Optimizing e-Drive ECU Testing with Comprehensive Turnkey HIL Solutions
Typhoon HIL, Inc.
Engineer and promote environmentally sustainable power technologies that scale.
In the fast-evolving world of e-Drive ECU testing for electrified vehicles, comprehensive turnkey HIL solutions are key to optimizing performance and ensuring system reliability. Through expert panel discussions, live demos, and an interactive Q&A session, Typhoon HIL's recent webinar shed light on the challenges and innovations in this space. Discover more about how these e-Drive HIL testing solutions can enhance your testing capabilities in this blog article.
Webinar Overview?| Introduction to e-Drive ECU Testing
In a recent webinar hosted by Typhoon HIL, the experts behind the e-Drive HIL Testbed gathered to discuss the evolving landscape of e-Drive ECU testing. The webinar, titled Optimizing e-Drive ECU Testing: Comprehensive Turnkey HIL Solutions, offered a deep dive into the challenges, motivations, and solutions shaping the future of ECU testing. The session covered a broad range of topics, including hardware and software demos, a panel discussion, and a valuable Q&A session, all aimed at a deep dive into optimizing e-Drive ECU testing.?
Moderated by Dovlyn Curtis, Global Marketing Director at Typhoon HIL, the webinar featured key insights from experts in the field, each contributing to different aspects of the discussion. Below, you can find the breakdown of the key segments from the webinar.?
Introduction | Understanding the Challenges and Motivations Behind e-Drive ECU Testing?
The first segment of the webinar featured a panel discussion led by Boris Jovanovic, Global Business Development Manager for e-Mobility, and Petar Gartner, Director of HIL Solutions at Typhoon HIL. They addressed the key challenges currently facing the automotive industry, particularly in the context of electric drives.?
The panelists emphasized the growing complexity of ECUs in modern vehicles and the necessity for more comprehensive testing approaches. With the rise of e-Mobility, the industry faces increased pressure to develop efficient and reliable systems, which makes Hardware-in-the-Loop (HIL) testing an essential solution. HIL simulations allow for testing under real-world conditions without risking hardware failure, saving both time and cost during development.?
Boris highlighted the importance of integration and customization in HIL systems, pointing out how turnkey solutions can significantly speed up the development process. Petar added that proper testing setups can identify critical performance issues early, preventing costly recalls and ensuring safety standards are met.?
Hardware Demo | Exploring the Hardware Side?
Next, the webinar shifted focus to the practical side of ECU testing with a live hardware demonstration led by Marko Marceta, Hardware Engineer at Typhoon HIL. This segment illustrated how a well-designed hardware setup can facilitate efficient and accurate testing of e-Drive ECUs.?
Marko provided a step-by-step walkthrough of the testing setup (see Fig. 1-3), showcasing how Typhoon HIL’s hardware seamlessly integrates with automotive ECUs to simulate a wide range of driving conditions. One key takeaway from this segment was the adaptability of the hardware for various types of ECUs, regardless of vehicle specifications. This adaptability ensures that the testing environment closely mirrors the actual conditions the ECU will experience in the vehicle, enhancing the reliability of the tests.?
This demonstration also highlighted the hardware setup optimization to perform rigid testing according to ISO26262 ASIL-D level requirements. The complete bench along with proper Temperature Emulation, Hardware Fault Insertion, and Rack Protection was on display for detailed review.?
Software Demo | Ensuring Efficiency Through HIL Testing?
Following the hardware demo, Jovan Zelic, Senior Modeling Engineer at Typhoon HIL, took the stage to showcase the software side of the HIL testing process. You can see the demonstrated model overview in Fig. 4. His demonstration underscored the critical role of Typhoon HIL’s vertically integrated software platform highlighting the ease of use from the modelling perspective as well as ultra-high fidelity implementations of a variety of machine and converter types.?
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Jovan began by outlining the basic structure of the traction inverter model with a PMSM. He demonstrated appropriate model parameterization, including the import and visualization of nonlinear machine parameters. The creation of the mechanical and thermal parts of the model was covered (see Fig. 5), along with the configuration of the CAN communication protocol used to establish communication between the HIL device and the ECU under test. The model creation concluded with an emphasis on the single-click compilation process, which enables the deployment of the designed model in a real-time simulation in under a minute. A real-time simulation time step of 300 ns was used.?
Once the model was compiled, manual and semi-automated testing was demonstrated using HIL SCADA (see Fig. 6-7). Easy confirmation of various ECU measurements was shown by comparing the ECU data, obtained via CAN, with the simulation data. Various simulation scenarios were conducted, including torque setpoint stepping and machine speed ramping up to 25,000 RPM. The demo was concluded with the physical fault insertion on one of the channels, with the ECU responding appropriately to the detected fault.?
Q&A Session | Closing Remarks?
The webinar concluded with closing remarks and an engaging Q&A session, where attendees had the opportunity to ask questions directly to the panelists. The Q&A covered a wide range of topics, from specific technical queries to broader questions about the future of HIL testing in the automotive industry.?
One of the key takeaways from the Q&A was the growing demand for flexible, scalable solutions that can adapt to the rapid pace of innovation in vehicle electrification, specifically tailored for testing the aspects of the vehicle that are related to power electronics components. The panelists emphasized that as vehicles become more advanced, the need for reliable and efficient testing methods will only increase.?
In their closing remarks, the panelists emphasized how Typhoon HIL’s turnkey solutions stand out by being specifically tailored for power electronics. These solutions offer high performance, seamless integration, and ease of use, addressing the unique challenges of testing complex automotive systems. By optimizing the testing process, Typhoon HIL enables engineers to efficiently validate e-Drive ECUs, ensuring reliability and safety in real-world applications.?
Conclusion | The Power of the e-Drive HIL Testbed?
This webinar highlighted the critical role of HIL testing in the development of modern automotive systems, particularly in the realm of e-Drive ECU testing. By combining cutting-edge hardware with a powerful software toolchain, Typhoon HIL offers a comprehensive, turnkey solution for engineers looking to optimize their testing processes.?
The panel discussions, live demos, and Q&A session provided valuable insights into the challenges and solutions in the industry today. As the e-Mobility sector continues to grow, so does the role of power electronics control testing. HIL testing will remain a cornerstone of innovation, ensuring that new technologies across various applications meet the rigorous demands of real-world reliability and safety. With vehicle electrification, HIL solutions for power electronics testing are proving to be an essential component within the vehicle development cycle.?
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