The dSPACE SCALEXIO customized system offers a comprehensive range of adaption and configuration options to meet customer-specific requirements.
Highly Flexible and Customizable
HIL system adapted to customer-specific applications and requirements
Wide Application Range
Scalable from single ECU up to turn-key integration testing
Outstanding Performance
Ideal for the most comprehensive HIL simulation models
Perfect Communication
Comprehensive support of automotive bus/network protocols
Standard-compliant testing
Fail-safe and fail-operational testing (LV123) with integration of real loads
What is SCALEXIO Customized System?
The dSPACE SCALEXIO customized system is a highly versatile hardware-in-the-loop simulator that offers a comprehensive range of adaption and configuration options to meet customer-specific requirements. It is scalable from small to large systems and can be used flexibly from components testing to simulating complete virtual vehicles.
Typical Application Areas
- Autonomous driving
- Electromobility
- Engine, powertrain, chassis, and body
- Truck applications (24 V/36 V)
- Racing applications (Formula One, Rally)
- Mechanical test benches
- Comprehensive closed-loop testing on ECUs, release/acceptance tests
- Networked ECUs
Key Benefits
- Highly scalable, modular rack concept that is flexible and open enough to meet any of your requirements
- The I/O hardware offers extensive I/O features and is largely software-configurable, which facilitates adapting the system to changing project requirements.
- The system is fully commissioned, documented, quality-assured and put into operation directly at the customer’s site.
- Adaptations and extensions are possible whenever required.
Working with the SCALEXIO Customized System
When you order a SCALEXIO Customized System it is tailored to your specific project requirements. This includes not only the exact I/O and bus and network interfaces you need, but also special requests such as safety doors or connectors, or individual dimensions.
dSPACE delivers a ready-to-use turnkey systems and supports you by integrating into your test process if needed.
Variants & Technical Details
Comprehensive Customization Options
- Maximum flexibility thanks to a modular concept
- Minimal hardware modifications needed if requirements change
- All signals accessible on terminal stripes for additional measurement tasks and for a flexible response to changing specifications
- Clear and transparent system architecture
- Multirack systems possible
Flexible, Modular Hardware
- Single-processor or multiprocessor system for high computation requirements
- Freely expandable with any SCALEXIO board according to project needs
- Expandable, e.g., with hardware for fault insertion and load simulation (customer-specific configuration)
- Expandable, e.g., with flexible FPGA boards
Signal Conditioning
- Signal conditioning included with SCALEXIO MultiCompact I/O and SCALEXIO HighFlex hardware
- Support of almost any signal type, e.g., digital in/out, analog in/out, relay simulation, current sink/source, LVT simulation, resistance simulation, and linear lambda probe simulation
- Additional modules on request
Simulation of Linear Lambda Probes
LSU (Lambda Sonde Universal, universal lambda probe) is a signal conditioning module that simulates the behavior of linear lambda probes. These probes measure the air-fuel ratio in a car’s exhaust system. The engine ECU reacts by varying the injection time, so the catalytic converter can operate at an optimal performance rate.
The LSU module allows for generating Nernst cell voltage on four independent channels based on pump current and Nernst cell inner resistance. The module functions as a linear probe or as a jump probe. Parameters such as maximum/minimum Nernst cell voltage can be adjusted.
Load Capabilities
- Modular load concept with customer-specific configuration
- Support of single-ended and double-ended loads
- Resistive loads or other kinds of equivalent loads
- Connection of electrically equivalent loads or low-power resistive loads
- Connection of real loads, optional rack integration
- Integration of customer's load panels
- High-speed electronic loads, e.g., simulation of electric machines
- Connection to high-voltage emulation systems and test benches
Programmable Power Supplies
The programmable power supply unit feeds the components to be tested and allows for simulating real voltages such as a vehicle’s battery voltage during start-up. The power supply unit is remotely controlled from within the real-time model.
Various power supplies are available for different applications, for example:
- 0 ... 20 V
- 0 ... 60 V
Coupling Options
To increase your computational power and available I/O interfaces, you can interconnect as many SCALEXIO customized systems as needed. If the project requirements change, you can easily adapt your testing system. Coupling SCALEXIO systems is done via IOCNET.
All software for configuring the system and controlling the simulation or test automation runs on a host PC. The PC is connected via Ethernet with the SCALEXIO system.
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).
Fault Simulation
Additional Fault Insertion Units for Customized Systems
For the customized system, additional types of fault simulation are available in addition to SCALEXIO Fault Simulation. This enables you to tailor the system to your project-specific requirements. The fault simulation for customized systems can be remotely controlled with the ControlDesk Failure Simulation Module or, optionally, with AutomationDesk.
Fault Simulation Variant 1
Variant 1 for fault simulation on SCALEXIO supports fault simulation on all ECU input and output pins. All digital and analog I/O boards from dSPACE can be used for fault simulation. The relay boards (DS291) for fault simulation can be used on their own for fault simulation on sensor signals (ECU inputs) or in conjunction with load boards (DS281) on actuator signals (ECU outputs). Fault relays are controlled via a serial RS232.
Fault Simulation Variant 2
The second fault simulation variant uses a central relay switching matrix (DS293) for fault simulation on ECU inputs and outputs. Five different system potentials (for example, Terminal 30, Terminal 31, Terminal 15) can be switched on three different rails via load modules (DS282). Further devices that can be connected, including various measurement devices (Meas0-4), an electronic source (Source), and Rsim modules for transition impedance. Fault simulation is controlled via a CAN interface.
High-Current Fault Simulation
The high-current fault simulation unit on SCALEXIO supports fault simulation on ECU inputs and outputs. One FIU controller card (DS5355) supports up to 19 signal channels on two high-current FIU relay trays (DS5390). Due to its modularity, the FIU controller card can be expanded to increase the number of channels. These relay trays allow for faults with currents up to 40 A. The FIU is controlled from ControlDesk via a serial RS232.
Customized Interfaces to Diagnostic and Calibration Hardware
Many companies already have their own diagnostic and calibration hardware to perform tasks such as reading out internal ECU variables from the fault memory. If you want to use your own diagnostic and calibration hardware, a special interface for SCALEXIO is needed, which, in some cases, might require engineering. You can connect any kind of measuring device, digital scope, and diagnostic device you like with special protocols such as GPIB or RS232.
Real System Components
In some cases, the real system components (such as injection valves, hydraulic components, and sensors) have to be integrated into SCALEXIO. This is necessary, for example, if components for the same ECU are provided by different suppliers and have to be checked together with the ECU within the simulated environment. Moreover, not every vehicle component can be simulated accurately enough with a justifiable amount of time and money. Some ECUs require real loads at their outputs to function.
Other Hardware Components
- Optional inclusion of third-party hardware, e.g., load panels, signal routing units, GPIB instruments
- Power switch modules
CAN Gateway
In large-scale CAN networks, testing bus communication plays a key role. Engineers need to test the behavior of ECUs and distributed functions if an expected CAN message fails to arrive or contains unexpected signals. To simulate faults, a CAN gateway module is inserted into the CAN network (see illustration). Each ECU can be connected individually to one of the two CAN controllers in the dSPACE Simulator. Signal manipulation via software allows you to change any CAN messages from any ECU to achieve a predefined effect on the other ECUs in the CAN network. The CAN software (dSPACE Bus Manager) offers a wide range of typical error situations right up to the message or individual signal level.
Overview
| Feature | SCALEXIO FIU | SCALEXIO Customized Rack Systems Variant 1 | SCALEXIO Customized Rack Systems Variant 2 | SCALEXIO Customized Rack Systems High-Current |
|---|---|---|---|---|
| General | Integrated with SCALEXIO MultiCompact I/O units and HighFlex boards |
|
|
|
| I/O boards with integrated FIU |
|
DS291 | DS282 | DS5355/DS5390 |
| Number of cards per simulator | Via the I/O boards | Configurable | Configurable | Configurable |
| Number of channels per card | Depends on I/O board | 10 | 10 | Up to 10 |
| Switch type |
|
Relay | Relay | Relay |
| Central modules |
|
- | 1 x DS293 | - |
| Max. continuous current | Up to 80 A (depends on I/O board) | 8 A | 8 A | 40 A |
| Possible fault types | SCALEXIO FIU | SCALEXIO Customized Rack Systems Variant 1 | SCALEXIO Customized Rack Systems Variant 2 | SCALEXIO Customized Rack Systems High-Current |
|---|---|---|---|---|
| Broken wire | Included | Included | Included | Included |
| Short circuit to ground | Up to 10 channels | Included | Included | Included |
| Short circuit to battery voltage | Up to 10 channels | Included | Included | Included |
| Short circuit to another ECU pin via common failrail | Up to 10 channels | Included | Included | Included |
| Broken wire with additional hardware (Rsim, Meas or Source) in series | Not available | Not available | Included | Not available |
| Short circuit to another ECU pin via additional hardware (Rsim, Meas or Source) | Not available | Not available | Included | Not available |
| Short circuit to 5 reference points (potential 0 ... 4) directly or via additional hardware (Rsim, Meas or Source) | Not available | Not available | Included | Not available |
