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Rapid Control Prototyping
For Powertrain Applications
Joe Cassar Team Leader Applications Engineering
April 16, 2015
dSPACE Inc. · 50131 Pontiac Trail· Wixom MI
Why Rapid Controls Prototyping?
 Test new ideas in a realistic environment to see if they are worth following up
 Get convenient access to all relevant data during validation
 Use a high-performance system with virtually no restrictions
 Have the flexibility to adapt the system to your application
 Get quick results and run iterations in a minimum of time
 Implement your Simulink® /Stateflow® model at the push of a button
© Copyright 2015, dSPACE GmbH
General Rapid Control Prototyping Development Process
Design, simulation and analysis
on a PC
I/O connection via library
Implementation
on RT hardware
Monitoring, tuning
Real-time simulation and verification in a real environment
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Implementation Software: RTI
 Graphical I/O configuration via comprehensive block libraries for Simulink®
 Comprehensive error checks
 Automatic code generation and implementation of MATLAB®/Simulink®/Stateflow®
models on dSPACE hardware
© Copyright 2015, dSPACE GmbH
Test and Experiment Software: ControlDesk Next Generation
 Powerful and easy-to-use monitoring and tuning software
 Virtual instrumentation, automation, and parameter set handling
 Managing and instrumenting real-time and PC simulation
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Different RCP Scenarios: Fullpassing – External Bypassing
Rapid prototyping
systems
Host PC
Signal conditioning,
power stages
Fullpassing
Bypass
interfaces
Production controller (ECU)
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Plant
External
Bypassing
Different RCP Scenarios: Fullpassing
Rapid prototyping
systems
Signal conditioning,
power stages
Fullpassing
Plant
Host PC
© Copyright 2015, dSPACE GmbH
Hardware: Overview and General Classification
Laboratory
In-vehicle
Modular
Modular boards
AutoBox
Modular system
MicroAutoBox
Compact
MicroLabBox
RapidPro
Single boards
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Hardware: Modular Laboratory Systems
Modular laboratory desktop and rack-mount prototyping system
 Gives you optimum scalability and flexibility
 Can be combined from modular board range
 Three housing variants with 4, 10 or 20 slots
 Several options for connection to host
(Ethernet, PCI, PCI Express, PCMCIA)
 Improved noise emission and vibration handling
 Ambient temperature: 0 ... +50 °C
 Power supply: 90 … 264 V AC (auto ranging)
© Copyright 2015, dSPACE GmbH
Hardware: Modular In-vehicle Systems - AutoBox
Modular in-vehicle prototyping system
 Gives you optimum scalability and flexibility
 Can be combined from modular board range
 Two housing variants with 7 or 14 slots
 Several options for connection to host
(Ethernet, PCI, PCI Express, PCMCIA)
 AutoBoot option (PCIMCIA) for stand-alone operation
 Ruggedized design (shock- and vibration-tested)
 Ambient temperature: 0 ... +55 °C
 Power supply: 8 ... 60 V DC (battery)
© Copyright 2015, dSPACE GmbH
Hardware: Modular Board Architecture
Scalable and modular hardware boards for multiple applications
 Boards can be installed in a
separate dSPACE Expansion Box or,
for in-vehicle use, the mobile AutoBox
 High processor power
PowerPC 750GX, 1 GHz (single core)
PowerPC P5020, 2 GHz (dual core) or
AMD Opteron™, 2.6 GHz (quad core)
 High performance with
multiprocessor systems
 Fast access to I/O hardware
 Variety of combinable I/O boards available
© Copyright 2015, dSPACE GmbH
Hardware: Compact System for In-vehicle – MicroAutoBox II
MicroAutoBox II: dSPACE´s compact in-vehicle prototyping system
 Several variants with diverse I/O incl. CAN, LIN, K/L Line, FlexRay interfaces
 Variant with user programmable FPGA (Xilinx Kintex-7)
 Ethernet Host and I/O interfaces
 USB interface for long-term data acquisition
 Higher calculation power: IBM PPC 750 GL, 900 MHz
 All variants can be combined with the EmbeddedPC extension
 Ruggedized design (shock and vibration tested)
 Operating temperature: -40 ... +85 °C
 Power supply: 6 ... 40 V DC (battery)
© Copyright 2015, dSPACE GmbH
MicroAutoBox II variants – one basis, all possibilities
DS1507
Busses
And Bypassing
DS1511
Universal I/O
More digital I/O
DS1513
Universal I/O
More analog I/O
More CAN
Option for all variants
Embedded PC
Extension
© Copyright 2015, dSPACE GmbH
DS1511/1514 &
DS1513/1514
Enhanced Universal I/O
FPGA/FlexRay/CAN FD/IP
E-Motor Control
I/O Extension
Hardware: Signal Conditioning and Power Stages - RapidPro
Compact and flexible signal conditioning, power stages, and intelligent I/O subsystem
for dSPACE prototyping systems
 Scalable and modular system architecture
 Variety of off-the-shelf signal conditioning and power stage modules available
 Hardware and software configurable modules
 For in-vehicle and laboratory use
 Ruggedized design (shock and vibration tested)
 Operating temperature: -40 ... +85 °C
 Power supply: 6 ... 60 V DC (battery)
© Copyright 2015, dSPACE GmbH
RapidPro Independent Power Stage and/or Signal Conditioner
RapidPro Power Unit and/or SC Unit
Custom Wire Harness
Custom Wire Harness
RCP or ECU
ETH_CAB1
3rd party USB mass
Storage device
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15
RapidPro Intelligent Peripheral Unit
RapidPro IIO
Custom Wire Harness
LVDS_ CAB15
RCP
ETH_CAB1
3rd party USB mass
Storage device
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16
Hardware Architecture of Intelligent RapidPro
System
I/O Connectors
H
Connector Panel
SCM SCM
1
2
SCM SCM
5
6
SCM SCM
3
4
SCM SCM
7
8
Power
supply
µC
Router
Control Unit
Power Units
SC Units
I/O Connectors
H
Connector Panel
PSM 1
PSM 2
PSM 3
PSM 4
PSM 6
PSM 5
Power
supply
µC
Router
I/O Connectors
S
Connector Panel
SCM SCM
1
2
SCM
3
SCM
4
Router
FPGA
H
Host
IF
Slave
IF
SCM
5
SCM
6
MCM
Flash
SRAM
Power
supply
Unit Connection Bus (UCB)
© Copyright 2015, dSPACE GmbH
RapidPro Control Unit
RapidPro Control Unit
 Up to 6 signal conditioning
modules (SCM) per unit
Unit Connection Bus
SCM 4
SCM 5
Power
supply
SCM 6
SCM 3
SCM 2
SCM 1
 2 slots for communication modules
(COM)
 MPC565 microcontroller module
 Reconfigurable on-board logic (FPGA)
MPC565
microcontroller
module
COM 1
COM 2
Connectors to sensors
LVDS USB
© Copyright 2015, dSPACE GmbH
 Unit connection bus for
additional SC and Power Units
Example Configuration for Engine Management
PowerUnit
RapidPro units and modules
PowerUnit
SC Unit
Control Unit
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19
Modules used for Engine Control Applications
Thermocouple
Direct injection
Denso Lambda UHEGO
EGOS
Crank/Cam
Knock
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20
Crank and CAM Processing Traditional Sensors
Profiles of Variable Reluctance Crank Shaft Sensor (top) and Hall-Effect CAM Sensor
(bottom)
© Copyright 2015, dSPACE GmbH
RapidPro ControlUnit: Any Crank-Cam technology
Any Crank-Cam technology for enhanced engine control development
 Comprehensive support of various crank-cam wheel geometries, e.g.
 Asymmetric positioned crank gaps
 Asymmetric positioned cam markers
 Crank wheel without gaps and
wheel with multiple markers
cam
 Generic, table based approach with file-based user entry of the crank and cam
wheel geometry planned
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22
Crank Processing
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Crank/CAM: Start/Stop functionality via Wavetable
Start/Stop functionality for enhanced engine control development
 Allows development of Start-Stop systems
 Support of sensors with duty cycle direction output
 Forward rotation: 45usec per crank teeth
 Backward rotation: 90usec per crank teeth
 Typical sensors: Bosch DG-23i, Denso crank sensor
 Rotation detection until standstill
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24
SC-CCDI 6/1 Crank-CAM processing Module
© Copyright 2015, dSPACE GmbH
Knock Sensor Interface
© Copyright 2015, dSPACE GmbH
RPCU Injection and Ignition
© Copyright 2015, dSPACE GmbH
RPCU Injection and Ignition
© Copyright 2015, dSPACE GmbH
DS1664 Solenoid Direct Injection Power Stage
© Copyright 2015, dSPACE GmbH
Injection: Achieving Peak, Intermediate and Hold
© Copyright 2015, dSPACE GmbH
Low Side Driver for standard solenoids e.g. Port Injection
© Copyright 2015, dSPACE GmbH
Tula Technologies: Dynamic Skid Fire Feature
Source: DSPACE Magazine 1/2015
© Copyright 2015, dSPACE GmbH
Field Oriented Control of Brushless DC Motors
UBat
ZA+
Power stage (B6)
ZB+
Hall A
Hall B
ZC
+
Hall C
LB
LC
ZA-
ZB-
001 101 100 110 010
eRS
LA
ZC-
0°
120°
011 001 101
240°
zA+
zAzB+
GND
zB-
BLDC (Brushless Direct Current)
zC+
zC-
iA
iB
iC
20.04.2015
© Copyright 2015, dSPACE GmbH
33
ACMC Solutions for „standard“ control loops ~ > 25µs
 AC Motor Control Solution for DS5202 or MicroAutoBox with fixed FPGA code
 Control application is implemented on processor board (DS1005/1006/1007/1401) with help
of ACMC blockset
 I/O processing is implemented in FPGA
© Copyright 2015, dSPACE GmbH
34
XSG ACMC Solution for „very fast“ control loops << 25µs
(FOC)
 XSG AC Motor Control Solution for all user-programmable dSPACE FPGA platforms
 Open user-editable Simulink and XSG libraries
 Control application is implemented on FPGA (DS5203/1512/2655) with help of XSG ACMC
blockset and processor board (DS1005/1006/1007/1401/Scalexio)
© Copyright 2015, dSPACE GmbH
35
RapidPro High Current Modules: BLDC Motors
Use case: Driving brushless motors (BLDC and synchronous motors)
 Use of PS-HCHBD2/2 (DS1768) in the Electric Drive Mode (EDM)
 Two PS-HCHBD2/2 modules within a RapidPro PS unit form the inverter stage
 Output stages configurable as Two Half-Bridges or as Half-Bridge and Brake Chopper
motor phase 1
motor phase 2
motor phase 3
UBAT
brake chopper
BLDC Motor
© Copyright 2015, dSPACE GmbH
36
Important Notice
© Copyright 2015 dSPACE GmbH
All rights reserved. Written permission is required for reproduction of all or parts of this publication. The source
must be stated in any such reproduction.
This publication and the contents hereof are subject to change without notice.
Brand names or product names are trademarks or registered trademarks of their respective companies or
organizations.
© Copyright 2015 dSPACE GmbH - Subject to change without notice