Rapidpro Hardware

RapidPro Hardware

 Signal conditioning

 Power stages

 Intelligent I/O subsystems

dSPACE RapidPro Hardware

2 2008 Contents

RapidPro Hardware 4

RapidPro Hardware Introduction ______4 Use Scenario A: Signal Conditioning and Power Stages for dSPACE Prototyping Systems ______6 Use Scenario B: Intelligent I/O Subsystems for dSPACE Prototyping Systems ______8 ConﬁgurationDesk ______10 Hardware Overview ______11 RapidPro SC Unit ______12 RapidPro Power Unit ______14 RapidPro Control Unit with MPC565 ______17 RapidPro SC/PS Modules ______20 RapidPro Break-Out Boxes ______24

3 2008 RapidPro Hardware

RapidPro Hardware

Flexible hardware for rapid prototyping

Key Features  Scalable, modular and conﬁgurable  For in-vehicle, laboratory and system architecture test bench use

 Compact and robust enclosure  Comprehensive software support

Overview: Signal Conditioning and Power Stages for Intelligent I/O Subsystems for Use Scenarios dSPACE Prototyping Systems dSPACE Prototyping Systems The wide variety of sensors and actuators used The functions being developed and integrated in the automotive field, especially during the into cars are growing in complexity and vol- rapid prototyping phase, means that each sensor ume. The acquisition and generation of I/O or actuator often requires its own signal condi- signals is also growing in complexity, for ex- tioning and power stage circuits. Ideally, only a ample, in engine management applications. minimum of hardware development, or none at Moreover, sophisticated algorithms usually all, should be necessary to connect sensors and need to be processed in a minimum of time. actuators to the prototyping system. In reality, All these demanding tasks need to be performed the design and implementation of such circuits within a standard prototyping environment and can be an expensive and time-consuming task. require intelligent tools for assistance. With Configuring the signal conditioning and power RapidPro and further dSPACE hardware and soft- stage hardware later on during the course of a ware, you can build an intelligent I/O subsystem project also usually involves a lot of work. The based on an MPC565 microcontroller. flexibility and intelligent assistance provided by For details, see Use Scenario B (p. 8) the RapidPro hardware and the corresponding software from dSPACE will help you achieve chal- lenging tasks for signal conditioning and power stages with high efficiency. For details, see Use Scenario A (p. 6)

4 2008 RapidPro Hardware Intro

Key Benefits Description The RapidPro hardware works as an extension Off-the-shelf hardware- and software-configu- to dSPACE prototyping systems (MicroAutoBox/ rable signal conditioning (SC) and power stage modular DS1005-based system) as described in (PS) modules can be installed in the RapidPro Use Scenarios A and B (p. 6 and p. 8). Different units to set up individual systems that opti- unit types are available: the RapidPro SC Unit mally fit the needs of a particular application. (signal conditioning unit), the RapidPro Power Customer-specific modules are available on Unit (power stage unit), and the RapidPro Control request. The modular concept, using modules Unit (with MPC565 as an intelligent I/O subsys- that are hardware- and software-configurable, tem). With their compact and robust mechanical means that all components can be reused, recon- design, the units are ideally suited for in-vehicle figured, or extended, for example in later projects use, and can also be used on test benches and or if requirements change, with a minimum of in laboratories. The enclosure is designed so effort. In either case, the RapidPro hardware fits that you can use the units separately or con- perfectly into your dSPACE tool chain. nect several of them to build a stack for use as one physical unit.

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Several RapidPro units can be connected for RapidPro modules (p. 20) can be easily use as one physical unit. installed in and removed from the units.

Engineering Services for RapidPro To assist you with your function prototyping activities, dSPACE offers speciﬁc engineering services for RapidPro hardware:

 System design and configuration  Mapping of actuators and sensors to signal conditioning (SC) and power stage (PS) modules  Specification and assembly of wiring harnesses  Development of customer-specific SC and PS modules  Template Simulink/Real-Time Interface (RTI) models  Commissioning and system introduction onsite

5 2008 RapidPro Hardware

Use Scenario A

Overview Signal Conditioning and Power Stages for dSPACE Prototyping Systems The RapidPro SC Unit and the RapidPro Power Automotive protection and extensive diag- Unit (equipped with the relevant SC and PS nostic capabilities are especially important modules, p. 20) can be used as separate for power stages, for example, in safety-critical units in conjunction with prototyping systems applications. You can perform interactive diag- (MicroAutoBox, Modular Hardware includ- nostics with feedback to the model using the ing DS1005 plus I/O boards, Single-Board Real-Time Interface (RTI) RapidPro Diagnostics Hardware). The RapidPro SC Unit supports Blockset (p. 7) for Simulink (for MicroAutoBox your prototyping system wherever demand- plus RapidPro Power Unit). Using dSPACE‘s ing signal conditioning tasks such as signal ConfigurationDesk software you can easily con- protection, amplification, attenuation, filtering, figure the unit and carry out diagnostics (see and electrical isolation have to be performed. p. 10). In this use scenario, the RapidPro hard- In turn, actuators like drives, valves, injectors, ware can be used for developing control appli- lamps, and relays require high current and/or cations in fields such as engine, transmission, high voltage output drivers. The RapidPro Power chassis, body, and drives control. Unit provides your prototyping system with the necessary power stages.

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In this scenario, automotive sensors and actuators are adapted to a dSPACE prototyping system with the help of the RapidPro SC Unit and the RapidPro Power Unit.

6 2008 RapidPro Hardware Intro

RTI RapidPro Diagnostics Blockset Software for A separate diagnostics blockset is available for overload, undervoltage, overtemperature, and Use Scenario A the RapidPro Power Unit if used in combination short circuit to battery and ground. The diagnos- with MicroAutoBox. The blockset supports the tic information can be used in the model. The installed power stage (PS) modules and provides blockset also provides status information on the diagnostic functionalities such as open load, Power Unit itself.

The RapidPro Diagnostics Blockset for MicroAutoBox.

ConﬁgurationDesk  ConﬁgurationDesk (p. 10)

Hardware Hardware for  RapidPro Hardware (p. 11) Use Scenario A

7 2008 RapidPro Hardware

Use Scenario B

Overview Intelligent I/O Subsystems for dSPACE Prototyping Systems Applications such as engine management need An integrated Unit Connection Bus (UCB) allows to acquire complex I/O signals, for example, you to connect several RapidPro SC or Power for crankshaft and camshaft positions, and to Units directly to the Control Unit without external generate complex signals for ignition and injec- wiring. Communication between the RapidPro tion independently of the RCP system’s main Control Unit and the prototyping system is per- processor and the model’s simulation step size. formed via a high-speed link. A RapidPro Control Offloading specific, time-critical tasks like these Unit Blockset (p. 9) for MicroAutoBox and modu- to a dedicated microcontroller decisively reduces lar DS1005-based systems is available as an I/O the main processor’s load. The RapidPro Control Real-Time Interface (RTI) for Simulink. dSPACE‘s Unit variant with MPC565 is used in this scenario ConfigurationDesk provides intuitive configura- as a slave microcontroller to extend existing proto- tion of the unit and diagnostics handling (p. 10). typing systems with additional I/O functionality. In this use scenario, the RapidPro hardware can The RapidPro Control Unit variant can be used be used for developing control applications in together with the MicroAutoBox or a modular fields such as engine, transmissions, chassis, DS1005-based system (with DS4121 ECU Inter- body, and drives control. face Board) or can additionally be combined with other RapidPro units.

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In this scenario, two RapidPro units form a stack including signal conditioning and power stages, so that complex I/O signals can be acquired and generated independently of the main CPU of the prototyping system.

8 2008 RapidPro Hardware Intro

RTI RapidPro Control Unit Blockset Software for In conjunction with the MPC565-based Rapid- Use Scenario B Pro Control Unit, a generic Real-Time Inter- face (RTI) Blockset for Simulink is available for MicroAutoBox and modular DS1005-based systems. The blockset provides extensive standard I/O functionalities (PWM, bit I/O, A/D) including incremental encoder interface and stepper motor control, as well as diagnostic functionalities and special functionalities for engine, chassis and drives control. Examples:

 Crankshaft signal measurement  Engine speed and status  Camshaft signal measurement  Injection and ignition pulse generation  Angle-sychronized task triggers  Reading diagnostic data of modules  Checking the status of a carrier board

Functionalities can be combined with each other in realtime applications, e.g., drives and engine The RTI RapidPro Control Unit Blockset for functionalities. MicroAutoBox and DS1005.

When combining the MPC565-based RapidPro Control Unit and MicroAutoBox or the modular DS1005-based system, you gain additional functionalities for engine control compared to using the MicroAutoBox on its own:

MicroAutoBox plus RapidPro Control Unit

Topic Examples of extended functionality Crankshaft control  Crankshaft signals with up to 3600 pulses per wheel with or without gaps Camshaft control  Support of virtually every type of camshaft wheel  Phase measurement of camshaft position  Up to 4 camshaft wheels at a time Injection control  Generation of peak-and-hold pulse patterns (up to three phases)  Up to 10 injection pulses for one injection cycle Common  Up to 12 channels for injection plus 12 channels for ignition simultaneously  High engine angle resolution of 0.1°  4 periodical and 16 absolute angle-based interrupts per engine cycle

ConﬁgurationDesk  ConﬁgurationDesk (p. 10)

Hardware Hardware for  RapidPro Hardware (p. 11) Use Scenario B

9 2008 RapidPro Hardware

ConﬁgurationDesk

The ConﬁgurationDesk software allows you to conﬁgure the RapidPro hardware to meet individual requirements.

Description ConfigurationDesk ConfigurationDesk is a stand-alone Windows the RapidPro hardware to sensors and actuators, application that allows intuitive and efficient and enables you to monitor the hardware states configuration of the RapidPro hardware. Further- during operation. more, the software supports you when wiring

Feature Description RapidPro hardware configuration ConfigurationDesk displays the RapidPro hardware in a structured tree and a list view, and provides intuitive access to all the relevant configuration settings. Monitoring of analog and digital signal values is available to support you in connecting sensors and actuators to the RapidPro hardware when the system is put into operation. Diagnostics handling During operation, diagnostic information such as overcurrent, short circuit, open load, overheat, and over- and undervoltage detection is monitored and displayed. This makes it easy to detect and locate faults. Project management ConfigurationDesk’s Project Manager allows you to structure all the relevant project information such as hardware configurations and application-specific data. Wiring information To support you when wiring your RapidPro hardware, a pinout list with all the relevant information can be exported as a comma-separated value (CSV) file or a Microsoft Excel file.

10 2008 RapidPro Hardwarexyz Board Intro

Hardware Overview Component Description Further Use Use Information Scenario Scenario A B

RapidPro SC Unit  Signal conditioning unit See p. 12 x x  Slots for up to 8 signal conditioning modules  USB interface for hardware conﬁguration via ConﬁgurationDesk

RapidPro Power Unit  Power stage unit See p. 14 x x  Slots for up to 6 power stage modules  USB interface for hardware conﬁguration via ConﬁgurationDesk

RapidPro Control Unit  Intelligent I/O subunit for adding additional I/O See p. 17 – x with MPC565 functionality to the dSPACE prototyping system  MPC565 microcontroller module  Up to 6 signal conditioning modules  Up to 2 communication modules  USB interface for hardware conﬁguration via ConﬁgurationDesk  LVDS interface for high-speed slave communication with MicroAutoBox or DS1005 (via DS4121) SC Modules  4-channel sensor supply module See p. 21 x x  4-channel differential analog input module See p. 21 x x  10-channel analog input module See p. 21 x x  8-channel digital input module See p. 21 x x  8-channel digital output module See p. 21 x x  Crankshaft/ camshaft sensor input module See p. 21 x x  2-channel exhaust gas oxygen See p. 21 x x sensor module  4-channel knock detection sensor module See p. 22 – x  8-channel thermocouple sensor input module See p. 22 – x  Further modules are under development PS modules  2-channel full-bridge driver module See p. 22 x x  6-channel low side driver module See p. 22 x x  6-channel high side driver module See p. 23 x x  1-channel, high-current, full bridge driver module See p. 23 x x

 2-channel, high-current, half-bridge driver module See p. 23 x x

 2-channel direct-injection driver module1) See p. 23 x x  Further modules are under development

1) If the DS1664 2-channel direct injection driver module is used with RapidPro, electrically safe host PC interface cables (up to 300 V DC/ACRMS and 600 V peak) are mandatory for all connected systems such as RapidPro, MicroAutoBox, and DS1005. You must perform all the safety precautions described in the documentation.

11 2008 RapidPro Hardware

RapidPro SC Unit

Flexible signal conditioning unit

Key Features  Signal conditioning for  Slots for up to dSPACE prototyping systems 8 signal conditioning modules

 Easily adaptable to different sensor  Wide supply range (6 V to 60 V), types via conﬁgurable modules reverse and overvoltage-protected

Description Application Areas Key Benefits The RapidPro SC Unit in conjunction with the Like all the Rapid Pro units, the RapidPro SC Unit standard SC modules (p. 20) or customer- is highly modular, flexible, intelligent, and espe- specific modules lets you adapt almost any type cially designed for rapid prototyping in automo- of sensor (for example, temperature, pressure, tive applications. It comes with a robust, compact and crankshaft and camshaft sensors) to specific enclosure and an advanced mechanical concept. prototyping systems. It is not only suited to in-vehicle use, but also to the laboratory and the test bench. All inputs and outputs are automotive-protected. A RapidPro SC Unit can be equipped with single- and/or multi-channel SC modules mounted on the carrier board. The whole RapidPro SC Unit can be switched on or off from a dSPACE prototyping system via a remote control input, or all outputs deactivated via an enable/disable input. A USB interface is available for communicating with the host PC. dSPACE‘s ConfigurationDesk provides easy configuration of the unit and diagnostics handling (p. 10).

12 2008 RapidProxyz SC Board Unit

Technical Details

Parameter Specification General  8 slots for configurable, analog or digital signal conditioning modules (SC modules) (p. 20)  Support of modules with different form factors  Up to 64 channels per unit (for example, 40 analog plus 24 digital I/O or 40 digital plus 24 analog I/O)  Unit Connection Bus for use with RapidPro Control Unit (p. 17)  Onboard A/D converter to display I/O signals of the installed SC modules  Internal temperature and voltage monitoring  Remote control input to switch the unit on or off  Enable/disable input to switch all outputs of a unit on or off Software support Configuration  Configuration of the SC modules from a host PC via ConfigurationDesk (p. 10) Diagnostics  Diagnostics handling via ConfigurationDesk (p. 10) Electrical Power supply  +6 … +60 V DC characteristics  Load dump protection up to +100 V  Reverse voltage protection up to -100 V Mechanical Enclosure  Aluminum enclosure with cooling fins (no fan) characteristics  Advanced mechanical concept with special coulter clips for easy installation and module locking  Enclosure designed for flexible assembly (stack or single unit) Physical size  L: 200 mm (7.87 in.) (with cover and base plate)  W: 225 mm (8.86 in.)  H: 35 mm (1.38 in.) Physical size  L: 172 mm (6.77 in.) (without cover and base plate)  W: 225 mm (8.86 in.)  H: 25 mm (0.98 in.) Environmental Ambient temperature  -40 … +85 ºC characteristics (-40 … +185 ºF)

Order Information

Product Order Number RapidPro SC Unit  RAPIDPRO_1621 (please inquire)

Relevant Software and Hardware

Software Order Number Required ConﬁgurationDesk (p. 10)  CFD-C

Hardware Order Number Required SC Modules See p. 20 If the DS1664 2-channel direct injection driver module is used with  USB_CAB12 RapidPro (Power Unit), electrically safe host PC interface cables (up to 300 V (USB PC to LEMO cable DC/ACRMS and 600 V peak) are mandatory for all connected systems such with galvanic isolation, 5 m) as RapidPro, MicroAutoBox, and DS1005. You must perform all the safety  Further cables: please inquire. precautions described in the documentation. Optional RapidPro Power Unit (p. 14)  RAPIDPRO_1651 (please inquire) RapidPro Control Unit with MPC565 (p. 17)  RAPIDPRO_1601 (please inquire) Front connectors for RapidPro SC Unit  RPS_F1F2 Rear connectors for RapidPro SC Unit  RPS_R1R2 Crimping tool for RapidPro systems  RAPIDPRO_CRIMP RapidPro Break-Out Box for SC Unit (p. 24);  DS1687 2 x connection cable RapidPro SC Unit (F1/F2) and BoB (F1/F2), 0.5 m USB PC to LEMO cable, 3 m  USB_CAB6

13 2008 RapidPro Hardware

RapidPro Power Unit

Flexible power stage unit

Key Features  Power stages for  Slots for up to dSPACE prototyping systems 6 power stage modules

 Easily adaptable to different  Wide supply range (6 V to 60 V), actuators via conﬁgurable modules reverse and overvoltage-protected

Description Application Areas Key Benefits The RapidPro Power Unit, in conjunction with The RapidPro Power Unit is based on the same the standard PS modules (p. 20) or customer- advanced architecture as the RapidPro SC Unit specific modules, lets you adapt many different (p. 12). The main difference is that the power types of actuators (for example, drives, injectors, unit is designed to support high current signals valves, relays, ohmic loads) to specific prototyp- for driving actuators. The carrier board offers ing systems. space for up to six power stage modules (p. 20), with or without current feedback. Each Rapid- Pro Power Unit can have up to 48 power driver channels. The whole RapidPro Power Unit can be switched on or off from dSPACE prototyping systems via a remote control input, or all outputs can be deactivated via an enable/disable input. dSPACE‘s ConfigurationDesk provides easy configuration of the unit and extensive diagnostics handling (p. 10). Interactive diagnostics with feedback to the model can be performed with the appropriate Real-Time Interface (RTI) blocksets (p. 7 and p. 9)

14 2008 RapidPro Powerxyz Board Unit

Technical Details

Parameter Specification General  6 slots for configurable power stage modules (PS modules) (p. 20)  Support of modules with different form factors  Up to 48 power stage channels per power unit  Unit Connection Bus for use with RapidPro Control Unit (p. 17)  USB interface for communication with host PC  SPI interface for diagnostics with MicroAutoBox  Internal temperature and voltage monitoring  Remote control input to switch the unit on or off  Enable/disable input to switch all outputs of a unit on or off  Defined “powered-off” state during initialization and booting Software support Configuration  Configuration of the PS modules from a host PC via ConfigurationDesk (p. 10) Diagnostics  Diagnostics handling via ConfigurationDesk (p. 10)  Interactive diagnostics feedback to the model via the appropriate RTI blocksets (p. 7 and p. 9) Electrical Power supply  +6 … +60 V DC characteristics  Load dump protection up to +100 V  Reverse voltage protection up to -100 V Mechanical Enclosure  Aluminum enclosure with cooling fins (no fan) characteristics  Advanced mechanical concept with special coulter clips for easy installation and module locking  Enclosure designed for flexible assembly (stack or single unit) Physical size  L: 200 mm (7.87 in) (with cover and base plate)  W: 225 mm (8.86 in)  H: 35 mm (1.38 in) Physical size  L: 172 mm (6.77 in) (without cover and base plate)  W: 225 mm (8.86 in)  H: 25 mm (0.98 in) Environmental Ambient temperature  -40 … +85 ºC characteristics (-40 … +185 ºF)

Order Information

Product Order Number RapidPro Power Unit  RAPIDPRO_1651 (please inquire)

15 2008 RapidPro Hardware

Relevant Software and Hardware

Software Order Number Required ConﬁgurationDesk (p. 10)  CFD-C Optional Real-Time Interface  RTI RTI RapidPro Diagnostics Blockset (p. 7) Please inquire

Hardware Order Number Required PS Modules See p. 20 If the DS1664 2-channel direct injection driver module  USB_CAB12 (USB PC to LEMO cable with galvanic is used with RapidPro, electrically safe host PC inter- isolation, 5 m) face cables (up to 300 V DC/ACRMS and 600 V peak)  Further cables: please inquire. are mandatory for all connected systems such as RapidPro, MicroAutoBox, and DS1005. You must perform all the safety precautions described in the documentation. Optional RapidPro SC Unit (p. 12)  RAPIDPRO_1621 (please inquire) RapidPro Control Unit, MPC565-based (p. 17)  RAPIDPRO_1601 (please inquire) Front connectors for RapidPro Power Unit  RPP_F1F2 Rear connectors for RapidPro Power Unit  RPP_R1R2 Crimping tool for RapidPro systems  RAPIDPRO_CRIMP RapidPro Break-Out Box for Power Unit (p. 24);  DS1688 2 x connection cable RapidPro Power Unit (F1/F2) and BoB (F1/F2), 0.5 m USB PC to LEMO cable, 3 m  USB_CAB6

16 2008 RapidPro Control Unit withxyz MPC565 Board

RapidPro Control Unit with MPC565

Intelligent I/O subsystem for dSPACE prototyping systems

 MPC565 microcontroller module  Up to 6 signal conditioning modules Key Features  USB conﬁguration interface  Complex I/O signal generation and acquisition  LVDS slave communication interface

Application Areas Key Benefits Description The MPC565-based RapidPro Control Unit can be The MPC565-based RapidPro Control Unit is used as an intelligent I/O subunit to provide exist- based on the same architecture as the RapidPro ing prototyping systems – such as MicroAutoBox SC Unit (p. 12). Additionally, the RapidPro or AutoBox (including the DS1005 PPC Board Control Unit is equipped with a powerful and the DS4121 ECU Interface Board) – with microcontroller module, including an MPC565 additional I/O functionality. For example, in microcontroller, which is dedicated to handling applications such as engine or vehicle dynamics complex I/O tasks. The carrier board provides control, complex I/O tasks can be shifted from space for up to six signal conditioning modules the prototyping system to the RapidPro Control (SC modules) and two communication (COM) Unit. The RapidPro Control Unit also provides modules. The signal conditioning modules are space for signal conditioning modules, so that the same modules as for the SC Unit. The USB different sensors can be adapted to a specific configuration interface module is used for com- prototyping system. munication with the host PC. The LVDS slave interface module enables high-speed communication with dSPACE prototyping systems (MicroAutoBox or DS1005 via DS4121). The RapidPro Control Unit can be used separately or in combination with the other units to build an intelligent I/O subsystem tailored to a particular application. An integrated Unit Connection Bus allows you to connect several RapidPro SC or Power Units directly to the Control Unit without external wiring. Efficient configuration of a single control unit or a stack and diagnostics handling are provided by ConfigurationDesk (p. 10) via the USB configuration interface connected to the host PC. Interactive diagnostics with feedback to the model can be performed with the RTI RapidPro Control Unit Blockset (p. 9). This blockset also provides extensive standard I/O functionalities such as PWM, bit I/O, A/D and special functionalities for engine, chassis and drives control.

17 2008 RapidPro Hardware

Technical Details

Parameter Specification General  6 slots for configurable, analog or digital signal conditioning modules (SC modules) (p. 20)  Support of modules with different form factors  2 slots for communication interface modules (USB configuration interface module, LVDS slave interface module)  Unit Connection Bus to expand RapidPro Control Unit with several RapidPro Power and/or SC Units  Internal temperature and voltage monitoring  Remote control input to switch the unit on or off  Power management, sleep and wake-up via prototyping system Microcontroller module  MPC565, 56 MHz  4-MB external SRAM, 16-MB external flash  Onboard FPGA for additional functionality  48-channel time processing unit (TPU)  40-channel bit I/O  22-channel multi I/O timer (MIOS)  2 queued A/D converters with internal sample/hold  40 A/D converter channels (10-bit resolution, 4 µs conversion time per channel) Software support Configuration  Configuration of all connected units and modules from a host PC via ConfigurationDesk (p. 10) Diagnostics  Diagnostics handling via ConfigurationDesk (p. 10)  Interactive diagnostics feedback to the model via RTI RapidPro Control Unit Blockset (p. 9) I/O Real-Time Interface  RTI RapidPro Control Unit Blockset (p. 9) Electrical Power supply  +6 … +60 V DC characteristics  Load dump protection up to +100 V  Voltage reverse protection up to -100 V Mechanical Enclosure  Aluminum enclosure with cooling fins (no fan) characteristics  Advanced mechanical concept with special coulter clips for easy installation and module locking  Enclosure designed for flexible assembly (stack or single unit) Physical size  L: 200 mm (7.87 in) (with cover and base plate)  W: 225 mm (8.86 in)  H: 35 mm (1.38 in) Physical size  L: 172 mm (6.77 in) (without cover and base plate)  W: 225 mm (8.86 in)  H: 25 mm (0.98 in) Environmental Ambient temperature  -40 … +85 ºC characteristics (-40 … +185 ºF)

Order Information

Product Order Number RapidPro Control Unit  RAPIDPRO_1601 (please inquire) with MPC565 Stack:  RAPIDPRO_1601/1651 RapidPro Control Unit with MPC565 plus RapidPro Power Unit Stack:  RAPIDPRO_1601/1621/1651 RapidPro Control Unit with MPC565 plus RapidPro SC Unit plus RapidPro Power Unit

18 2008 RapidPro Control Unit with MPC565

Relevant Software and Hardware

Software Order Number Required ConﬁgurationDesk (p. 10)  CFD-C Real-Time Interface  RTI RTI RapidPro Control Unit Blockset (p. 9)  RTIRAPIDPRO_BS

Hardware Order Number Required SC Modules See p. 20 If the DS1664 2-channel direct injection driver module  USB_CAB12 (USB PC to LEMO cable with galvanic is used with RapidPro, electrically safe host PC inter- isolation, 5 m) face cables (up to 300 V DC/ACRMS and 600 V peak)  Further cables: please inquire. are mandatory for all connected systems such as RapidPro, MicroAutoBox, and DS1005. You must perform all the safety precautions described in the documentation. Optional RapidPro SC Unit (p. 12)  RAPIDPRO_1621 (please inquire) RapidPro Power Unit (p. 14)  RAPIDPRO_1651 (please inquire) Front connector1 for RapidPro Control Unit  RPC_F1 Front connector2 for RapidPro Control Unit  RPC_F2 Crimping tool for RapidPro systems  RAPIDPRO_CRIMP RapidPro Break-Out Box for Control Unit (p. 24);  DS1689 1 x connection cable between RapidPro Control Unit (F1) and BoB (F1), 0.5 m; 1 x connection cable between RapidPro Control Unit (F2) and BoB (F2); 0.5 m USB PC to LEMO cable, 3 m  USB_CAB6 LVDS-Link cable LEMO-1S to ZIF crimp contacts, 5 m,  LVDS_CAB1 85 °C LVDS-Link cable LEMO-1S to LEMO-1S, 5 m, 85 °C  LVDS_CAB2 LVDS-Link cable LEMO-1S to LEMO-1S, 5 m, 150 °C  LVDS_CAB3 LVDS-Link cable LEMO-1S to ZIF crimp contacts, 1 m,  LVDS_CAB9 85 °C

19 2008 RapidPro Hardware

RapidPro SC/PS Modules

Mountable signal conditioning and power stage modules for RapidPro units

Key Features  Hardware- and software-  Safe locking of modules on conﬁgurable standard modules RapidPro units

 Easy to mount on RapidPro units  Signal conditioning and power stage functionality

Description Application Areas Standard Modules and Custom Modules The RapidPro signal conditioning (SC) and power Besides the standard modules described in the stage (PS) modules bring vital signal conditioning following tables (p. 21 - p. 23), dSPACE also and power stage functionality to the RapidPro offers you engineering services to develop units. The SC modules can be installed in the individual signal conditioning and power stage RapidPro SC Unit and the RapidPro Control Unit. modules for your speciﬁc application scenario. The PS modules are installed in the RapidPro Power Unit.

Key Benefits A wide choice of hardware- and software- with the RapidPro units are automotive-protected configurable modules is available that provide and can be locked safely on the carrier boards standard solutions in many different applications. with coulter clips. This makes them suitable for Installing and removing the modules is easy, so in-vehicle applications. Modules are not limited the RapidPro units can be reused efficiently in in size. If complex electronic circuits require more different projects. Customer-specific modules will space or pins than a single slot module offers, also be available on request. All the modules used modules with other form factors can be used.

20 2008 RapidPro SC/PS Modules

Signal Conditioning (SC) Modules Signal Conditioning Module Description Order Number (SC Module) SC-SENS 4/1  4-channel sensor supply module  DS1626  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Software-adjustable voltage range: 2.5 V ... 20 V, adjustable in steps of 5.5 mV  Output power: 1.2 W per channel  Fully isolated outputs  Thermal overcurrent protection  Accuracy 1%

SC-AI 4/1  4-channel differential analog input module  DS1631  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Software-adjustable input range: ± 100 mV ... ± 50 V  Output range: 0 ... 5 V, ± 5 V, 0 ...10 V, ± 10 V, software-adjustable globally for all four channels  Four software-selectable 1st order low-pass filters (per channel). Cutoff frequencies: 10 Hz, 50 Hz, 100 Hz, 1 kHz  Input circuit: up to 4 hardware-configurable devices per channel, for example, pull-up, pull-down SC-AI 10/1  10-channel analog input module  DS1633  Requires 2 slots in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8))  Double size module (requires two slots)  Onboard sensor supply: 5 V, 1 W  External supply input  Input circuit: up to 9 hardware configurable devices per channel, for example, pull-up, pull-down, 1st order low pass filter

SC-DI 8/1  8-channel digital input module  DS1642  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Software-adjustable comparator threshold and hysteresis voltage, software- adjustable in a range of ± 39.5 V  Input voltage range: up to ± 55V continuous  Input circuit: up to 3 hardware-conﬁgurable devices per channel, for example, pull-up, pull-down SC-DO 8/1  8-channel digital output module  DS1646  Requires 1 slot in a RapidPro unit  Open collector output  Suitable for Use Scenario A and B (p. 6, p. 8)  Output current: each channel 1 A, total permissible current for all channels: 1 A  Output voltage: 40 V  Fully isolated outputs of one module (one common ground)  Overcurrent protection

SC-CCDI 6/1  Crankshaft/camshaft sensor input module  DS1637  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Connection of rotational speed sensors with open load voltage up to ± 200 V (± 60 V DC)  4 inputs for cam sensors with common ground SC-EGOS 2/1  2-channel, exhaust gas oxygen sensor module for connecting LSU4.2 and/or  DS1634 LSU4.9 Bosch lambda probes  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Based on Bosch ASIC CJ125  Lambda measurement range: 0.65 ... inf and 0.75 ... inf (software-conﬁgurable)  Pump reference current: 0 ... 150 µA (software-conﬁgurable in 10 µA steps)

21 2008 RapidPro Hardware

Signal Conditioning Module Description Order Number (SC Module)

SC-KNOCK 4/1  4-channel knock sensor module  DS1635  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario B (p. 8)  Based on Bosch ASIC CC196 (with on-board DSP)

SC-TC 8/1  8-channel thermocouple sensor input module  DS1638  Requires 3 slots in a RapidPro unit  Suitable for Use Scenario B (p. 8)  Suitable for type K thermocouples (support for further types such as type J planned)  One 24-bit A/D converter per channel, sampling rate for each converter (software-conﬁgurable) 0.1 Hz ... 50 Hz  Splitter cable plus memory identifying the connected thermocable and thermocouples  High-precision cold junction compensation

For more detailed information, please contact dSPACE. Further signal conditioning modules are under development. Contact dSPACE for further information and let us know about your requirements for future modules.

Power Stage (PS) Modules Power Stage Module Description Order Number (PS Module) PS-FBD 2/1  2-channel full-bridge driver module  DS1661  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Each driver 5 A continuous, 7 A peak (depends on the Power Unit the module is mounted in)  Maximum supply voltage: 40 V continuous, 45 V peak (0.5 sec)  Usable as: full-bridge, half-bridge, low or high side driver  Software adjustable current limitation and switch-off time  High-side rise time: 1.8 µs typ., 3.5 µs max., high-side fall time: 0.2 µs typ., 0.8 µs max., low-side rise time: 6.5 µs typ., 11 µs max., low-side fall-time: 4.3 µs typ., 6.5 µs max.  Detailed load failure diagnosis  Current measurement with software adjustable filters (2nd order) on both channels  Overload protection, overtemperature protection, short-circuit protection to ground, UBAT and across the load  Integrated on carrier board: load dump protection up to +100 V, reverse voltage protection up to -100 V PS-LSD 6/1  6-channel low-side driver module  DS1662  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  4 output channels with up to 5.28 A (hardware-configurable)  2 output channels with up to 1 A  Max. supply voltage: 37 V continuous  Clamping voltage: 45 V or 70 V (depending on hardware configuration)  Switching time: <10 µs  Detailed load failure diagnosis  Current measurement with hardware-adjustable low-pass filter (1st order) on channel 1 and 2  Overload protection, overtemperature protection, short-circuit protection to ground, active output clamping  Integrated on carrier board: load dump protection up to +100 V (only valid for internal voltage supply of the module), reverse voltage protection up to -100 V

22 2008 RapidPro SC/PS Modules

Power Stage Module Description Order Number (PS Module) PS-HSD 6/1  6-channel high-side driver module  DS1663  Requires 1 slot in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  4 output channels with up to 5 A, clamping voltage 48V  2 output channels with up to 1 A, clamping voltage 63V  Max. supply voltage: 36 V continuous, 40 V peak  Switching time: <30 µs  Load failure diagnosis  Current measurement with hardware-adjustable low-pass ﬁlter (1st order) on channel 1 and 2  Overload protection, overtemperature protection, short-circuit protection to ground, UBAT and across the load, active output clamping  Integrated on carrier board: load dump protection up to +100 V (only valid for internal voltage supply of the module), reverse voltage protection up to -100 V

PS-HCFBD 1/1  1-channel high-current full bridge driver module  DS1667  Requires 3 slots in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)

 Up to 60 A peak current, 30 A continuous (Tambient= 25 °C, filter frequency 1 kHz, corresponding duty cycle)  Up to 60 A peak current (1s), 17 A continuous (depends on ambient temperature)  Max. supply voltage: <20 V continuous  Current measurement with hardware-adjustable low-pass filter (1st order)  Internal free-wheeling diodes  Protection against: short circuit, overtemperature, and overvoltage  Load failure diagnostics PS-HCHBD 2/1  2-channel, high-current, half-bridge driver module  DS1668  Requires 3 slots in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Each channel up to 30 A peak current (1s), 25 A continuous (depends on ambient temperature)  Usable as half-bridge or low-side or high-side driver output  Max. supply voltage: <20 V continuous  Current measurement with hardware-adjustable low-pass filter (1st order) for each channel  Internal free-wheeling diodes  Protection against short circuit, overtemperature, and overvoltage  Load failure diagnostics

PS-DINJ 2/11)  2-channel direct-injection driver module  DS1664  Requires 2 slots in a RapidPro unit  Suitable for Use Scenario A and B (p. 6, p. 8)  Single or double injector operation mode (two injectors of the same bank cannot be driven at the same time)  Booster voltage U max: 100 V (If the DS1664 2-channel direct injection driver module is used with RapidPro, electrically safe host PC interface cables (up to 300 V DC/ACRMS and 600 V peak) are mandatory for all connected systems such as RapidPro, MicroAutoBox, and DS1005. You must perform all the safety precautions described in the documentation.)  I max: 30 A peak, 15 A continuous  Control of start injection  Software-adjustable booster voltage  Software-adjustable injection duration (peak and hold times)  Software-adjustable peak current (upper and lower values), subpulse A and B available for Use Scenario B  Software-adjustable hold current (upper and lower values)  Detailed load failure diagnosis

23 2008 RapidPro Hardware

RapidPro Break-Out Boxes1)

Desktop connection panels for RapidPro systems

Key Features  Fast and ﬂexible sensor and  Checking and reconnecting signals actuator connection without changing an existing cable harness

Description Key Beneﬁts With the RapidPro Break-Out Boxes, you can accessory in setting up signal conditioning, connect sensors and actuators to RapidPro power stages and intelligent I/O subsystems with units ﬂexibly (p. 12 - 17) and see at a glance RapidPro units in combination with dSPACE pro- which signals are connected, including their sta- totyping systems. Each RapidPro Break-Out Box tusses. You can also reconnect signals without provides a number of multicolor LEDs, one LED changing an existing cable harness. This makes per signal. The LEDs indicate different voltage the RapidPro Break-Out Boxes an important ranges of the power supply by different colors.

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1) Devices connected to RapidPro Break-Out Boxes can feed in high currents and high voltages which can be dangerous for the user. Under all circumstances, you must observe all the safety precautions described in the documentation of the RapidPro Break-Out Boxes and of the devices connected!

24 2008 RapidPro Break-Out Boxes

Technical Details

Parameter Speciﬁcation General  Three variants for different RapidPro units: DS1687 for SC Unit, DS1688 for Power Unit, DS1689 for Control Unit  I/O connectors a) for connection to RapidPro units and b) for connection to an existing cable harness  Each Break-Out Box provides the same number of terminals as the connected unit: up to 6 terminal points for each signal. There are knife disconnectors to interrupt the signal path.  LEDs to indicate signal status (one multicolor LED for each signal path). Indication adjustable to different voltages. Slide switch to turn all LEDs on/off. Electrical Power supply  +6 … +60 V DC characteristics  MINI® Fuse (blade type automotive fuse): 1x 10 A (Break-Out Box for SC Unit), 2x 30 A (Break-Out Box for Power Unit), 1x 5 A or 1x 10 A (Break-Out Box for Control Unit)  Load dump protection up to +100 V  Reverse voltage protection up to -100 V Mechanical Physical size  L: 356 mm (14 in) characteristics  W: 224 mm (8.8 in)  H: 50 mm (1.95 in) Environmental Ambient temperature  0 … +70 ºC (+32 … +158 ºF) characteristics

Order Information

Product Order Number RapidPro Break-Out Box for SC Unit; 2 x connection cable RapidPro SC Unit (F1/F2)  DS1687 and BoB (F1/F2), 0.5m; RapidPro Break-Out Box for Power Unit, 2 x connection cable RapidPro Power  DS1688 Unit (F1/F2) and BoB (F1/F2), 0.5m RapidPro Break-Out Box for Control Unit, 1 x connection cable between RapidPro  DS1689 Control Unit (F1) and BoB (F1), 0.5m; 1 x connection cable between RapidPro Control Unit (F2) and BoB (F2), 0.5m

Relevant Software and Hardware Software Order Number Required ConﬁgurationDesk (p. 10)  CFD-C

Hardware Order Number Required RapidPro unit with corresponding SC/PS modules See p. 11

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01/2008 © Copyright 2008 by dSPACE GmbH. All rights reserved. Written permission is required for reproduction of all or parts of this publication. The source must be stated in any such reproduction. dSPACE is continually improving its products and reserves the right to alter the speciﬁcations of the products contained within this publication at any time without notice. Brand names or product names are trademarks or registered trademarks of their respective companies or organizations.