Laboratory: Hardware-in-the-Loop Laboratory for Mobile Propulsion Systems

 

Since winter semester 2022/23, the Hardware-in-the-Loop Laboratory for Mobile Propulsion Systems will be offered at the Teaching and Research Area Mechatronics in Mobile Propulsion (MMP). The course is interdisciplinary and addresses students in the Master programs of General Mechanical Engineering, Automation Engineering, Automotive Engineering, Energy Engineering, Automotive Engineering and Transport, Simulation Sciences, Business Administration and Engineering (specializations: Power Engineering - Electronics and Control, Automotive Engineering) and Computational Engineering Science (CES).

 

Content

As a result of increasingly stringent emission legislation, the electrification and hybridization of vehicle propulsion systems and the associated development effort are constantly increasing. Virtualization and digitalization represent a way of addressing the increased development effort with the simultaneous demand for short development times and low development expenses. One option is the execution of hardware-in-the-loop (HiL) tests, where physical components are integrated into a real-time simulation of the modeled complete vehicle in a virtualized environment and tested flexibly.

At the beginning of this module, students are introduced into the basics to understand HiL methods. An overview of HiL systems, electrotechnical basics, automotive bus systems and real-time modeling is given. In addition, students will obtain insights into the structure and functionality of electrical drive trains. The focus is put on learning methodical competences in the field of setting up and testing on exemplary HiL test benches for a battery management system (BMS) and an electric traction machine.

In the further process of this laboratory, the learned competences will be demonstrated in small group exercises on HiL test benches. In a first step, the electrotechnical basics are elaborated in practical exercises on the HiL. Specific automotive sensor and signal types along with inputs and outputs will be explained to the students. Building on this knowledge, the HiL set-up will be extended by signal lines independently by the students. The real-time models are extended by the students and the input/output interfaces (I/Os) of the hardware are connected to the simulator. Furthermore, the students are introduced to the functionalities of BMS by the means of a HiL simulator. The control of a permanently activated synchronous machine is implemented and applied by means of a second HiL simulator for the corresponding control unit. Using a third HiL simulator for a control unit and actuators as well as sensors of an internal combustion engine, the students acquire skills for fault identification and advanced measurement techniques in a closed-loop control.

 

Topics

• HiL methods, such as the design of setups, the development of real-time simulation environments, and the execution and analysis of tests
• Classification of HiL methods in automotive SW development (V-model) and drive development (ECU calibration)
• Application fields of HiL methods in the automotive context
• Real-time modeling and simulation in HiL applications
• Electrical engineering basics and sensor and signal theory for HiL test benches
• Practical implementation and realization of test cases at the HiL
• The industry established tool chain for HiL setup and applications
• Automotive bus systems and their functionality in a control network

• Restbus Simulation of a CAN network

• Inputs and outputs (I/O) of ECUs and their simulation
• Design and functionality of electrical powertrains
• Battery modules, battery management systems (BMS) and BMS functionalities
• Control of permanently activated synchronous machines
• Basics of real-time modeling of electrical powertrain components using Field Programmable Gate Array (FPGA) programming

 

Learning Goals

Copyright: © FEV Europe GmbH

• System understanding of the entire HiL architecture
• System understanding of automotive ECUs and handling of bus communication
• System understanding of the complex interactions in HiL closed control loops
• Handling of HiL tools for setting up a test bench with real ECUs and for analyzing and evaluating test cases of real hardware components and SW
• Handling of complex system setups of HiL for conventional and electrified drives of modern vehicles
• Analysis and evaluation of results from HiL(simulation results with I/O, route and control models)
• Linkage of theory and practice

 

Teaching and Learning Methods

Copyright: © RWTH Aachen | MMP

• Preparation for for practical implementation in the laboratory through joint preliminary discussions and exercises with all groups
• Interactive individual group work with supervision for practical laboratory sessions
• Consultation hours by appointment and also shortly before the exam

 

Preliminary Discussion

• In the first preliminary meetings, the basics for the practical laboratory content are presented under the guidance of scientific staff. Subsequently, the tutors present exercises and these are carried out together.
• The preliminary meeting is divided into several blocks depending on the topics.
• It is tried to make the grouping of students for the later laboratory in the preliminary meeting. Here you have the possibility to register for the dates of the groups by giving preferences.
• Please note that we can only offer you a place in the lab if you have registered in advance and attended the preliminary meetings.

 

Small Group Exercise

• Laboratory units are offered for the implementation of the preliminary discussion contents and further intensification of practical exercises. In these units, the students of individual groups carry out the set-up work independently with the help of the laboratory supervisors.
• The laboratory takes place several times during the week. The dates for the different groups (two groups at the same time per laboratory unit) of the laboratory can be found in RWTHOnline.

 

Examination

At the end of the course, your acquired knowledge will be assessed in an oral exam. Several examination dates are offered, and you will have the opportunity to influence these dates in order to avoid any collisions with other examination dates.

 

Consultation Hours

• Details will be announced
• Starting with laboratory units
• Mail requests to:
  orga-hilma@mmp.rwth-aachen.de