Accelerating automotive test development may 2008


Published on

Discover how Virtual Instrumentation (LabVIEW and Modular I/O) accelerates Automotive Test development.

Published in: Automotive
  • Be the first to comment

No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide
  • 2 minutesBefore we move on to general trends in Automotive engineering; a quick look at the some automotive trends in Eastern Europe (mentioned the country and replace slide accordingly)…Explain Car production trendVW just opened a new manufacturing plant Refer to article in EE Times about More design validation is moving to Eastern EuropeR&D centers have opened (BOSCH)Moreover, in a distribute world – integration of remote facilities into the process is an important topic…Both, Design validation and manufacturing are test intensive; To ensure the design will actually function the way it was intended to function & to provide solid feedback to the actual design teams;to ensure great user experience and reduce the amount of “after-service” necessary to fix problems that could have discovered during the end-of-line test. TRANSITION: So let’s take a look at global Automotive Trends…
  • 1974 Honda Civic CVCCIn 1970, the U.S. passed the Clean Air Act of 1970, which set the scene for emissions standards and emissions control equipment such as the catalytic converter. In Japan Soichiro Honda of Honda Motor Co. introduced the CVCC stratified-charge engine, which not only met the U.S. emission standards without a catalytic converter but also met the stringent Japanese emission standards. In 1975 Honda exported the Honda Civic CVCC 1500 to the U.S. The four-door vehicle had a wheelbase of 2280 mm (90 in) with a front track of 1300 mm (51 in) and rear track of 1280 mm (50 in). It had a curb weight of 730 kg (1610 lb). The engine was an inline four cylinder mounted transversely with a 15° incline forward. The 1.5-L engine had a bore of 74 mm (2.91 in), stroke of 86.6 m (3.41 in), and a compression ratio of 8.1:1. Five main bearings supported the one-piece forged crankshaft. A single belt drove the overhead camshaft that operated three valves per cylinder. In the stratified-charge engine there was a tiny auxiliary chamber atop the main combustion chamber. Thus there is one valve for the auxiliary chamber and one for the intake and exhaust for a total of three valves per cylinder.Mechatronics is the new term that pulls it all together…now you don’t have to be good a mechanics which you have to understand how electronics interfaces with mechanics and guess what you’ll have to program something too.
  • How hard can this be?How complex can it be? Here is a very simple example, This example code is using 2 threads to access some shared memory. Firstly, its difficult to pick out where the two threads begin and end. You cannot quickly view what is happening in parallel as the text is itself sequential by nature.
  • And another application using the PXI parallel platform.Deep inside Eaton Corp. is a team of developers whose sole mission is to refine the test and measurement systems used in the company’s truck R&D division. This case study explains how this team harnessed the performance of new multi-core Intel® processors and the multithreaded architecture of National Instruments LabVIEW* graphical programming software to more than quadruple the number of channels running through their systems and achieve real-time determinism.They got there using standard, off-the-shelf desktop systems, keeping power consumption, thermal output, and – most importantly – costs, down. The move to Intel’s multi-core processors also enabled Eaton to put their system in a mobile platform so that testing can be done in the vehicle instead of in dynamometers for more accurate, efficient performance feedback.
  • Unfortunately, in many companies the test process has not changed much. When the first version of the product is design one uses a traditional approach of building a prototype and making measurements…the late we find bugs in the design process the more expensive it is to fix them. You can only imagine what this means with products getting more and more complex and with the market pressure to design them faster and faster….The worst case is really when you have to do validation and design debugging on the manufacturing floor with manufacturing test equipment.
  • Accelerating automotive test development may 2008

    1. 1. Virtual Instrumentation – Accelerating Automotive Test Development“Developing Complex Systems Faster and Cheaper”<br />Thorsten Mayer<br />National Instruments<br />
    2. 2. National Instruments<br />Leaders in Computer-Based Measurement and Automation, headquartered in Austin, TX USA<br />Long-term Track Record of Growth and Profitability<br />Fortune’s 100 Best Companies to Work for Ninth Consecutive Year<br />16% of revenue invested in R&D<br />Dr. Truchard and Jeff Kodosky inducted into Electronic Design Hall of Fame for their pioneering work in virtual instrumentation<br />More than 4,700 employees ( > 2000 engineers) worldwide in over 40 countries (>1000 employees in Eastern Europe)<br />$ 740M record revenue in 2007<br />Net Revenue in Millions<br />
    3. 3. NI Automotive Customers<br />Audi<br />Toyota<br />Nissan<br />Honda<br />Bosch<br />Continental<br />Delphi<br />Visteon<br />Autoliv<br />DaimlerChrysler<br />Land Rover<br />Jaguar<br />BMW<br />Volkswagen<br />TRW<br />General Motors<br />Eaton Corp<br />Lear Corp<br />Saab<br />Ford<br /><ul><li>Siemens VDO
    4. 4. Breed Technologies
    5. 5. Fiat
    6. 6. MagnetiMarelli
    7. 7. Ferrari
    8. 8. Skoda
    9. 9. Suzuki
    10. 10. Valeo
    11. 11. Volvo</li></ul>…to name a few<br />
    12. 12. NI in Automotive Applications<br /><ul><li>Gearbox Health Monitoring System
    13. 13. PC Based Automotive Steering Gear Test Rig
    14. 14. Field Trial & Application Trial Kits for GDU and Glow Plug
    15. 15. Tire Unbalance Test System
    16. 16. Networked Test System For Braking Components
    17. 17. Automated Fuel Injection Pump Test Stand
    18. 18. Inspection of Automobile Spark Plugs
    19. 19. Weiss Cold Chamber Monitoring & Brake Test System
    20. 20. CAR Body Shell Stress test
    21. 21. ECU validation and End-Of-Line test
    22. 22. Automated Vision System for Electronic Automotive Cluster
    23. 23. Starter Motor Durability Test Stand
    24. 24. Car Window Regulators Testing System
    25. 25. Hardware in The Loop</li></ul>…to name a few<br />
    26. 26. Vehicle Production Capacity – Eastern Europe<br />“Cheap car trend pushes development to Central Eastern Europe” <br />EE Times Europe, 28 March 2008<br />
    27. 27. Automotive Technology Timeline<br />Telescope<br />Shock<br />Absorber<br />Mechanics<br />Steel<br />Car<br />Body<br />4 Wheel<br />Hydraulic<br />Brakes<br />Independent<br />Suspension<br />Electric<br />Starter<br />Power<br />Steering<br />Flashing<br />Turn Signals<br />Air<br />Conditioning<br />Electronics<br />1900 1910 1920 1930 1940<br />Assembly<br />Line<br />Mass Produced<br />Front Drive <br />Mass<br />Production<br />AT<br />Power<br />Steering<br />MacPherson<br />Strut<br />Carburetor<br />Drum<br />Brakes<br />Mechanics<br />Electronics<br />Continuously<br />Variable<br />Transmission<br />Mass<br />Production<br />HEV<br />Sensors<br />Cruise<br />Control<br />Emissions<br />Control<br />Electronic<br />Fuel Injection<br />Antilock<br />Brakes<br />Telematics<br />Air Bags<br />Fuel Efficiency<br />ECU<br />Software/Microprocessor<br />1950 1960 1970 1980 1990<br />Traction<br />Control<br />Alt Fuel<br />Keyless<br />Entry<br />Gasoline<br />Direct<br />Injection<br />Variable<br />Valve<br />Timing<br />Mass<br />Production<br />Disc Brakes<br />Regenerative<br />Braking<br />Widely used<br />Catalytic<br />Converter<br />Production<br />Turbo <br />Charge<br />TPMS<br />Power<br />Locks<br />Mechatronics and<br />Algorithm Engineering<br />Adaptive<br />Cruise<br />Control<br />Commercially<br />Available<br />Automatic Parking<br />Commercially<br />Available<br />Fuel Cell<br />PHEV<br />HCCI<br />2000 2010 2020 2030 2040<br />
    28. 28. Automobiles Then and Now…<br />Mechanics and hydraulics<br />3 ECUs<br />AM/FM radio<br />Relay-control units<br />CAN<br />Electromechanics<br />15 to 80 ECUs<br />Telematics (Infotainment)<br />Power-control units<br />CAN, FlexRay, MOST, IDB ...<br />ABI Research: „40% of the car will be electronics by 2010 !“<br />
    29. 29. …Software Defines The Functionality<br />Great benefits but also a few challenges…<br />Car Radio<br />
    30. 30. P a r a l l e l<br />Technology Evolution<br />
    31. 31. Testing Becomes More Difficult<br />Navigation<br />Cellular<br />Phone<br />CD+RW<br />PC/WWW/ Email<br />Automotive<br />Telematics<br />TV<br />Games<br />DVD+RW<br />Remote Diagnostics<br />AM/FM Stereo<br />Satellite Car Alarm/Radio<br />
    32. 32. Function Generator<br />Programmable Switch<br />Oscilloscope<br />Communications Analyzer<br />Pattern Generator<br />Logic Analyzer<br />DMM<br />Power Supply<br />LCR Meter<br />Spectrum Analyzer<br />A Traditional Approach Does Not Scale Anymore<br />Automotive<br />Telematics<br />
    33. 33. Test Development Accelerators<br />Abstraction – Fast Development<br />Reconfiguration – Fast Adaptation<br />Integration – Fast Assessment<br />
    34. 34. Use a Common Platform Approach Virtual Instrumentation<br />
    35. 35. Test Development Accelerators<br />Abstraction – Fast Development<br />Reconfiguration – Fast Adaptation<br />Integration – Fast Assessment<br />
    36. 36. Increasing Levels of Software Abstraction<br />System design platform<br />C#<br />C++<br />Abstraction<br />C<br />Assembly language<br />Machine code<br />System complexity<br />
    37. 37. LabVIEW Graphical Programming<br />Compiled graphical development environment<br />Development time reduction of four to ten times<br />Tools to acquire, analyze, and present your data<br />
    38. 38. Speed Development with Graphical Programming<br />LabVIEW<br />C*<br />C*<br />LabVIEW<br />* does not include code to generate UI<br />
    39. 39. Abstractions – Leveraging Latest Technology Trends<br />
    40. 40. Multicore has Arrived<br />“Intel pledges 80 cores in five years” <br /> - Paul Otellini, Intel CEO<br />Intel Developer Forum,September 2006<br />19<br />
    41. 41. Impact on Engineers and Scientists<br />You must create multithreaded applications to maximize benefit from multicore processors. <br />Measurement or Control Application<br />Data Acquisition<br />UserInterface<br />Network<br />Comm.<br />Logging<br />THREAD<br />THREAD<br />THREAD<br />THREAD<br />Operating System<br />CPU Core<br />CPU Core<br />CPU Core<br />CPU Core<br />20<br />
    42. 42. Example: Text-Based Multithreading<br />void ThreadTwo( void *){  for ( int i = 0; i < 10000; i++)  {    // Request ownership of the critical section    EnterCriticalSection(&g_criticalSection);<br />    // Access the shared resource    g_iResult += 1;<br />    // Release ownership of the critical section    LeaveCriticalSection(&g_criticalSection);  }<br />  // Finished  g_bThreadTwoFinished = true;  _endthread();}<br />int main(){  // Initialize the critical section  InitializeCriticalSection(&g_criticalSection);<br />  // Start the threads  _beginthread(ThreadOne, 0, NULL);  _beginthread(ThreadTwo, 0, NULL);<br />  // Wait for the threads to finish  while (( false == g_bThreadOneFinished)  || ( false == g_bThreadTwoFinished))  {    Sleep(1);  }<br />  // Release resources used by the critical section  DeleteCriticalSection(&g_criticalSection);<br />  // Print the result  printf("Result: %i ", g_iResult);<br />#include <windows.h> <br />#include <stdio.h> <br />#include <conio.h> <br />// CriticalSection.cpp<br />#include <windows.h>#include <stdio.h>#include <process.h> <br />CRITICAL_SECTION g_criticalSection;bool g_bThreadOneFinished = false;bool g_bThreadTwoFinished = false;int g_iResult = 0;<br />void ThreadOne( void *){  for ( int i = 0; i < 10000; i++)  {    // Request ownership of the critical section    EnterCriticalSection(&g_criticalSection);<br />    // Access the shared resource    g_iResult += 1;<br />    // Release ownership of the critical section    LeaveCriticalSection(&g_criticalSection);  }<br />  // Finished  g_bThreadOneFinished = true;  _endthread();}<br /> }<br />
    43. 43. Graphically Simplifying Parallelism<br /><ul><li>Graphical approach intuitively exposes thread opportunities
    44. 44. LabVIEW automatically creates multiple threads</li></li></ul><li>Parallel Application: Automotive Test<br />In-vehicle test system for truck transmissions using LabVIEW<br /><ul><li>Acquired and analyzed 16 channels on a single-core system
    45. 45. Now acquire and analyze 80+ channels on a multicore system</li></ul>“There was no need to rewrite our application for the new multicore processing platforms.”<br />Scott Sirine<br />Lead Design Engineer<br />Eaton Truck Division<br />23<br />
    46. 46. Abstraction – Enabling Technologies<br />F<br />E<br />AB<br />CD<br />Z<br />Y<br />W X<br />Graphically Programming for FPGAs<br />VHDL<br />F = {(A+B)CD}  E<br />
    47. 47. Application-Ready FPGA Platform<br /><ul><li>Integrated I/O
    48. 48. High performance
    49. 49. Truly parallel
    50. 50. Flexible
    51. 51. Reliable
    52. 52. Software configurable</li></li></ul><li>Acceleration Through Abstraction<br />LabVIEW Graphical Development<br />P a r a l l e l<br />
    53. 53. Test Development Accelerators<br />Abstraction – Fast Development<br />Reconfiguration – Fast Adaptation<br />Integration – Fast Assessment<br />
    54. 54. Function Generator<br />Programmable Switch<br />Oscilloscope<br />Communications Analyzer<br />Pattern Generator<br />Logic Analyzer<br />DMM<br />Power Supply<br />LCR Meter<br />Spectrum Analyzer<br />Today’s Challenges: The Traditional Approach<br />Automotive<br />Telematics<br />
    55. 55. The Virtual Instrumentation Approach<br /><ul><li>Integrated SW & HW
    56. 56. Flexible performance
    57. 57. Small size
    58. 58. High throughput
    59. 59. Cost effective</li></ul>Automotive Telematics<br />
    60. 60. LabVIEW Everywhere<br />Plug-in<br />Devices<br />Traditional<br />Instruments<br />
    61. 61. Accelerating Platform - Test: PXI<br />PXIe-8130<br />Intel Dual Core<br />PXI Express<br />Bus<br />R Series PXI DAQ<br />3M Gate FPGA<br />Modular<br />Instruments<br />Windows or<br />RT OS<br />LabVIEW<br />Sound & Vibration<br />Toolkit, Vision<br />Module …<br />NI-DAQmx, <br />NI-DMM,<br />NI-Scope…<br />
    62. 62. NI PXI – Engine Test Simulator<br />MicroNovaUses LabVIEW FPGA for Exact and Comprehensive Engine Simulation to test the engine ECU in a BMW 12-cyclinder hydrogen-based series car<br />Intel-based PC<br />running Windows<br />Ethernet<br />Engine signals<br />Engine Control Unit (ECU)<br />Intel-based PXI System<br />running Real-Time Operating System<br />(Simulates a BMW)<br />
    63. 63. PXI Multimedia & Telematics ATE System<br />Averna, Inc.<br />Power consumption tests<br />I/O tests<br />Parametric tests<br />Vision and display tests<br />GPS tests<br />Cell phone tests<br />Multimedia tests<br />Bluetooth tests<br />Automotive amplifier tests<br />Satellite receiver tests<br />
    64. 64. Accelerating Platform - Control: CompactRIO<br />FPGA<br />Point-to-Point<br />FPGA Data Links<br />C Series<br />Parallel I/O<br />LabVIEW<br />Real-Time<br />Thread-Safe<br />Libraries<br />Multithreaded<br />RT OS<br />LabVIEW FPGA<br />34<br />
    65. 65. CompactioRIO – Full Authority Engine Control<br />“In past projects, we spent at least two man-years and $500,000 to develop similar ECU prototyping systems from custom designed hardware. For this project, the equipment costs, including the motorcycle and CompactRIO, were $15,000. In addition, we spent about three man-months on this project.”<br /> – Carroll G. Dase, President of Drivven, Inc.<br /><br />
    66. 66. CompactRIO - In-Vehicle Datalogger<br />Application: Vehicle Datalogger<br />Portable, rugged and extremely versatile<br />Onboard analysis and diagnostics <br />Easily and single-handedly navigate all device functions<br />In-vehicle, laboratory, environmental chamber, wind tunnel, endurance, calibration/diagnostics<br />Platform: CompactRIO<br />Software: LabVIEW, Real-Time and FPGA<br />
    67. 67. Abstraction – Fast Development<br />Reconfiguration – Fast Adaptation<br />Integration – Fast Assessment<br />Test Development Accelerators<br />
    68. 68. Verification/<br />Validation<br />Manufacturing and<br />Deployment<br />Design and<br />Simulation<br />Research/<br />Modeling<br />Physical World<br />Virtual World<br />The Future Of Virtual Instrumentation<br />
    69. 69. A Typical Design Cycle<br />Manufacturing and<br />Deployment<br />Board and Silicon <br />Prototype<br />Design and <br />Simulation<br />Theory and <br />Research<br />Cost of Finding a Bug<br />Virtual World<br />Physical World<br />
    70. 70. Test Refines Simulation and Validation<br />Road Load <br />Data Flow <br />RLD Measurements<br />Courtesy of DaimlerChrysler, General Motors, and MSC Software.<br />
    71. 71. High-Level Design Models<br />C Code<br />Dataflow<br />Textual Math<br />Simulation<br />Statechart<br />LabVIEW<br />Graphical System Design Platform <br />FPGA<br />Desktop<br />Microprocessors<br />Real-Time<br />
    72. 72. I/O<br /> I/O<br />I/O<br />Processor<br />FPGA<br />PXI RIO<br />Custom I/O<br />CompactRIO<br />Integrated<br />The Deployment Curve<br />PCI RIO<br />System Flexibility and Price<br />CompactRIO<br />Modular<br />LabVIEW<br />Number of Systems Deployed<br />
    73. 73. Manufacturing and<br />Deployment<br />Research/<br />Modeling<br />Making Test Integral to the Design Cycle<br />Virtual Instrumentation – <br />Accelerating Automotive Test Development<br />Design, Prototype, <br />and Test<br />
    74. 74. Software Defined Test Systems<br />