Once the ECU functions are implemented on the production ECU, they have to be tested in realistic scenarios. This can be done by means of hardware-in-the-loop (HIL) simulation, which simulates the ECU’s environment (interacting components or even a whole system). With HIL simulation, you can easily cover all the different motor varieties and their ECUs.
For realistic battery management controller tests, dSPACE offers the HIL simulator system SCALEXIO and special hardware and software for battery simulation, such as
real-time hardware for HIL tests with high-voltage accuracy and galvanic isolation or simulation models for lithium-ion batteries and nickel-metal hydride batteries. For the real-time simulation of electric drive systems, dSPACE provides FPGA-based I/O for capturing the gate driver signals and simulating the motor current. Combined with simulation models, e.g., the ASM Electric Components Library for processor-based simulation and the XSG Electric Components Library for FPGA-based simulation, you can build a powerful HIL test system. With the new Electrical Power Systems Simulation Package, the simulation models for processors and FPGAs can simply be generated directly from the circuit topology. dSPACE systems cover applications from rectifiers and inverters for closed-loop simulation with an electric drive controller, to DC/DC converters, to wind/solar energy converters.
Simulating the ECU environment (interacting components or even a whole system) has several advantages:
ECUs and other systems for controlling electric motors can be accessed by the HIL simulator at different levels. Which interface to use depends on the testing purpose and project conditions: