The SCALEXIO rack system is very flexible due to extensive I/O features. All hardware is software-configurable, making it easy to adapt the system to changing project requirements.
One for All
HIL simulator for a wide range of applications
Full Flexibility
Comprehensive, software configurable I/O functions and connection of real loads
All Inclusive
Integrated Failure Insertion Unit & Signal Conditioning
Compact full-featured HIL Testing System
Pre-configured for typical automotive applications - ready to use
What is the SCALEXIO Rack?
The SCALEXIO rack system is a 19'' off-the-shelf HIL simulator available in up to 12 height units. The system already includes pre-configured hardware for typical automotive applications, e.g., engine or vehicle dynamics.
Typical Application Areas
- Autonomous driving
- Electric motor simulation for hybrid and electric powertrains
- Engine, powertrain, chassis
- Truck applications
- Racing applications
Key Benefits
- Can be equipped with boards providing onboard signal conditioning and integrated fault simulation, thus making it ideal for ECU testing.
- Wide range of SCALEXIO boards available, such as SCALEXIO I/O boards, FPGA subsystems, MultiCompact units, and HighFlex boards
- Easy to adapt to changing project requirements thanks to software-configurable hardware
Working with the SCALEXIO Rack System
Typically a SCALEXIO Rack System is equipped with a SCALEXIO Processing Unit, a DS2680 I/O Unit, a HighFlex I/O board, and a power supply. With this minimal configuration the system is suitable equipped for a wide range of standard applications.
- SCALEXIO HighFlex Boards provide very flexible, finely scalable channels that are each galvanically isolated and configurable per software.
- The SCALEXIO MultiCompact I/O Unit offers a high number of I/O channels resutling in a low cost per channel.
- Software for configuration the system and controlling the simulation round off the installation.
SCALEXIO HighFlex and MultiCompact Boards - What are the differences?
- The SCALEXIO HighFlex boards are I/O boards with flexible I/O channels, integrated signal conditioning and onboard Failure Insertion Unit, e.g., for ECU HIL tests requiring the simulation of electrical failures
- The SCALEXIO MultiCompact Unit (DS2680 and DS2690) are boards with a high number of I/O channels as well as integrated signal conditioning and onboard Failure Insertion Unit, e.g. for powertrain and vehicle dynamics scenarios
Variants & Technical Details
Programmable Power Supplies
The programmable power supply unit feeds the components to be tested and allows for simulating real voltages, such as the vehicle battery voltage during start-up. The power supply unit is remotely controlled from the real-time model.
Various power supplies are available for different applications, for example:
- 0 ... 20 V
- 0 ... 60 V
Fault Simulation
For fault simulation, the SCALEXIO rack system provides I/O boards with integrated fault simulation, namely the HighFlex boards (DS2601, DS2621, DS2642, and DS2671) and MultiCompact I/O Units (DS2680 and DS2690).
Technical Details
| Parameters | Specification |
|---|---|
| General |
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| Connecting with other systems |
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| Ambient temperature |
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| Operating humidity |
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| Size |
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| Mass |
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| Internal power supply1) |
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| Power supply for external devices1) |
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1) Without a SCALEXIO Processing Unit
Fault Simulation
Hardware Components
The SCALEXIO Failure Insertion Unit (FIU) consists of several components:
- An onboard failure routing unit (FRU) on the I/O channels prepares fault simulation by switching the I/O channels to failrails. The FRU is available for each channel on the MultiCompact and HighFlex boards and uses relays to provide the features of the central failure simulation unit to each channel.
- Depending on their properties, the channels are connected to the failure simulation system by the high-current (up to 80 A) or the low-capacitance (up to 1 A) failrail. The low-capacitance failrail for an optimized signal quality connects signal generation channels and bus channels to the central FIU. The high-current failrail connects signal measurement channels to the central FIU.
- The central FIU is located on either the DS2642 FIU & Power Switch Board or the DS2680 I/O Unit. The central FIU uses semiconductor switches for switching the faults. It switches very fast, which makes it possible to simulate loose contacts or insert faults for a very precise duration.
- The failrail segment switch is used to switch selected segments into the failrails for fault simulation. This way, the conducting capacity can be minimized to avoid signal corruption, even for large simulation systems that have a high number of inputs/outputs or that are distributed across several cabinets.
| Fault Type | Fault on Single Signals | Fault on Several Signals |
|---|---|---|
| Open circuit | 1 channel | All channels1) |
| Short circuit to ground or UBAT | 1 channel | Up to 10 channels1) 2) |
| Short between channels | 2 channels | Up to 10 channels1) 2) |
| Fault with pulsed switching | Yes | No |
1) Requires the option “Activation by FRU relay” and is only possible on I/O channels without current enhancement.
2) Depending on the ampacity of the failrail.
License Concept
The SCALEXIO HighFlex and MultiCompact boards include a fault simulation (FS) function. You need an additional FS license to activate the fault simulation. The FS license will be checked at the host PC. Each license can be used for one SCALEXIO system. The licenses are scaled for fault simulation with different numbers of I/O channels capable of fault simulations. The fault simulation is configured in ConfigurationDesk, so you need the appropriate SCALEXIO Failure Simulation license for the number of I/O functions that are mapped to channels with an FRU that you use in your real-time application. The FS license is needed only for running the simulation, not for configuring the I/O channels with ConfigurationDesk.
Tracing FIU States
The diagnostic functions of ECUs have to detect each fault within a specified time. To help test an ECU’s diagnostic functions, SCALEXIO provides FIU state tracing. This enables you to measure or plot FIU states and therefore to monitor the time from a change in FIU state to any other event, such as the detection of the fault.
Faults on Multiple Signals
SCALEXIO supports the simultaneous insertion of multiple faults during simulation to allow fault classes such as broken wire, short circuit to ground or UBAT, or short between channels. This function can be enabled in ConfigurationDesk for channels without current enhancement.
Overview
| Feature | SCALEXIO FIU |
|---|---|
| General | Integrated with SCALEXIO MultiCompact I/O units and HighFlex boards |
| I/O boards with integrated FIU |
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| Number of cards per simulator | Via the I/O boards |
| Number of channels per card | Depends on I/O board |
| Switch type |
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| Central modules |
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| Max. continuous current | Up to 80 A (depends on I/O board) |
| Possible fault types | SCALEXIO FIU |
|---|---|
| Broken wire | Included |
| Short circuit to ground | Up to 10 channels |
| Short circuit to battery voltage | Up to 10 channels |
| Short circuit to another ECU pin via common failrail | Up to 10 channels |
| Broken wire with additional hardware (Rsim, Meas or Source) in series | Not available |
| Short circuit to another ECU pin via additional hardware (Rsim, Meas or Source) | Not available |
| Short circuit to 5 reference points (potential 0 ... 4) directly or via additional hardware (Rsim, Meas or Source) | Not available |
