Case study of hardware-in-the-loop (HIL) test system for hybrid vehicle engine controls with functional safety built on National Instruments technology. Presented at NIWeek 2018 by Dan White of LHP

2. Daniel White
Solutions for Simulating and Testing Hybrid Powertrain Controls

3. Agenda
▪ Functional Safety and Electrification trends in
Automotive
▪ Challenges for HIL:
▪ ISO 26262 HIL Test Systems for functional safety
requirements
▪ Key challenges for hybrid powertrain HIL
simulation and their solutions
▪ Specific Use Case Solutions
▪ Testing a brake-throttle override safety feature
▪ Testing a 48V (P0) mild hybrid with eBoost

4. The revolution is already underway
Needs:
▪ People
▪ Process
▪ Training
▪ Tools
"Functional Safety with ISO 26262,
Principles and Practice (Webinar Part
1)", Dr. Christof Ebert, Dr. Arnulf
Braatz, Vector Consulting Services
(April 29, 2014)

5. Electrification Trend

6. HIL for functional safety requirement verification
ISO 26262

7. HIL for hybrid vehicle controller verification

8. LHP Engineering Solutions
▪ Founded 2001 in Columbus,
IN
• Privately held
• Automotive Engineering Experts
▪ Industries
• Automotive, Trucking, Rail
• Industrial, Commercial, Medical
• Manufacturing, Energy
▪ Primary Applications
▪ Powertrain
▪ Power Generation
▪ Autonomous Controls
▪ IoT, Factory IoT
LHP LocationsAt a Glance
▪ 400+ Employees World Wide
▪ 80-100 customers

9. LHP Functional Safety Expressway
▪ GAP and RAP
▪ Tool Qualification
▪ TUV FSCAE Training

10. Now LHP Technology Solutions
-LHP took control of the Powertrain Controls Group on May 15th 2017
-Engine Control Systems
-Combustion Analysis System
-Motor Control and Battery Management
-Powertrain HIL Test Platform
-Engine Test Suite signal conditioning
-Hybrid vehicle simulation
-The group builds Engine Control Systems and HIL Test Systems
based on NI hardware
Powertrain Controls Group

11. Brake-Throttle Override
NHTSA-2012-0038-0001
Notice of proposed rulemaking

12. BTO Requirements
Safety Goal – The System
should not transfer excess
power to the wheels where it
causes unintended acceleration
Derived requirement 2 – The system must
reduce power to the wheels if the powertrain
controller determines that the inputs to the
brake and accelerator pedals are conflicting.
At vehicle speed > 10mph, when a conflict exists
between APP and brake pedal, the system shall override
the accelerator pedal input and must reduce output
force to the driving wheels to a controllable level.
Once engaged, the override must remain engaged at
any speed as long as brake pedal application is
maintained and as long as APP input is in conflict with
the brake pedal.
Derived requirement – The system should verify
the intent of the driver by detecting conflicting
pedal inputs and reduce power if a conflict exists.

13. Tool Qualification for HIL Test System
• Is the HIL verifying safety
requirements?
• Can a defect in the HIL
introduce or fail to detect safety
violations?
• What is the confidence that the
HIL will detect a safety
requirement failure?

14. Verification of HIL
HIL
DUT
Fault Insertion
HIL Test System Verification
Test coverage for each safety failure use case
• May require creating a special DUT
that can deliberately violate the safety
requirement
• May require a fault insertion unit
between the HIL and DUT
Examples:
Brake throttle override condition can persist for more than 1 second before triggering fault and torque reduction
Fault can clear when vehicle speed falls below 10 mph and both pedals still applied.

15. 48V Technology
eBoost Belt driven starter/generator

16. Engine Start/Stop resync
HIL Simulator Challenge:
Engine Backlash Simulation
in FPGA for ECM resync
control testing

17. ISG with eBooster Simulation

18. Summary
Solutions for Simulating and Testing Hybrid Powertrain Controls
▪ Functional Safety
▪ HIL must be qualified using LHP Tool Qualification Kit
▪ LHP has performed ISO 26262 tool qualification, consulting, and training
▪ RMS receives ISO 26262 process certification from TUV Nord based on LHP
Functional Safety Expressway
▪ Electrification
▪ Hybrid and EV powertrain controls simulation and test pose special challenges
▪ LHP Technology Solutions Powertrain Controls Group builds custom powertrain
controls and HIL systems for many automotive customers
▪ Hybrid powertrain LHPU bootcamp in San Antonio (Powertrain Controls Group)
▪ LHP is building HV power boxes and gateways for EV conversions

19. Want to learn more?
Come see us in booth 226
Dan White
dan.white@lhpes.com
Powertrain Controls Group
technologysolutions@lhpes.com
LHP Technology Solutions
12001 Network Blvd.
San Antonio, TX 78249
(210) 556-3316

20. Before you go,
take the survey.