PC-Based Validation of ECU Software Sean Wyatt - ETAS, Inc. Embedded System Workshop Venue: Oakland University School of Engineering and Computer Science, Rochester, MI Date: October 13, 2012 What you will learn Motivation for PC-Based Development How to create MiL and SiL platforms using ETAS INTECRIO software; How to calibrate C-code using production tools like ETAS INCA; How to improve productivity, reduce cost by leveraging the PC platform; 2 Agenda Why PC-based Development Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 3 Agenda Why PC-based Development Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 4 Why PC-Based Development? Engine Management Transmission Management Effort Vehicle Motion Management Battery Number of calibrations Management Brake Consumption and Management emission requirements Increased inter domain connectivity SW- SW- SW- Component 1 Component 2 Component 3 AUTOSAR AUTOSAR AUTOSAR Interface Interface … Interface AUTOSAR-RTE Basic Software Module (BSM) Microcontroller Abstraction 100% ECU Hardware 25000 4000 9000 12000 16000 0% New layered standard 1997 2002 2004 2007 2010 New functions and architecture variants Engine control complexity 5 Why PC-Based Development? Simulation Benches Vehicles Today – 70% 2015 – 40% 2015 – 40% Effort Today – 25% 2015 – 20% Today – 5% 6 Why PC-Based Development? “Road to lab to math is basically the idea that you want to be as advanced on the evolutionary scale of engineering as possible. Math is the next logical step in the process over testing on the road and in the lab. Math is much more cost effective because you don’t have to build preproduction vehicles and then waste them. We’ve got to get out in front of the technology so it doesn’t leave us behind. We have to live and breathe math. When we do that, we can pass the savings on to the consumer.” - A senior auto executive Summary: Development hardware (ECUs, vehicles etc.) is expensive and PCs are more powerful and inexpensive than ever. Why PC-Based Development? Automotive industry is already leveraging PC- based development for a range of activities, e.g.: – software functional testing and V&V – legacy c-code simulation on the PC – target-like timing analysis (RTOS) – calibration development – system development using plant models – complete ECU hardware emulation But more can be done. Several studies.. 9 Agenda Why PC-based Validation Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 10 Definitions Our Definition: A virtual ECU development environment is characterized by the absence of physical hardware, i.e. PC-based representation of all components, with or without real-time execution 11 Evolution of Virtualization ECU Application Models, Software Driver, Vehicle and Environment Models 4 Virtual Environment 3 Real ECU Real Vehicle 2 1 Real Environment 12 What’s included for today? Included: ECU algorithm models or embedded code ECU real-time operating system (RTOS) and other basic software components Physical systems (e.g. engine, transmission, body, chassis, driver, environment models) Not included: Virtualization of the ECU hardware (e.g. microcontroller, peripherals) Virtualization of the physical buses (e.g. CAN, FlexRay) 13 Steps to Create a Virtual Environment Physical Models or ECU Algorithm ECU Embedded stimuli Models Code The main ingredients Integration and Build Environment Execution Platform Instrumentation The glue and tools necessary Verification and Calibration and Automatic Testing Validation Measurement The development tasks you are interested in 14 Model-in-the-Loop (MiL) Simulation • Defined as the ECU algorithm model “in-the-loop” with the plant models – May be run within the modeling environment, or Physical Models or ECU Algorithm stimuli Models IntegrationConnect models and Build in Simulink Environment RunExecution in Simulink Platform under Windows 15 Model-in-the-Loop (MiL) Simulation • Defined as the ECU algorithm model “in-the-loop” with the plant models – May be run within the modeling environment, or – Run as an executable under Windows - from model-generated code Physical Models or ECU Algorithm stimuli Models code gen code gen Integrate model-code and compile RunExecution executable Platform under Windows 16 Software-in-the-Loop (SiL) Simulation • Defined as the ECU embedded software “in-the-loop” with the plant models – May be run within the modeling environment, or Physical Models or ECU Embedded stimuli C-Code S-functions Connect models and S-functions Integration and Build Environment (containing code DLLs) in Simulink RunExecution in Simulink Platform under Windows 17 Software-in-the-Loop (SiL) Simulation • Defined as the ECU embedded software “in-the-loop” with the plant models – May be run within the modeling environment, or – Run as an executable under Windows Physical Models or ECU Algorithm ECU Embedded stimuli Models C-Code code gen code gen Integrate model-code with ECU code Integration and Build Environment and compile RunExecution inexecutable Simulink Platform under Windows 18 Agenda Why PC-based Validation Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 19 Virtual Setup for ECU Development Environment (Road, Wind, etc.) Vehicle Driver Subsystem Subsystem Subsystem (e.g. Engine) (e.g. Transmission) (e.g. Chassis) Set-Point (Sensor) Sensor Actuator Sensor Actuator Sensor Actuator Vehicle Network (e.g. CAN) 20 Virtual Setup for ECU Development Environment (Road, Wind, etc.) Vehicle Driver Subsystem Subsystem Subsystem (e.g. Engine) (e.g. Transmission) (e.g. Chassis) Set-Point (Sensor) Virtual Sensor/Actuator Signal Bus Vehicle Network (e.g. CAN) 21 Virtual Setup for ECU Development Environment (Road, Wind, etc.) Driver Vehicle Subsystem Models (e.g. Engine, Transmission, Chassis) Set-Point (Sensor) Virtual Sensor/Actuator Signal Bus Vehicle Network (e.g. CAN) 22 Virtual Setup for ECU Development Environment (Road, Wind, etc.) Driver Vehicle Subsystem Models (e.g. Engine, Transmission, Chassis) Set-Point (Sensor) Virtual Sensor/Actuator and Network Signal Bus m2 m4 m6 m1 m3 m5 m7 function1 function 2 function 3 23 What is INTECRIO? Virtual Sensor/Actuator and Network Signal Bus 26 What is INTECRIO? Plant Models Application Software Driver,Vehicle,Environment Design and Specification Simulink ASCET Simulink C-code obj, lib, dll code gen code gen INTECRIO RTA-OSEK for PC Target HEX and A2L files 27 Key Takeaways PC-based development of ECU software is becoming more widespread due to cost and performance advantages INTECRIO is a versatile platform for PC- based verification and validation (e.g. in MiL and SiL phases) 28 Agenda Why PC-based Validation Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 29 INTECRIO for MiL Simulink Simulink R2007a R2011a Embedded Coder Simulink Coder Hex and A2L Virtual Prototyping 30 INTECRIO for MiL 31 INTECRIO for MiL: Demo Setup • Goal: Simulate a Simulink-based plant (throttle) + Simulink throttle controller specification. THR_Cor Actual Position Desired Position Simulink Algorithm Throttle Plant Model 32 Agenda Why PC-based Validation Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 33 INTECRIO for SiL – 2 steps Simulink Models Software Component INTECRIO HEX and A2L files 34 INTECRIO for SiL – Step 1 with INCODIO Measure C-code Create Interface Calibrate Schedule 35 INTECRIO for SiL 36 INTECRIO for MiL + SiL: Demo Setup • Goal: Verify that the C-code implementation of the Throttle Controller matches specification, reusing the stimulus and plant Simulink models. THR_Cor Actual Position Desired Position C-Code Algorithm Throttle Plant Model 37 Calibration of C-code with INCA 38 Key Takeaways MiL: INTECRIO integrates one or more Simulink models at the code level, adds scheduling information and compiles for PC target. SiL: INCODIO parses C-code and makes it visible to INTECRIO for integration with models or other C-code. INTECRIO adds scheduling information and compiles for PC target. Calibration: An industry standard tool like INCA can be used to pre-calibrate ECU software in the SiL environment 39 Agenda Why PC-based Validation Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 40 INCA with INCA-SIP Algorithm Engineer ® Simulink INCA Control & Plant Models Legacy C-code .dll INCA-SIP API XCP on Ethernet Windows 41 INCA with INCA-VLINK Calibration Engineer ® Simulink INCA Control & Plant Models Legacy C-code .dll INCA-EIP INCA-VLINK compile TCP/IP on Ethernet Windows 42 ISLOAR-EVE* (ETAS Virtual ECU) Authoring Virtual Instruments INCA Windows Ethernet *Product not yet released 43 Agenda Why PC-based Validation Definitions What is INTECRIO? Model-in-the-loop with INTECRIO Software-in-the-loop with INTECRIO Other ETAS Solutions Summary 44 Summary Virtual techniques can substantially lower the cost of verification and validation of ECU control models and software. Calibrators can use the same tools in the virtual environment as in the vehicle. Re-use of test cases, models and calibration data across the development cycle further optimizes cost and effort. AUTOSAR architecture further enables validation