoline engines or up to 12-cylinder diesel engines (car or truck). The system can optionally be extended, e.g. for fault simulation or the integration with measurement and calibration tools. The system configuration may be adapted for other applications, such as testing transmission ECUs.
The new product model with integrated system configurations is built on established technologies. PT-LABCAR is designed to reduce the effort for project-specific engineering and to simplify the start-up, configuration, and maintenance of HiL solutions.
Advanced Wiring Architecture
As a key component of PT-LABCAR, the LABCAR Connector Box standardizes the wiring harness of the entire system by providing all external connections required for powertrain applications. This approach considerably reduces the effort for system integration: real loads or dummy loads can be easily exchanged in response to test requirements and ECU properties. In addition, an optional breakout box covers the requirements for manual testing by providing access to all ECU pins. The breakout box is designed to fit into the 9-U-housing.
PC-Empowered Simulation
PT-LABCAR integrates a standard PC with Pentium processor, running a Linux real-time operating system. Unlike a proprietary approach, this powerful architecture allows users to take advantage of the favorable trend in the PC market: The simulation-PC can be exchanged without reconfiguration or extensive modifications, as higher-performance models become available on the market. PT-LABCAR thus enables users to run precise simulations with the best possible breadth and depth of test coverage, while their investments in specialized hardware and software are protected.
The standard PC also provides PCI and PCI-Express busses. Additional boards – that use the CAN bus for ECU communication, for example – can thus be integrated into the overall system.
Modular System
PT-LABCAR was designed with outstanding scalability: 300 signal pins and 50 additional high-current pins cover the requirements for both, routine test projects and sophisticated projects that involve advanced ECUs. The optional fault simulation component produces faults for up to 80 channels. If an even higher channel count is required, several fault simulation components can be cascaded.
To satisfy exceptional performance requirements, the standard power supply can be replaced with a more powerful model.
Software Configuration Templates
The software package designed for PT-LABCAR includes LABCAR-OPERATOR, add-ons for a seamless integration of MATLAB®/Simulink®, and LABCAR-RTPC. Preconfigured software templates simplify ECU-specific project configurations such as setting model parameters. Software templates also simplify the pin map-ping between simulation model and ECU connectors, leveraging the standardized pin assignment of the LABCAR Connector Box.
The PT-LABCAR software package includes a running idle controller simulation model. In addition, the system documentation provides recommendations for routine tasks in system configuration and maintenance, e.g. how best to handle a model switch.
Proven Technology
Boards for generating and measuring ECU signals are accommodated within the system using proven LABCAR technology. Various boards have been redesigned for enhanced functionality.
High performance technical features ensure the versatility of the system. For example, the galvanic separation of the signal generation channels supports the exact simulation of an engine’s knock sensors, while the ECU can be accessed in real time.
Sophisticated software functions support the special requirements of the ECU development process, e.g., by providing efficient variant handling. The system’s interaction with LABCAR-AUTOMATION further simplifies its integration into complex process and tool landscapes.