Key Considerations for Powertrain HIL Test

Safety, availability, and cost considerations can make performing thorough tests of embedded control devices using the complete system impractical. Hardware-in-the-loop (HIL) simulation is a real-time test technique used to test these devices more efficiently. During HIL test, the physical system that interfaces to an embedded control device is simulated on real-time hardware, and the outputs of the simulator mimic the actual output of the physical system. The embedded controller “thinks” it is in a real system. HIL simulation meticulously tests embedded control devices in a virtual environment before proceeding to real-world tests of the complete system. This application note covers recommended best practices for powertrain HIL testing. Introduction to Engine ECU HIL Test ................................................................................................................. 2 What is HIL Simulation? ................................................................................................................................. 2 Increasing Efficiency With HIL Simulation ......................................................................................................... 2 HIL Test Software Fundamentals ....................................................................................................................... 3 Simulation Fundamentals .................................................................................................................................. 4 Plant Models and Model Sources .................................................................................................................. 4 Ensuring Accurate Simulation Through Determinism ..................................................................................... 5 Key Considerations for Different Types of Powertrains ...................................................................................... 5 Combustion Powertrains ................................................................................................................................ 5 Hybrid and All-Electric Powertrains ................................................................................................................. 9 Maximizing Test Coverage ................................................................................................................................10 Building Test Cases ........................................................................................................................................10 Safety ............................................................................................................................................................10 Functionality ................................................................................................................................................. 12 Performance ................................................................................................................................................. 12 Requirements Creation, Traceability, and Fulfillment ....................................................................................... 13 The Importance of Requirements Traceability .............................................................................................. 13 Test Automation ........................................................................................................................................... 13 Selecting the Right HIL System for Your ECU.................................................................................................. 13 Openness, Extensibility, Flexibility ............................................................................................................... 13 The Importance of HIL Test System Flexibility ................................................................................................. 14 Global Services and Support ........................................................................................................................... 15 References ...................................................................................................................................................... 16 NATIONAL INSTRUMENTS APPLICATION NOTES