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Rapid Prototyping Automotive ECUs with CompactRIO (cRIO) and PXI

Rapid Prototyping Automotive ECUs with CompactRIO (cRIO) and PXI. Carroll G. Dase President, Drivven, Inc. cRIO and PXI ECU Prototyping Platforms. CompactRIO (cRIO) Compact, rugged features 200 – 400 MHz CPUs Up to 512 Mb Flash / 128 Mb RAM 1M or 3M gate FPGA PXI Multi GHz CPUs

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Rapid Prototyping Automotive ECUs with CompactRIO (cRIO) and PXI

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  1. Rapid Prototyping Automotive ECUs with CompactRIO (cRIO) and PXI Carroll G. Dase President, Drivven, Inc.

  2. cRIO and PXI ECU Prototyping Platforms • CompactRIO (cRIO) • Compact, rugged features • 200 – 400 MHz CPUs • Up to 512 Mb Flash / 128 Mb RAM • 1M or 3M gate FPGA • PXI • Multi GHz CPUs • Multi Gb memories, large hard drives • Many I/O card types, including FPGA

  3. Why a cRIO / PXI ECU? • Full-authority engine, vehicle and test cell control within single system • Perform R&D or component testing with OEM engines • Rapidly prototype control and DAQ systems for concept engines • Using OEM ECUs for R&D or testing requires expensive / lengthy original design team support and coordination

  4. Why a cRIO / PXI ECU? • Develop experimental algorithms which OEM ECUs cannot execute • LabVIEW graphical programming environment is easy to use • Assemble unique combinations of I/O not possible with OEM ECUs • Sophisticated data acquisition synchronized with control within single hardware / software platform

  5. How is a cRIO / PXI ECU Possible? • National Instruments’ Open hardware/software architecture for cRIO I/O modules

  6. How is a cRIO / PXI ECU Possible? • Drivven’s expertise with developing research and production engine control systems

  7. How is a cRIO / PXI ECU Possible? • Drivven’s line of cRIO modules designed specifically for direct automotive sensor and actuator interface – available commercially-off-the-shelf

  8. Drivven Automotive cRIO Modules • ADCombo Module Kit: • 21-Ch. automotive-style analog inputs, 12-bit, 4 kS/s per channel • 2-Ch. VR sensor inputs, 200mV – 150V • 2-Ch. Hall-effect sensor inputs • VR/Hall Module Kit • 6-Ch. VR or Hall-effect sensor inputs • Individually software selectable as VR or Hall

  9. Drivven Automotive cRIO Modules • Port Fuel Injector Driver Module Kit • 4-Ch. Low/high impedance port fuel injector drivers • 4-Ch. General purpose solenoid drivers (0-100% duty cycle) • Short/open circuit diagnostics and protection • Spark Driver Module Kit • 8-Ch. Inductive ignition coil drivers • Short circuit and thermal protection

  10. Drivven Automotive cRIO Modules • GDI / Common Rail Diesel Injector Driver Module Kit • Internal boost power supply up to 150 V • 3-Ch., configurable peak (30 A) / hold (12 A) injector drivers • Short/open circuit diagnostics and thermal protection • Electronic Throttle Driver Module Kit • 2-Ch., Electronic throttle drivers • Short circuit and thermal protection

  11. Drivven Automotive cRIO Modules • O2 Sensor Module Kit • 2-Ch. wide-band Bosch LSU-4.2 oxygen sensor controllers • 4-Ch. narrow-band Oxygen sensor inputs • Sensor diagnostics and short circuit protection • Add custom calibration for specialized fuels • Low Side Driver Module Kit • 8-Ch. General purpose solenoid drivers (0-100% duty cycle) • Short/open circuit diagnostics and protection • Software option for 0-2A solenoid current control

  12. Drivven EPT VIs • Engine Position Tracking (EPT) VIs • Track angular position of crankshaft to sub-degree resolution • Supports most common trigger patterns in the industry • N-M (example: 60-2) • Plus 1 (example: 6+1) • Encoder (example 360 count optical encoder) • Chrysler 36-4 • Use to internally simulate crank/cam patterns for easy bench testing during application development • Drivven can quickly develop EPT for custom patterns

  13. Using Drivven Products • Common interface between EPT VIs and engine-synchronous output module kits • Module FPGA and RT software handles precise timing of fuel/spark outputs so that researchers only program in terms of engineering units (msec, crank-angle degrees, frequency, duty cycle, etc.)

  14. Using Drivven Products • Growing engine control application template base • Open source LabVIEW applications • Open source engine control algorithms • Develop custom engine control application in days, not months • Turn-key solutions, so powertrain engineers can focus on their research without getting side-tracked by efforts to get an engine under control

  15. Drivven Online

  16. Drivven Online

  17. Where to Start? • Determine control / DAQ requirements and select: • CompactRIO? • PXI? • Gather engine I/O requirements • Crank/cam sensors, pressure sensors, thermistors, switches, potentiometers, battery-level voltages, O2, etc. • Fuel injectors, ignition coils, pressure regulator, EGR valve, throttle, wastegate, etc.

  18. Where to Start? • Does baseline calibration data exist for this engine? If not… • OEM ECU mapping is possible with Drivven / NI products • Collect and analyze data (Drivven has examples) • Format data for control use (Drivven has example) • Wiring harness – OEM or custom? • Spare OEM ECUs are handy for harness connection points • Wiring and connector decisions play big role in project success

  19. Examples • CompactRIO installation example

  20. Examples • Yamaha YZFR6 Wiring Example

  21. Examples • John Deere lean, split-engine control strategy

  22. Examples • Turbo-charged motorcycle development for Formula SAE

  23. Building the Control Application • This is where the Powerpoint portion of the presentation ends and the application exploration begins • From here, there will be only place holder slides describing the topics of discussion • We will browse the application VIs and discuss the steps involved with building an application from scratch

  24. Building the Control Application • Project Explorer • Create cRIO target and FPGA target • Add generic cRIO modules • Add FPGA I/O • Add blank top level FPGA and RT VIs

  25. Building the Control Application • Drivven product directories

  26. Building the Control Application • LabVIEW FPGA VI • Single Cycle Loop

  27. Building the Control Application • LabVIEW FPGA VI • Cluster interfaces

  28. Building the Control Application • LabVIEW RT VI • Top level layout • Outer Flat Sequence Structure • Calibration loading/saving • Timed Loop • Inner Flat Sequence Structure • Use of local variables • Hierarchical design

  29. Building the Control Application • LabVIEW RT VI • Reading Inputs • Making engineering units from FPGA data

  30. Building the Control Application • LabVIEW RT VI • Performing engine calculations • Open source algorithms from Drivven

  31. Building the Control Application • LabVIEW RT VI • Writing Outputs • Converting engineering units to FPGA data

  32. Building the Control Application • Calibration Display • Drivven’s CalVIEW

  33. Building the Control Application • Run engine control demo

  34. Q & A

  35. Contact Drivven for Full Authority ECU Prototyping Drivven, Inc. San Antonio, Texas www.drivven.com info@drivven.com +1 970.212.3366

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