Rapid Function Development

Fast and reliable

New functions for the electric drive train must be developed fast and reliably. This applies to individual components such as the closed-loop controlling of the electric motor, the battery and thermal management, but also for the common drive management of gearbox, electric motor and combustion engine with Start-Stop operation, recuperation and Power-Boost (hybrid management).

In addition to many approved solutions ETAS offers a lot of innovations.

Four examples:

Through direct coupling of the ECU internal calculation function to control the inverter with the plant model, the exact information is at hand to calculate the model without time loss through ECU hardware interfaces.

Function-in-the-Loop

The Function-in-the-Loop (FiL) technology is a cost-efficient alternative to HiL validation which is at some stages rather complex. It offers the opportunity to connect regulating functions in the ECU directly on the basis of physical values to the simulation target LABCAR-RTPC. This dispenses with the detour of using controller interfaces and test hardware. This approach significantly reduces expenditures on hardware and configuration performance compared to an HiL system. A large part of the test, which must later be regressively completed on the HiL system using identical ECU hardware and the related platform software, can be done earlier in development thus allowing errors to be detected at an early stage in the process.

FiL is particularly well suited for signals which only occur within a single control function. The controller can here be tested independently to the sometimes very expensive hardware I/O. This is the case, for instance, when real sensors in the vehicle are to be replaced through model calculations of the ECU software, as e.g., in HEV temperature and energy models.

Through direct coupling of the ECU internal calculation function to control the inverter with the plant model, the exact information is at hand to calculate the model without time loss through ECU hardware interfaces. The plant model receives the required signals earlier and gains an additional time window to calculate the inverter/e-drive model.

Running several HiL simulations in parallel on several multi-core processors opens up capacity

HiL Tests with Multicore-PC

The HiL system LABCAR by ETAS is used in many hybrid and fuel cell drives development projects and in addition to the modular hardware architecture the possibility to calculate model parts simultaneously on different processor cores of the Multicore-RTPC is highly appreciated. Even high-capacity requirements of hybrid systems are met reliably. Moreover, the simulation of many battery cells the parallel calculation of Multicore Processors offers distinct benefits.

EHOOKS

The bypass hooks in the software play an important role. EHOOKS is a method for external and internal bypass concepts facilitating the flexible and easy insertion of hooks into existing software states without changing software source code. Example: Expanding an ECU for engine control by hybrid functionality through OEM.

Pre-calibration

Due to the increased number of calibration sizes, the pre-calibration at early stages in development is gaining more and more importance – especially in hybrid drives. To facilitate this ETAS offers innovative solutions from the INCA product family. With Simulink®-INCA coupling (INCA-SIP) or open XCP interface for simulation PC (INCA-SCX) it is possible to use INCA via appropriate interfaces as consistent experiment and calibration surface and to carry out calibrations on the virtual model before the respective hardware is available. The developed data records can be reused in the following calibration steps.

Rapid Function Development – Products