dSpace User Conference

Body Subsystems Test Automation using the

dSPACE Hardware-in-the-Loop setup

Venkata RK Pinnelli

Suresh H

Mohammed Haneefa Kolari

14-Sep-2012

General Motors Testing Environments

Test Environments:

SubSystem Level Validation

System Level Validation

Vehicle Level Validation

Subsystem Level Software Verification

Component Level Validation

Requirements

(Vehicle)

Requirements

(System )

Requirements

( SubSystem )

Component

SW Verification

System

SW Verification

Vehicle

Validation

Subsystem

SW Verification

Requirements

(Component)

Vehicle level

Validation

System level

SW Verification

Component level

SW Verification

Requirements

(Vehicle)

Requirements

(System)

Requirements

( Subsystem )

Component

SW Verification

System

SW Verification

Vehicle

Validation

Subsystem

SW Verification

Requirements

(Component)

Vehicle level

Validation

System level

SW Verification

Component level

SW Verification

Subsystem

SW Verification

Subsystem level

SW Verification

dSPACE HIL Benches

Subsystems within Body Domain

Passive Entry and Passive Start

Power Windows

Power Sunroof Seat Memory & Heating/Cooling

Power Mirrors

Wash/Wipe

Exterior and Interior Lighting

Seat Supervised movements

Tools Used

• Simulation and Automation

– Plant Model – Tools: Matlab / Simulink ToolBoxes

– GM Internal Tool for Real-Time Simulation of GMLAN

– dSPACE Experiment – Tools: dSPACE ControlDesk

– Design of Simulator Boxes – Tools: Microsoft Visio

– Diagnostics – Intrepid / Vector tools

– Test Automation – GM Internal Tool

Requirements

Validation Testing Environment Development

HIL Test Environment Development Process for Subsystems Software Verification

Subsystem Requirements

Analysis

Bench Setup as per requirements

Plant Model Development

dSPACE ControlDesk Experiment

Development

Manual Software Verification

Verification Report

Requirement / Software / Hardware

modification

Hardware Requirements

Analysis

Automated Test Procedure

Develolpment

Automated Software

Verification

dSPACE SW (ControlDesk etc.,)

Internal GM SW Tool Suite

Test Environment Setup

Ho

st P

C

Plant Model Development

HIL Simulator

Compiled Model

Compiled Script

HIL I/O

Cards

Test Report

Test Bench

Hardware Test setup

The Test bench setup is a functional reproduction of a vehicle’s electrical system

HIL Test Setup Progression for Software Verification

Component Level Test Bench

Vehicle Level Test Bench

Subsystem Level (e.g. Body Electronics)

Component Under Test is present on the bench

All ECUs applicable to a Subsystem (e.g. Entry Controls) are present on the bench

All ECUs applicable to a Vehicle are present on the bench

Vehicle Parts on Body Subsystem Test Bench

• Vehicle parts on Body Subsystem test bench include:

• Electronic Control Units applicable to every subsystem

• Actuators, and Loads (e.g. Wiper motor, Head Lamps, Steering columns, Pedals, Window Regulators, Latches)

• Switches (e.g. Ignition, Wiper, Memory, Mirror, Seat, Windows )

Over 100 Vehicle parts

Simulation Environment for Body Subsystem Test Bench

• Relays to simulate/control switches for fault creation

• Signal conditioning circuits to have the required voltage and signal levels for

dSPACE I/O

• Simulation of sensors and actuators

• Fault Insertion circuits for short to Battery / GND and Open scenarios

• Instrumentation of the actual vehicle parts for controlling through dSPACE

• Hardware fixtures to obtain the feedback from the vehicle parts to dSPACE

• Communication panels for High speed CAN, Low speed CAN and LIN along with

standard Diagnostic tools

Body Subsystem Test Bench Control and Feedback Mechanisms

• Instrumented switches for operation and control by dSPACE

• String Potentiometers for position calculations

• Encoders for speed calculations

• High resolution camera for image capturing

• General purpose linear actuators for creating obstructions, moving vehicle parts, operating switches.

• Monitoring the actuator control lines from ECUs through dSPACE

• Monitoring sensor feedback signals to the ECUs through dSPACE

Enables complete test automation for a given subsystem

Bench Setup Overview

ECU

Loads

HIL

Relays / Fuses

Other Modules

Communication panels

Breakout Panel

Wash/Wipe Subsystem - Modules

• Wiper Modules Front and Rear Wiper motors are controlled by the Body Control Module (BCM). Front Wiper motor can operate at Low Speed, High Speed and Intermittent modes based on the switch inputs, where as rear motor has one speed.

• Stalk Switch Hardware Switch inputs are connected to the BCM. Switches are also simulated in plant model to support automation.

• Rain Sensor Module Rain Sensor Module senses the intensity of the rain. It sends this information to BCM. The module is simulated in the plant model.

• Front and Rear Wash Pump: BCM controls wash motors for both Front and Rear.

Wash/Wipe Subsystem – Bench Setup Host PC

BCM

Activation status, position, speed feedback

Front Wiper Control

HIL Simulator

Rear Wiper Fixture

Front Wiper Fixture

LIN Rain Sensor Module

Activation status, position, speed feedback

Rear Wiper Control Stalk Switch Input

Front Wiper Control signal monitor

Rear Wiper Control signal monitor

Other Simulated Inputs

Other Feedback signals

Rain Sensor Signals

Simulated Stalk switch

Wash/Wipe Subsystem – Automation Setup

• Software for Wash/Wipe Subsystem is verified for Front and Rear modules

• Switches are simulated in the plant model

• Rain Sensor module is simulated in the plant model

• Activation status, Speed and Position feedbacks are monitored – Wiper position

Wiper position feedback is monitored using the dSPACE setup. A position sensor is used for measuring the position

– Wiper speed

A speed sensor is used to measure the speed of the motor and the feedback is monitored using the dSPACE setup

Software Verification

Wash/Wipe Subsystem

Acknowledgements

Mina Khoee-Fard

Engineering Group Manager, General Motors

Tarek Lahdhiri Engineering Specialist,

General Motors

Shubha Channappa Sr. Engineering Manager,

General Motors

Thank You