Tech Briefs Magazine - August 2022 - 7

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ECU Testing and Verification Using Hardware-in-the-Loop Simulation
Thorough and reliable testing is essential to verify and test controller designs. The automotive and aerospace industries have the most challenging
electronic testing requirements. Electronic Control Units, or ECUs, are often used in these industries, where high reliability and high
operational predictability are critical. The correct operation of these ECUs is typically verified by using Hardware-in-the-Loop Simulation (HILS).
Paul Bovingdon, Technical Engineering Manager at Pickering Interfaces, discusses the current trends in testing and benefits of using the industry
standard PXI platform for HILS automated fault insertion and sensor simulation.
Tech Briefs: Why is it essential to automate
fault testing for electronic control
units?
Paul Bovingdon: There are different ways of
testing electronic control units (ECU). In the
past, some people have manually controlled
them, but that can be quite time-consuming
and prone to human error. By automating
the testing, you speed up that process and remove the possibility
of doing something wrong.
Tech Briefs: What are some of the commonly used verification
and testing systems for this process?
Bovingdon: You can do it manually by using
breakout systems and wiring things up.
However, you can also get large preconfigured
systems that you can buy off-the-shelf.
But, when you have modular-based systems,
customers can pick and choose what they
require and build their systems.
Tech Briefs: How does the Hardware-inthe-Loop
Simulation (HILS) system work?
Bovingdon: Essentially, you are taking a
real-world system and replacing it with test
equipment that could be rack-mounted or on
your bench. For example, suppose you want
to simulate a temperature sensor, such as
a Thermocouple RTD or Thermistor. In that
case, you can use electronic hardware that
will basically output the signal that the real-world sensor would
output. In addition to this, you can use fault insertion modules. So,
for instance, if something is wired up incorrectly - you have broken
cables, shorted cables, or high resistance - you can have all that set
up in your electronic test system.
Tech Briefs: What are the advantages of using the PXI platform
for HILS automated fault insertion and sensor simulation?
Bovingdon: The real advantage is scalability. Because PXI is a modular
system, if you wanted to start with just a small system on your
bench for early development and prototyping, you could just buy a
small number of modules in a small chassis. It saves complexity and
cost, and that gives you exactly what you need. You can have it on
your desk next to you, but when you are moving into more involved
R&D, you can take that system and expand it by adding extra chassis
or modules. Another advantage of PXI is that it's a multi-vendor
platform, not a Pickering platform. This means you could buy fault
insertion simulation products from us and then go elsewhere and
Tech Briefs, August 2022
buy CAN communication cards or digital multimeters and scopes
for the same system.
Tech Briefs: With new technologies being introduced every day
in automotive and aerospace, how will testing technologies
evolve over the next five years?
Bovingdon: Testing technologies are always expanding as protocols
develop. These industries are using higher voltage as an
example, especially as they are getting into electric vehicles -
they are using higher and higher voltages. Many modern cars,
especially high-performance ones, are going to 800 volts and
beyond. So, we must keep up on both the switching and simulation
sides. Also, more radar systems are being added to vehicles, so
people can see what's happening around them. Again, you need
higher frequencies. Also, for communication systems testing, a
few years ago, people were happy with 100Base-T1, which was
a single twisted pair Ethernet standard, but now it's going into
1000Base-T1, so now it's gigabit Ethernet over a single twisted
pair. The industry is really trying to keep up with these new
protocols and developments to provide the test equipment that
customers need. That's an advantage of a modular system; your
entire system won't be obsolete as things evolve. All you need to
do is take out a module that is no longer up to standard and put
in a new one. You don't need to throw away everything else; you
can just upgrade.
Read On
For more information about PXI fault insertion and sensor simulation,
visit www.pickeringtest.com. Watch the full interview
at www.techbriefs.com/ei2208/video/pickering_interfaces.
www.techbriefs.com
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Tech Briefs Magazine - August 2022

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