What is HIL (HardWare In The Loop)
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Transcript of What is HIL (HardWare In The Loop)
Indianapolis Office16469 Southpark DriveWestfield, IN 46074
St. Louis Office2025 Zumbehl RoadSuite 304Saint Charles, MO, 63303
www.ballsystems.com+1 (317) 509-6410
Modeling Discussion Agenda
• Problems with complex systems
• Complex machines defined
• Intro to modeling & Hardware-in-the-Loop (HIL)
• Cost and quality benefits of model-based testing
• Introduction to Ball Systems
• How can we help?
Problem Statement
Complex machines containing multiple embeddedsystems create unique and diverse testing challenges:
• Availability of product and/or test system for testing
• Cost / time to build a system prior to testing
• High cost to test (capital, facilities, maintenance,manufacturing time, scrap, redesign, etc.)
• Time consuming testing, especially for extensiveregression testing
• System validation challenging due to complexity.Unable to test to limits and beyond
• Repeatability challenging for large physical systems
• High cost of failure (production test, field, customerissues, etc.)
Complex Machines Defined
Plant
EmbeddedReal-Time Control
System
Complex machines such as Draglines, Spacecraft,Vehicle Engines, Blast Hole Drills, Jet Engines, etc.typically have multiple Embedded Real-Time ControlSystems controlling one or more complex (typically)physical components called the “Plant”
Why Modeling and Simulation?
Modeling andsimulation canreduce risk andtime to market andincrease theefficiency inmultiple areas ofthe productdevelopment cycle:
• Model-In-Loop• Software-In-Loop• Hardware-In-Loop• Rapid Control
Prototyping
NI’s VeriStandsoftware platformprovides seamlessintegration ofmodelingthroughout theproductdevelopment cycle
Product DevelopmentV-Diagram
• HIL allows a product development or product testengineer the ability to mimic (or model) the behaviorof the Plant using a combination of electronichardware and custom software
• HIL replaces the Plant under control with a softwaremodel of the physical Plant and all related dynamicsystems
• Modeling improves test and development throughsimulating the use of real world systems
• Models also allow for rapid design iteration, andvalidation at much lower cost
• These models are then “interfaced” with anelectronic control system through the use of an HILhardware test system and associated software tosimulate actuators, sensors, etc.
HIL Allows Modeling of Machines
A software modelis a mathematicalrepresentation ofa physical systemand sometimes ofa control systemas well
Plant SoftwareModel
HIL System Schematic
I/OSignals
Host PCRunning
NIVeriStand
Plant Software Model
ControlSystemReal-Time System
The Plantsoftware model,the host PCrunning NIVeriStand, andthe NI Real-TimeHIL Systemeffectively“replace” thePlant
• HIL increases the speed and scope of testing whilereducing risk and cost
• Ideally an embedded control system is tested against thereal Plant
• However frequently the real Plant imposes limitations orrisks on the scope of the testing
• For example, in the case of an electronic control system,certain testing may lead to dangerous test conditions:
• Testing at or beyond the range of the certain controlsystem parameters or Plant capabilities
• Testing and verification of the system at failureconditions and beyond (“corner cases”)
• HIL provides an efficient and safe environment where thetest or application engineer can focus on the functionalityof the controller without risk to himself or the Plant
Quality of Model-based Testing
Balance Time & Cost vs. Real World
HIL = The Best of Both Worlds
Rea
l Wor
ld C
orre
latio
n
Time and Cost
Virtual Simulation
Hardware-in-the-Loop
Proving Ground orCustomer Site
HIL simulationallows theengineer to costeffectivelybalance rapidverification,validation, andregressiontesting with real-world interaction
Who is Ball Systems?
• Founded in 1966, today Ball Systems is a leader in customelectronics and electronic test solutions and software for Fortune 500companies worldwide
• Comprehensive and strategic offerings and capabilities• Strategic consultation on design of corporate test strategies and development
processes• Test system and test software design; COTS, custom design, etc.• Software design and architectures; NI Suite, Visual Studio, Firmware• Electrical circuit and system design; Analog, Digital, FPGA, Embedded Micro• Custom PCBs/PCAs• Mechanical fixture and
machine design• Controls and machine
vision design• Contract manufacturing
including PCAs, testsystems and racks, testfixtures, customelectronics, machines, etc.
National Instruments StrategicAlliance Partner & HIL Experts
• Programming expertise w/entire NI suite• Certified architects and developers
• Strategic NI HIL / VeriStand Partner• Trained programmers who have implemented
numerous HIL & VeriStand solutions• Experience with VeriStand since inception at NI
• HIL systems developed and delivered for automotive andheavy industrial companies including:
• Caterpillar:• Design and fabrication of HIL hardware test system• Design and development of HIL software including
FPGA programming and VeriStand
• Cummins:• Development of HIL software including seamless
integration with extensive existing test architecture
• 100’s of NI PXI, cRIO, etc. systems integrated worldwide
How Can Ball Systems Help?
• Consult to develop strategies to determine theeffectiveness of an HIL approach
• Development of HIL systems and software
• Staffed on-site validation, verification, andregression testing and test management
• Development of software models
• Design and development of control systems forproducts (e.g., NI cRIO based control systems toreplace existing PLC based systems)
Contact:
Terrance Bradford+1 (317) 509-6410www.ballsystems.com