Hardware in Loop System Design

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Hardware in Loop System Design and Case Study

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  • Hello, Everyone Myself Parul Goyal from Idea Research, Pune. We are a small team of IIT graduates working on Model Based System Engineering in Multidisciplinary Engineering Domains The purpose of this presentation is to discuss a case study, where we deployed NI-PXI real time hardware in hardware in loop simulation for one of our projects on flight control system
  • The block diagram shows a simplified and generic closed loop system of an industrial application – it could be an automobile application, mining or construction equipment or an aerospace application
  • An industry, which is focused on product development could be designing a new product or upgrading an existing one. The product has to go through a ‘product development life cycle’
  • In the concept evaluation phase, feasibility of a solution is analysed, market analysis is done before taking it to the design and development phase The product development life cycle will include ‘concept evaluation, feasibility studies and market analysis’ etc Once the new product idea is evaluated, project goes to the ‘design and development phase’. One of the main activities of Design & Development phase is ‘Digital Prototyping’
  • Digital prototyping includes, development of physics based plant model using any of the modeling tool (MATLAB Simulink, Easy5 etc). The plant model could be a low-fidelity or high-fidelity system level plant model. For example – an aircraft model, which includes flight dynamics modeling, aerodynamics modeling, propulsion system model, structures and stability models etc
  • Or, the model could be a subsystem level model – e.g a complicated hydraulic system of a vehicle. Which includes – several types of control valves, sensors n actuator types, load types (an accumulator), pump system, tank unit etc The digital prototyping could be as complicated as system itself
  • Another activity of the ‘design n development’ phase is controls development
  • The phase C of the product development cycle is validation and verification phase, in which we use Model in Loop and Hardware in Loop processes for design and controls optimization
  • Verification & Validation phase or in short V&V involves verification , which is verifying if we are building the right kind of product. Does it meet the specifications? Validation, which is validating – does the product actually work as per the customer requirement?
  • Model in Loop simulation (MIL) includes – controller and plant model integration on a simulation platform Designing a control input, close to real system and checking the performance of controller and plant But we can’t rely on the system performance obtained through Model in Loop simulation as its not possible to simulate real time system behavior
  • HIL testing allows us to cosimulate plant and controller on a real time platform. The figure shows a HLS setup. Control and Simulation tool box. The HLS system includes a Real Time Processor, in this case – NI-PXI, which enables us to quickly and easily deploy controlled models or plant model on real time platform. An Input/Output (I/O) interface allows the plant to communicate to ECU (where controller code is residing) A monitor can be connected to the Ni-PXI real time hardware to display ‘CPU usage’, ‘execution time’ etc
  • In industries, any system highlevel block diagram can be represented as shown in the figure. Target to design the control system or
  • Hardware in Loop System Design

    1. 1. Multidisciplinary Product Development Cycle & Deployment of NI-PXI Real Time Hardware in Hardware-in-Loop Simulation Parul Goyal
    2. 2. Multidisciplinary Closed Loop Systems In General Plant Sensors Controller Actuators
    3. 3. Multidisciplinary Closed Loop Systems In General…. continued Plant Sensors Controller Actuators Industry Focus New Hardware Design and Controller Development Upgrading the Existing Design
    4. 4. Product Development Cycle Phases Phase A (Concept Phase) Requirement Analysis/Feasibility Studies/Market Analysis Phase B (Design & Development) Digital Prototyping of hardware , Controls Development
    5. 5. Digital Prototyping of Hardware Complete System Level Plant Model Design of An Aircraft Plant Sensors Controller Actuators Flight Dynamics Aero Dynamics Propulsion Structures Stability
    6. 6. Digital Prototyping of Hardware …. continued Hydraulic Sub System System Dynamics Flow Dynamics Actuators Sensors Control Valve Dynamics Check Valve Dynamics Supply/Drain .System Relief Valve Dynamics Regulating Valve Dynamics Hydraulic Cylinder Hydraulic Motors Load Dynamics Accumulator Pump Dynamics Reservoir Compensating Valve Dynamics Pressure Sensor LVDT Plant Sensors Controller Actuators
    7. 7. Product Development Cycle Phases Phase A (Concept Phase) Requirement Analysis/Feasibility Studies/Market Analysis Phase B (Design & Development) Digital Prototyping of hardware, Controls Development
    8. 8. Complex Controls with Cascade Architecture Adaptive Control Design Atg_demand Atg_demand mgdot Rtp_plant Rtp_controller Rtp_dot Actuators Sensors Inner Loop Controls Outer Loop Controls Gas Generator Plant Model Reconstruct Burn Rate (rtp) Adaptive Control Logic (determine rtp_dot) Main Controller
    9. 9. Product Development Cycle Phases Phase A (Concept Phase) Requirement Analysis/Feasibility Studies/Market Analysis Phase B (Design & Development) Digital Prototyping, Controls Development Phase C (Validation & Verification) MIL/HIL/Hardware Design & Controls Optimization Production Level Testing
    10. 10. Validation & Verification (V&V) Phase C (Validation & Verification) MIL/HIL/Hardware Design & Controls Optimization Production Level Testing Verification: Does the product development conform to the specifications? Validation: Does the Product Actually Do What the User Really Wants? <ul><li>Processes: MIL/HIL </li></ul><ul><li>Limited Bench Availability </li></ul><ul><li>Saves Cost & Time </li></ul>
    11. 11. Hydraulic Control Valve Body Controller – Shift Sequencing Driver Input <ul><li>Cosimulation Involving Controller Model & Plant Model (Controlled System Model) in a Non-Real Time Environment </li></ul><ul><li>An Easy Way of Testing Control Algorithm and Identifying Infeasible Designs </li></ul>Validation and Verification (V&V) Model in Loop Simulation Plant – Hydraulic Subsystem
    12. 12. Validation and Verification (V&V) Hardware in Loop Simulation <ul><li>Cosimulation Involving Controller Code on Target Control Unit & Plant Model (Controlled System Model) in a Real Time Computer </li></ul>Outputs NI-PXI Real Time Processor Operator Interface S/w Lab view Installed Ethernet I/O Interface Analog, Digital, CAN ECU Unit Under Test Test Commands Control Commands Display Processor Info Monitor
    13. 13. Designing a HIL System <ul><li>Real Time Hardware Compatibility with Industry Standard Protocols </li></ul><ul><li>Real Time Hardware Compatibility with Variety of Control Unit Configurations </li></ul><ul><li>Ease of Deployment </li></ul><ul><li>Monitoring of All Vital Parameters </li></ul><ul><li>Time of Execution/Memory Allocation Analysis </li></ul>Ethernet I/O Interface Analog, Digital, CAN
    14. 14. Case Study (Development of Effective Flight Control Systems of an Aircraft) Pitch Yaw Roll Flight Control Surfaces Rotational Degrees of Freedom
    15. 15. Case Study (Development of Effective Flight Control Systems of an Aircraft) …… continued
    16. 16. Case Study (Development of Effective Flight Control Systems of an Aircraft) …… continued Outputs NI-PXI Real Time Processor Operator Interface S/w Lab view Installed Ethernet Test Commands Display Processor Info Monitor
    17. 17. Case Study (Development of Effective Flight Control Systems of an Aircraft) …… continued
    18. 18. Thank You!
    19. 19. Back Up Slides

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