Development of PC-Based HIL Simulator "CRAMAS 2001"
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Development of PC-based HIL Simulator "CRAMAS 2001" ●Takeshi Fukazawa ●Norio Yamada ●Takeshi Yasuda ●Naoya Kamiyama Abstract In recent years, the automobile industry has been actively promoting the development and evaluation of products in virtu- al space to reduce development time and high costs for repeated prototypes. The utilization of 3D-CAD and computer simu- lation is one facet of this development. In vehicle control system development, the demand has been increasing for Hardware-In-the-Loop Simulators (HIL Simulators), which simulate the behavior of a given system in real time. In 1996, as automobile electronic control units (ECUs) became progressively higher in performance and highly complicat- ed, a workstation-based HIL Simulator for an Antilock Brake System (ABS) ECU was developed at our company to reduce the number of design/evaluation man-hours and to improve product quality. Since then we have expanded the field of its application to engine control ECU and automatic transmission ECU, and have developed a personal-computer-based HIL Simulator to reduce size and cost. At the same time, HIL simulator usage has grown within the company, and some have been sold outside our company. To create a support tool that can be used not only in the automotive field but in a broad range of other fields, a high-speed, multipurpose, expandable system named CRAMAS 2001 (ComputeR Aided Multi-Analysis System 2001), which is based on a standard PC and PCI bus, has been developed using the knowledge gained during the development of HIL Simulators, and will now be introduced in this paper. FUJITSU TEN TECH. J. NO.17(2001) 14 Development of PC-based HIL Simulator "CRAMAS 2001" 1. Introduction based on the CompactPCI (Peripheral Component In recent years the automobile industry has been uti- Interconnect) standard. By using a personal computer as lizing tools such as 3D-CAD and simulation systems to the host machine and adopting a commercially available shorten development periods and reduce prototype costs. Intel CPU board for the instrument rack side, we were In the field of vehicle control development, the needs for able to create a HILS system that had superior cost per- a Hardware-in-the-Loop Simulation (HILS) are increas- formance. ing to evaluate the behaviors of a given system virtually To be able to adapt to expanding uses and changing and in real-time. To improve quality and reduce the num- needs, however, the CRAMAS required that a special I/O ber of design and evaluation man-hours that accompany board be designed; and consequently, the lead time until a the development of high-performance, large-scale elec- single new system was ready for start-up became longer. tronic control units (ECUs) for automobile electronic Furthermore, several obstacles were in the way. For control equipment, our company developed a simulator, instance, a PC DOS (IBM) operating system was used for an ECU design support tool. Since then, the HILS has real-time processing during simulation; consequently, the been used effectively in our ECU evaluation process. full performance of 32-bit architecture could not be uti- With the aim of creating a support tool that can be lized. To eliminate such problems and construct a more used not only in the automotive sector but in a broad timely HILS system, we have developed the PCI bus range of other fields, we utilized know-how that was based CRAMAS 2001. acquired during the development of the aforementioned simulators to develop the CRAMAS 2001 (ComputeR 3. System configuration Aided Multi-Analysis System 2001 ), a high-speed, mul- 3-1 Hardware overview tipurpose, expandable system that is based on a personal Figure 1 shows an example of the system configura- computer PCI bus. tion of a CRAMAS 2001 system that was made for a powertrain ECU. Broadly speaking, the system consists 2. Development history and aim of two parts: a personal computer for setting up simula- In fiscal year of 1996, our company developed a HILS tion conditions, taking measurement data, and monitoring system that utilized an engineering workstation (EWS) as data; and the CRAMAS main unit for performing simula- the host machine which was equipped with I/O boards tion operations and processing signal input and output in based on the Versa Module Europe (VME) bus standard. real-time. These two parts are connected with an Ethernet But since the system utilized an EWS as the host cable, which enables real-time data measurement and machine, it was expensive and never really came into monitoring. standard use. So in FY 1997, we developed the CRA- A PCI bus is used for the bus system so that the sys- MAS, a HILS system that utilized a personal computer as tem could be set up by selecting motherboards, CPU the host machine and that was equipped with I/O boards boards, and instrument racks that have a commercially available PCI bus (Figure 2). When this report was writ- CPU Board� ten, CPU boards having a clock speed of 1.5 GHz could （Pentium）� be obtained. In the future it will be possible to improve PC CORE Board� (ECU/RAM Value measurement) performance at a lower cost as the clock speed of CPUs CORE Board � Power Supply� Control Unit in commercially available personal computers continues PCI Bus (Pulse Input / Output) CAN Communications� Pulse Interface to improve. Board ECU The instrument board rack that was adopted has a ADIO Board ADIO Interface backplane based on the PCI Industrial Computer ADIO Board ADIO Interface Manufacturers Group (PICMG) standard, making it pos- sible to mount six PCI-bus-standard I/O boards (here- Fig.1 System configuration of CRAMAS 2001 inafter referred to as "PCI instrument boards"). FUJITSU TEN TECH. J. NO.17(2001) 15 Development of PC-based HIL Simulator "CRAMAS 2001" can be disconnected, producing a configuration that con- sists only of the digital signal processor. Moreover, an FPGA ranging from 50,000 to 200,000 gates can be 20 Slot Rack 14 Slot Rack Desktop PC Rack 8 Slot Rack selected, making it possible to create a configuration that meets the given need. 1CPU/17PCI 2CPU/7PCI×2 4CPU/2PCI×2 ATX Motherboard 1CPU/6PCI 1CPU/10PCI Table 1 shows the hardware specifications of the Base System CORE board. Ethernet Card Examples of special signal processing boards that uti- picmg SBC lize the CORE board are described as follows. ・Host section is brought to the rack� and made into a PC integrated system � Table 1 CORE board specifications ・Construction of distributed processing system PCI I/O Board� (by Fujitsu Ten) There are rack mount-type racks that are� Micro� Manufactured by Toshiba� ATX motherboard compatible. computer� TMPR3927F� Fig.2 Utilization of commercially available products � Built in PCI Bus Interface � One advantage of the PCI instrument board is that � Clock speed: 133MHz external bus 66MHz� commercially available items can be easily used if they FPGA Manufactured by Altera Japan� 2 × EPF10K130E 130,000 gate � meet PCI bus standards. And for interface circuits that are 1 × EPF10K50S 50,000 gate� electrically compatible with the ECU, we developed a ※For standard installation� compact interface rack that can be inserted into the 5-inch ※Expandable up to 200,000 gate FPGA bay installation space of the PCI instrument rack, thus ・Digital Input：Output: 56ch, 3.3V� reducing size and conserving space. ・Analog output: � 3-1-1 CORE board ＊Fast CH 2ch,±5V Resolution 12Bit 5MHz� To be able to meet a variety of user needs within a ＊Other 6ch,±5V Resolution 12Bit 10KHz� short period of time, we developed a CORE board that ・Analog input: 8ch,±5V Resolution 12Bit 10KHz� can change the circuit configuration using a field pro- ・External factor interrupt Input: 4ch, 3.3V� grammable gate array (FPGA). ・Serial Communications: 2ch As shown in Figure 3, a CORE board consists of a digital signal processor and analog signal processor. CPU ① Input-output signal for engine control firmware and FPGA logic programs are downloaded from Engine control systems handle a large number of sen- the host PC, making it possible to quickly develop and sor and actuator signals that are difficult to process provide various types of I/O hardware for users. with ordinary A/D, D/A, and digital I/O. Typical sig- The digital signal processor performs periodic signal nals include the following: engine revolution angle measurement, periodic signal generation, and other spe- signals, vehicle speed signals, ignition signals, knock cial types of signal processing, using an FPGA and exe- signals, and fuel injection signals. cuting the peripheral functions of a microcomputer. The digital signal processor executes signal "genera- The analog signal processor utilizes a D/A converter tion" processing for engine revolution angle signals and A/D converter, as well as an FPGA to achieve high- and vehicle speed signals, and "measurement" pro- speed microcomputer input-output. And by outputting cessing for ignition signals and fuel injection signals. desired waveform data to the D/A converter, it is possible Each processing is achieved through FPGA logic. As to achieve high-speed generation and output of various for the knock signals, "knock signal generation tim- waveforms that fit the given purpose. A CORE board has ing" is generated in the digital signal processor; then a two-story configuration consisting of a digital signal this signal is transmitted to the analog processor via processor and analog signal processor (Figure 4). If the the communications bus between the FPGAs, and analog signal processor is not needed, the second level sine wave data is output to the D/A converter. FUJITSU TEN TECH. J. NO.17(2001) 16 Development of PC-based HIL Simulator "CRAMAS 2001" ② Internal data measurements of ECU microcomputers 3-1-2 Interface The RAM values of microcomputers used for ECUs For the EWS-based CRAMAS and the initial CRA- are measured by using the communications function MAS interface circuit unit, a special rack (interface rack) of a Non-Break Debug module (NBD), a debugging on which multiple interface boards were mounted was unit with built-in microcomputer.