The document discusses modeling and simulation techniques like Hardware-in-the-Loop (HIL) testing that can help test complex machines with multiple embedded systems more efficiently by replacing physical components with software models, allowing tests that would be too risky, expensive, or time-consuming with physical systems; it also introduces Ball Systems as an expert in HIL testing and modeling who can help clients develop HIL strategies, systems, software, and models to validate products.

1. Indianapolis Office
16469 Southpark Drive
Westfield, IN 46074
St. Louis Office
2025 Zumbehl Road
Suite 304
Saint Charles, MO, 63303
www.ballsystems.com
+1 (317) 509-6410

2. Modeling Discussion Agenda
• Problems with complex systems
• Complex machines defined
• Intro to modeling & Hardware-in-the-Loop (HIL)
• Cost and quality benefits of model-based testing
• Introduction to Ball Systems
• How can we help?

3. Problem Statement
Complex machines containing multiple embedded
systems create unique and diverse testing challenges:
• Availability of product and/or test system for testing
• Cost / time to build a system prior to testing
• High cost to test (capital, facilities, maintenance,
manufacturing time, scrap, redesign, etc.)
• Time consuming testing, especially for extensive
regression testing
• System validation challenging due to complexity.
Unable to test to limits and beyond
• Repeatability challenging for large physical systems
• High cost of failure (production test, field, customer
issues, etc.)

4. Complex Machines Defined
Plant
Embedded
Real-Time Control
System
Complex machines such as Draglines, Spacecraft,
Vehicle Engines, Blast Hole Drills, Jet Engines, etc.
typically have multiple Embedded Real-Time Control
Systems controlling one or more complex (typically)
physical components called the “Plant”

5. Why Modeling and Simulation?
Modeling and
simulation can
reduce risk and
time to market and
increase the
efficiency in
multiple areas of
the product
development cycle:
• Model-In-Loop
• Software-In-Loop
• Hardware-In-Loop
• Rapid Control
Prototyping
NI’s VeriStand
software platform
provides seamless
integration of
modeling
throughout the
product
development cycle
Product Development
V-Diagram

6. • HIL allows a product development or product test
engineer the ability to mimic (or model) the behavior
of the Plant using a combination of electronic
hardware and custom software
• HIL replaces the Plant under control with a software
model of the physical Plant and all related dynamic
systems
• Modeling improves test and development through
simulating the use of real world systems
• Models also allow for rapid design iteration, and
validation at much lower cost
• These models are then “interfaced” with an
electronic control system through the use of an HIL
hardware test system and associated software to
simulate actuators, sensors, etc.
HIL Allows Modeling of Machines
A software model
is a mathematical
representation of
a physical system
and sometimes of
a control system
as well
Plant Software
Model

7. HIL System Schematic
I/O
Signals
Host PC
Running
NI
VeriStand
Plant Software Model
Control
SystemReal-Time System
The Plant
software model,
the host PC
running NI
VeriStand, and
the NI Real-Time
HIL System
effectively
“replace” the
Plant

8. • HIL increases the speed and scope of testing while
reducing risk and cost
• Ideally an embedded control system is tested against the
real Plant
• However frequently the real Plant imposes limitations or
risks on the scope of the testing
• For example, in the case of an electronic control system,
certain testing may lead to dangerous test conditions:
• Testing at or beyond the range of the certain control
system parameters or Plant capabilities
• Testing and verification of the system at failure
conditions and beyond (“corner cases”)
• HIL provides an efficient and safe environment where the
test or application engineer can focus on the functionality
of the controller without risk to himself or the Plant
Quality of Model-based Testing

9. Balance Time & Cost vs. Real World
HIL = The Best of Both Worlds
RealWorldCorrelation
Time and Cost
Virtual Simulation
Hardware-in-the-Loop
Proving Ground or
Customer Site
HIL simulation
allows the
engineer to cost
effectively
balance rapid
verification,
validation, and
regression
testing with real-
world interaction

10. Who is Ball Systems?
• Founded in 1966, today Ball Systems is a leader in custom
electronics and electronic test solutions and software for Fortune 500
companies worldwide
• Comprehensive and strategic offerings and capabilities
• Strategic consultation on design of corporate test strategies and development
processes
• Test system and test software design; COTS, custom design, etc.
• Software design and architectures; NI Suite, Visual Studio, Firmware
• Electrical circuit and system design; Analog, Digital, FPGA, Embedded Micro
• Custom PCBs/PCAs
• Mechanical fixture and
machine design
• Controls and machine
vision design
• Contract manufacturing
including PCAs, test
systems and racks, test
fixtures, custom
electronics, machines, etc.

11. National Instruments Strategic
Alliance Partner & HIL Experts
• Programming expertise w/entire NI suite
• Certified architects and developers
• Strategic NI HIL / VeriStand Partner
• Trained programmers who have implemented
numerous HIL & VeriStand solutions
• Experience with VeriStand since inception at NI
• HIL systems developed and delivered for automotive and
heavy industrial companies including:
• Caterpillar:
• Design and fabrication of HIL hardware test system
• Design and development of HIL software including
FPGA programming and VeriStand
• Cummins:
• Development of HIL software including seamless
integration with extensive existing test architecture
• 100’s of NI PXI, cRIO, etc. systems integrated worldwide

12. How Can Ball Systems Help?
• Consult to develop strategies to determine the
effectiveness of an HIL approach
• Development of HIL systems and software
• Staffed on-site validation, verification, and
regression testing and test management
• Development of software models
• Design and development of control systems for
products (e.g., NI cRIO based control systems to
replace existing PLC based systems)
Contact:
Terrance Bradford
+1 (317) 509-6410
www.ballsystems.com