DSPACE Power-Electronis and Electric-Drives 2016 English1

www.dspace.
com
Power Electronics and

Electric Drive Technology
Developing, implementing, and testing electronic control units
Power Electronics and Electric Drive Technology
Introduction ____________________________________________________________ 3
dSPACE Tool Chain for Electric Drives
Controller Design and Rapid Control Prototyping _________________________ 4
Controller Implementation and Production Code Generation _______________ 5
Controller Tests and Hardware-in-the-Loop Simulation ____________________ 6
Use Case Overview _________________________________________________________ 8
Use Cases for the Automotive Industry
Vehicle Traction
RCP System for Hybrid or Fully Electric Powertrains _________________ 9
HIL Simulation for Vehicle Traction Motors ________________________ 12
Vehicle Auxiliary
Rapid Control Prototyping for Small Electric Motors ________________ 15
HIL Systems for Emulating Small Electric Motors ___________________ 18
Battery Management System
Measuring and Balancing Lithium-Ion Cell Stack Voltages ___________ 20
HIL Tests for Battery Management Systems _______________________ 22
Production Code Generation for Battery Management Systems ______ 25
Hybrid Controllers
Developing Controller Software with RCP Systems _________________ 27
HIL Simulation of Hybrid Control Units ___________________________ 29
Vehicle DC/DC Converters
RCP Systems for DC/DC Controllers ______________________________ 32
HIL Tests for DC/DC Converters _________________________________ 34
Test Bench
Developing and Testing Mechatronic Systems _____________________ 37
Use Cases for Industrial Applications
Industrial Drive Control
RCP Tests for Industrial Drive Controllers __________________________ 41
HIL Simulation for Industrial Drive Controllers _____________________ 43
Use Case for Robotics
RCP Systems for Robotic Motion Controllers _____________________________ 46
Use Case for Railway Technology
HIL Tests for the Power Equipment of Electric Trains _______________________ 47
Use Case for the Electric Power Industry
HIL Simulation of Power Supply Systems ________________________________ 50
General Products __________________________________________________________ 52
Electric-Drive-Specific Products _______________________________________________ 55
Index ____________________________________________________________ 60
Introduction
Power Electronics and Electric Drive Technology

Developing, implementing, and testing electronic control units
Why Electric Drives? Requirements

Electric drives offer many advantages and have a wide- All the advantages of electric drives also come with specific
ranging application potential, so it is only natural that their requirements for the development and test process.
use has increased during the last years. Electric motors can As electric drives provide high dynamics, the same is needed
be very small and fit almost anywhere. They have very high for the prototyping systems used to validate and run the
dynamics and provide high torques at low rotational speeds. controller in the real environment and for the test system
Other advantages include improved energy savings due to that verifies the correct behavior of the final production ECU.
power-on-demand functionality, better controllability, and Some of the resulting challenges are short simulation step
easier maintenance. sizes, the simulation of sensor input, and the synchroniza-
All this combined with the increasingly strict regulations tion with pulse width modulation (PWM).
regarding emission standards for automotive applications
will further boost the use of electric drives.
Why dSPACE?
With decades of experience, dSPACE knows about the Sophisticated software supports the transition from the first
special requirements of electric drives and offers a com- function model in Simulink® to comprehensive real-time
prehensive tool chain for rapid control prototyping (RCP), tests. dSPACE hardware and software together provide a
ECU autocoding, and hardware-in-the-loop (HIL) simula- seamless tool chain whose individual parts are finely tuned
tion. The dSPACE products work together seamlessly to to each other.
provide a convenient development and test environment. dSPACE supports customers worldwide from the first control-
They benefit from hardware such as powerful real-time ler development to the last approval tests. Throughout the
processors, user-programmable FPGAs, and comprehensive development process, dSPACE Engineering Services provide
I/O interfaces. dSPACE also offers dedicated function librar- assistance for even the most challenging projects. All this to
ies for data processing and for controller or plant models. provide the greatest flexibility at the highest convenience.
Project Experience
dSPACE has successfully completed turn-key projects in Power windows

all kinds of application areas from the automotive indus- Auxiliary aggregates: oil pumps, water pumps, etc.

try, to transportation, renewable energies and the capital Wind energy and photovoltaic energy converters

goods industry, to medical engineering and the aerospace Electric trains

industry. The projects cover topics such as Printing machines

Electric steering and brake systems Roller mills for cold and warm roll forming

Powertrain and traction actuators Zinc coating plant (headway and drive control)

Starter-generator systems Artificial respirators

Electric vehicles and mild/full hybrid systems Magnetic resonance tomography

Hydrogen vehicles Bipedal walking robot and other robots

DC/DC converters Smart grid controllers

AC and DC chargers 3
2016
dSPACE Tool Chain for Electric Drives
dSPACE offers a complete and integrated tool environ- just in individual project phases. dSPACE systems support
ment for the development of embedded control software established development processes, particularly for embed-
and systems. The tools and systems are convenient to use ded control unit development, help you meet functional
and will save you valuable development time and money, safety requirements, and give you ways to adapt your pro-
whether you apply them throughout the entire process or cess chains to new challenges.
Controller Design and Rapid Control Prototyping

The increasing popularity of electric motors entails a higher New controller functions are typically developed on the basis
effort for developing, validating and implementing the re- of models in MATLAB®/Simulink®/Stateflow®.
quired control algorithms. This additional workload can be The dSPACE RCP systems make the new control algorithm
minimized by using model-based design along with rapid tangible and let you optimize and test new control strate-
control prototyping (RCP) to accelerate design iterations of gies in a real environment quickly and without barriers. This
the control algorithm on the real ECU. helps you detect design faults and correct them immediately.
I/O implementation
MATLAB®/Simulink®, XSG and configuration
Controller design
Fast iteration
Real-Time
Real-time RCP system Interface (RTI)
ControlDesk®
Monitoring Build and

Real plant and testing download
Development process with rapid control prototyping.
4
2016
Introduction
Fast Iterations – Maximum Freedom

dSPACE offers a wide range of off-the-shelf software and With the dSPACE implementation software Real-Time
hardware components for in-vehicle use (e.g., the modular Interface (RTI), models designed with MATLAB/Simulink/
AutoBox and compact MicroAutoBox II) and laboratory Stateflow can be implemented on the dSPACE RCP hard-
or test bench use (e.g., the modular Expansion Box and ware at the click of a button. The graphical RTI block library
compact MicroLabBox®). Since the RCP hardware is far with numerous interface functions lets you connect inputs
more powerful than actual production ECUs with regard to and outputs to the model. With the dSPACE experiment
processing power and memory space, almost no hardware software ControlDesk®, you can use graphical instruments
limitations have to be considered. The RCP hardware can be to optimize the control algorithm by monitoring and tun-
used as an ECU substitute or extension of an existing ECU, ing variables during run time. If the function of the control
e.g., if you have to adapt only parts of the ECU functionality. algorithm itself has to be modified during the tests, you can
To connect RCP systems to an existing ECU, dSPACE offers simply correct it in Simulink and flash it to the hardware
a comprehensive ECU interface tool environment (e.g., ECU again until all requirements are met. The perfect interaction
Interface Manager, DCI-GSI2). of dSPACE hardware and software provides a convenient
development and test environment.
Controller Implementation and Production Code Generation

Once the new functions are developed and tested thor- Highly Efficient, Highly Configurable Code
oughly, they need to be implemented on the target ECU. TargetLink was specifically designed for production-quality
This means generating production code from the MATLAB®/ autocoding. The highly efficient code it produces has two
Simulink®/Stateflow® model while taking into account the major benefits:
specific ECU's characteristics, such as memory and comput- A low impact on the RAM/ROM/stack memory
ing power. Short worst-case execution times (WCET)
dSPACE’s production code generator, TargetLink®, gener-
ates highly efficient C code straight from MATLAB/Simulink/
Resource Consumption
Stateflow and allows for early verification through built-in TargetLink®
code
simulation and testing. This drastically reduces the time
Handwritten code
needed for implementation and achieves systematic consis- 100%
tency between the specifications and the production code.

Changes at the model level are quickly transferred to the
code.
ROM RAM Execution time
Source: European Automotive Tier 1 Internal Study
Source: Evaluation of Automatic Code Generation Tools,
Department of Automatic Control, Lund University
The TargetLink code easily matches the efficiency of human pro-

grammers in terms of memory consumption and execution speed –
without compromising readability.
5
2016
Introduction
TargetLink Features at a Glance Support of modular, component-based development

Production code generation directly from Simulink®/ Efficient data management with the TargetLink Data

Stateflow Dictionary
Highly efficient fixed-point and floating-point code High-performance, native AUTOSAR support

Comprehensive fixed-point support including Certified for ISO 26262, IEC 61508, and derived

autoscaling standards
Powerful software design and testing features TargetLink Ecosystem – powerful tool chain for model-

Direct verification by MIL/SIL/PIL simulation with based development extended by complementary tools
integrated data logging and plotting and services from third-party providers
Modeling the control algorithm Embedded

system
Adding software specifications

for software unit design
Integrating
.c and deploy-
Simulink®/ ing code
TargetLink® model
Generating Building
.c code .c target
Model-in-the-loop simulation Software-in-the-loop simulation Processor-in-the-loop simulation

on host PC on host PC on evaluation board
 Checking the control algorithm  Simulating the generated code  Testing and verifying the code on
 Logging and plotting signals  Checking software structure the target platform Typical development process
and behavior  Profiling the RAM/ROM stack
for production code generation
and execution time
with TargetLink.
Controller Tests and Hardware-in-the-Loop Simulation

Once the ECU functions are implemented on the production simulating the motor current. Combined with simulation
ECU, they have to be tested in realistic scenarios. This can models, e.g., the ASM Electric Components Library for
be done by means of hardware-in-the-loop (HIL) simulation, processor-based simulation and the XSG Electric Compo-
which simulates the ECU’s environment (interacting components Library for FPGA-based simulation, you can build a
nents or even a whole system). With HIL simulation, you can powerful HIL test system. With the new Electrical Power
easily cover all the different motor varieties and their ECUs. Systems Simulation Package, the simulation models for
For realistic battery management controller tests, dSPACE processors and FPGAs can simply be generated directly from
offers the HIL simulator system SCALEXIO® and special the circuit topology. dSPACE systems cover applications from
hardware and software for battery simulation, such as rectifiers and inverters for closed-loop simulation with an
real-time hardware for HIL tests with high-voltage accuracy electric drive controller, to DC/DC converters, to wind/solar
and galvanic isolation or simulation models for lithium-ion energy converters.
batteries and nickel-metal hydride batteries. For the real-
time simulation of electric drive systems, dSPACE provides Simulating the ECU’s environment (interacting components
FPGA-based I/O for capturing the gate driver signals and or even a whole system) has several advantages:
6
2016
Introduction
Function tests are possible at an early development

Failures and the ECU’s behavior in what are normally

stage, even before all parts are available in reality dangerous situations can be tested with no risk for the
Laboratory tests reduce time and costs and take place
driver or the controlled machine
under controlled conditions The tests are reproducible and can be automated

ControlDesk® AutomationDesk ModelDesk Automotive SYNECT®

Test experimentation Test automation Model parameterization Simulation Models Test data management,
Real-time models workflow management, etc.
for vehicle development
ConfigurationDesk®
Configuration and
implementation software
Unit under test HIL simulator
Different Ways to Access Electric Motor ECUs

ECUs and other systems for controlling electric motors can Electric power level: Emulation of the electric motor

be accessed by the HIL simulator at different levels. Which and simulation of the mechanical environment:
interface to use depends on the testing purpose and project Production ECU, including power stages, can be

conditions: used
Signal level: Simulation of the power electronics, Full access to the model

the electric motor, and the mechanical environment: Motor parameters can be set flexibly within

Very scalable, as parameters can be set flexibly a certain power range
regardless of the power level
Full access to the model Mechanical level: Simulation of the mechanical

Internal signals of the ECU must be accessible environment, production ECU, and real motor:
Testing of mechanical parts
Motor
shaft
Application Motion Power stage Motor Transmission

controller controller
Current Rotational speed

Position
Rotational speed
Torque
Position
Simulation at Simulation at Simulation at Simulation at
communication level signal level power level mechanical level
7
2016
Introduction
Use Case Overview
The following section presents a number of typical use cases drive application areas, which are indicated in the follow-
for dSPACE systems in specific electric drive applications. ing table:
Many of the use cases are also relevant for other electric
Use Case Application Area Rapid Hardware-

Automotive Industrial Electric Railway Control in-the-
Industry Applications Power Proto- Loop
Technology
Industry typing Simulation
Vehicle traction – Page 9 Page 12

Developing converter control strategies for hybrid and fully

electric powertrains
Testing controllers for electric motors at signal level

In-vehicle auxiliary units – Page 15 Page 18

Developing controllers for small electric motors

Testing small electric motors at electric power level

Battery management – Page 20 Page 22

Developing and validating battery management algorithms

Testing battery management systems, including battery cell

emulation
Production code generation – Page 25
Automatic code generation for safety-critical applications
Hybrid controllers – Page 27 Page 29
Developing controller software for hybrid electric vehicles

Testing ECU networks with distributed functions of hybrid

electric powertrains
In-vehicle DC/DC converters – Page 32 Page 34
Developing converter functions
Testing power electronics control units
Test benches – Page 37
Simulating the environment for mechatronic systems

Steering test bench

Brake test bench

Industrial drive control – Page 41 Page 43

Developing and validating algorithms

Testing controller algorithms

Robotics – Page 46 --
Developing motion controllers

Railway technology – -- Page 47

HIL simulation for the power equipment of electric trains

Electric power industry – -- Page 50

HIL simulation of power supply systems

8
2016
Use Cases
RCP Systems for Hybrid and Fully Electric Powertrains

Developing converter control strategies
Application Areas Key Points
Developing and verifying control strategies and
Flexible solutions tailored to various electric motors

distributed ECU functions for powertrain systems Dedicated FPGA-based I/O interfaces with convenient

In-vehicle and laboratory systems for fast and
Simulink® blocksets for electric drive applications
convenient verification User-programmable FPGA with ready-to-use libraries

for even the fastest control loops
Support of dedicated converter protocols like TWINsync

Support of all major automotive bus systems for easy

integration into the ECU network
Processor-based dSPACE Components Customer Components

computation
1 ... n
MicroAutoBox II LTi
TWINsync ServoOne
LVDS
or PGI1
AutoBox with or Motor

DS1007 1 ... n
Host PC, e.g., with
dSPACE ControlDesk® Third-party
motor
controller and
CAN converter
Ethernet
Example 1: Processor-Based Control of an Electric

Motor
For applications using a converter from LTI, such as the LTi synchronous control of more than one converter. Instead
ServoOne , dSPACE provides a dedicated TWINsync solution. of an LTI converter, you can also use further third-party
The solution consists of an FPGA-based hardware called Pro- converters. For this case, dSPACE supports communication
grammable Generic Interface (PGI) and a Simulink blockset via CAN and Ethernet, and more communication networks
for convenient configuration. This enables the RCP platform are to come. In both scenarios, the computation of the
(MicroAutoBox II or DS1007 installed in an AutoBox) to inter- algorithms is processor-based, making it suitable for sample
face various converters via TWINsync. To give you maximum times up to 20 µs.
flexibility for your prototyping setup, dSPACE supports the
9
2016
Use Cases
dSPACE Components Customer Components

Processor-based
computation
Optional 1 ... n
MicroAutoBox II LTi
Optional
LVDS
TWINsync ServoOne
or PGI1
AutoBox with or Motor

DS1007 Optional 1 ... n
Host PC, e.g., with
dSPACE ControlDesk®
CAN, Ethernet Third-party
converter
CAN, Ethernet, FlexRay, etc.
Dedicated ECU interface
ECU
Function bypassing
Example 2: ECU included

If your test setup already includes an ECU, you can use the automotive bus system like CAN, FlexRay, or Ethernet. The
RCP platform (MicroAutoBox II or DS1007 installed in an power stages that are already implemented on the ECU
AutoBox) to extend the ECU via bypassing. Unlike fullpass and the cable harness to the electric motor can be reused
approaches, where the ECU is completely replaced by the in this method.
RCP system, bypassing is used to develop only individual For convenient measurement and calibration, ControlDesk®
parts of the ECU software from scratch, e.g., the electric has access to all variables during run time. You can also log
motor control function. In this case, the new functionality data to a USB device during run time for postprocessing
is calculated on the RCP system, which is connected to the purposes.
ECU via a low-latency ECU interface (e.g., DCI-GSI2) or an
Example 3: FPGA-Based Control of an Electric Motor

For test setups requiring very fast sample times shorter than If the sample times are longer than 20 µs, the AC Motor
20 µs, RCP platforms including a user-programmable FPGA Control Solution can be used. Please see page 17 for more
are the right choice. MicroAutoBox II is available in variants information.
with a user-programmable FPGA module, and if you are
using modular hardware, e.g., AutoBox with a DS1007,
you can simply add a DS5203 FPGA Board.
For convenient FPGA programming, a fully model-based
tool chain is available. The FPGA controller model can be
developed in MATLAB®/Simulink with the RTI FPGA Program-
ming Blockset and the Xilinx® System Generator for DSP.
dSPACE also offers the XSG AC Motor Control Library, which
provides preconfigured function blocks for all major electric
motor features like PWM generation; Hall, encoder, resolver,
EnDat and SSI sensor processing; and angular computation. The XSG AC Motor Control Library enables model-based program-
ming of the FPGA on the DS5203 FPGA Board or the DS1553 AC
10 Motor Control Module for MicroAutoBox II.
2016
Use Cases

FPGA-based
computation
MicroAutoBox II AutoBox with

and DS1553 DS1007 PPC Processor Power
or Motor
AC Motor Board and DS5203 amplifier
Control Module FPGA Board
FPGA Programmable per Application

The DS5203 FPGA Board and the MicroAutoBox variants In addition, the DS5203 offers 6 ADC, 6 DAC and 16 digital
with a DS1514 FPGA Board can be adapted to various tasks, I/O channels as well as connection to the processor board via
so you can react flexibly to tougher requirements, such as a PHS bus. The DS1514 can be used together with different
signal conditioning, new interfaces, or speeding up model I/O modules dedicated for special use cases, like the DS1553
parts. with I/O interfaces for electric motor control.
FPGAs are especially useful for relieving the processor board
of tasks such as signal preprocessing during ECU develop-
ment. Running at 80/100 MHz, the dSPACE FPGA boards
are ideal for application fields like fast current control loops,
customized PWM pattern generation, and electric drive
projects. The DS5203 and the DS1514 work closely together
with the XSG model library. The DS5203 features the freely The number of the DS5203 I/O channels can be increased by piggy-
programmable Xilinx Kintex®-7 FPGA with Vivado® support. back modules.
Housing for In-Vehicle Applications

Please see page 17 for more information on the different
housings for modular hardware.
Products Involved in This Use Case (Excerpt)

DS1007 PPC Processor Board, page 53 MicroAutoBox II, page 53
DS5203 FPGA Board, page 56 Programmable Generic Interface (PGI), page 54
DS1553 AC Motor Control Module, page 57 TWINsync Solution, page 59
XSG AC Motor Control Library, page 55
11
2016
Use Cases
HIL Simulation for Vehicle Traction Motors

Controller tests for electric motors at signal level
At the signal level, the test system is connected to internal This example describes FPGA-based simulation with
interfaces of the electric drive control unit: to the signals of SCALEXIO®. FPGA-based simulation is typically used if very
the gate drivers and to the signals of the current transduc- high computation speed is needed.
ers. Any power electronics devices are disconnected from If you do not need high computation speed, you can also
the device under test. This approach enables maximum perform processor-based electric motor simulation tests
scalability and full model access. with SCALEXIO. The motor and inverter models are then
computed on the SCALEXIO Processing Unit. Please see
page 43 for more information.

Testing electric motor ECUs for powertrains, e.g.:
Very high oversampling rate according to the PWM

Hybrid and battery electric vehicles
switching frequency
Fuel-cell vehicles
No PWM synchronization necessary

Testing all other kinds of electric motor controllers
Simulation of current ripples (PWM effects)

that require high precision for simulating higher Fast signal computation with user-programmable FPGA

fundamental frequencies and stability Motor and inverter models on FPGA

Developing electric powertrains
Ready-to-use open FPGA models for all common

Developing off-highway vehicles
motors and sensors
Nonlinear effects by means of FEM-based

parameterization (e.g., JMAG)
Sample times of < 500 ns for highest simulation quality

FPGA-based acquisition of gate driver signals

FPGA-based simulation of current and position sensor

signals
Convenient graphical system configuration


ConfigurationDesk, page 52 SCALEXIO, page 54
DS2655 FPGA Base Board, page 57 SCALEXIO Processing Unit, page 54
DS2655M1 Multi-I/O Module, page 58 XSG Electric Components Library, page 55
DS2655M2 Digital I/O Module, page 58 XSG Utils Library, page 56
12
2016
Use Cases

Computation of the motor and
power electronics model SCALEXIO® HIL simulator
DS2655 FPGA Base Board DS2655M1 Gate signals

Multi-I/O Module
Current signals
IOCNET Position sensor signals
DS2680 I/O Unit
IOCNET Further signals

Electric motor controller
SCALEXIO Processing Unit
Buses without power electronics
Computation of the
vehicle model Ethernet
Host PC, e.g., with

FPGA for Short Sample Times

The DS2655 FPGA Base Board has been designed for applica-
tions that require very fast, high-resolution signal processing,
such as electric motor HIL simulation. It includes a powerful,
freely programmable field-programmable gate array (FPGA),
the Xilinx Kintex-7 160T. To include I/O channels, you can
connect up to five I/O modules to the board. Together with
the XSG Electric Components Library, the DS2655 provides
the fast reaction times required for simulating electrical
machines in closed-loop operation with a controller.
For expanding the I/O channels of the DS2655, there are

two I/O modules: the DS2655M1 Multi-I/O Module and
the DS2655M2 Digital I/O Module. They provide the high
number of digital and analog I/O channels needed for
applications such as electric drives.
The DS2655 FPGA Base Board and the DS2655M1 and DS2655M2
modules.
13
2016
Use Cases
Software-Based FPGA Configuration

The SCALEXIO system for HIL simulation provides a wide access. The programs can be downloaded to the FPGA via
range of I/O hardware which enables you to connect various ConfigurationDesk®.
converter and motor types. You can test the program in offline simulation before imple-
You can program applications for the DS2655 FPGA Base menting it on the real-time hardware. This lets you react
Board's FPGA with Xilinx System Generator, and the RTI flexibly to new requirements, such as new interfaces or
FPGA Programming Blockset enables the I/O and processor having to accelerate the execution of submodels.
Plant Models for FPGA-Based Simulation

Electric motor control applications that demand very high Components and Characteristics
precision and correspondingly high sampling rates are best Permanent magnet synchronous motor (PMSM)

simulated on field-programmable gate arrays (FPGAs). The Brushless DC motor (BLDC)

XSG Electric Components Models (closed-loop simulation Advanced inverter model supporting the discontinuous

components) are implemented as Xilinx System Generator conduction mode (DCM)
(XSG) models that run on a dSPACE DS5203 FPGA Board Asynchronous squirrel cage induction motor

(PHS-bus systems) or DS2655 FPGA Base Board (SCALEXIO), Resolver, sine, TTL, and Hall encoders

so you can use the same workflows for controller develop- XSG Electric Components Library containing the XSG

ment and testing. This makes it possible to perform closed- Utlis Library, which offers further functionality
loop simulations of electric devices and their controls at very Delta-star connection configurable for three-phase

high sampling rates in real time. motor models
Direct FPGA I/O Access

In addition to the plant models, for the DS5203 and DS2655
boards the XSG Electric Components Library provides en-
hanced I/O functions from the contained XSG Utils Library,
e.g., for timing analyses and digital input source captur-
ing. The XSG Electric Components Library and the DS5203/
DS2655 boards can be used together for E-motor simulation
at both the signal and the power level.
14
2016
Use Cases
Rapid Control Prototyping for Small Electric Motors

Controller development for in-vehicle auxiliary systems
Validating control algorithms for auxiliary electric
Compact RCP hardware for use in the vehicle

motors under real conditions Software- and hardware-configurable off-the-shelf

In-vehicle testing of systems such as air conditioning,
modules for signal conditioning and power stages
power windows, seats, and mirrors Flexible solutions tailored to various electric motors

AC Motor Control Solution for convenient access and

fast implementation of electric motor control features
Dedicated FPGA-based I/O interfaces with convenient

Simulink® blocksets for electric drive applications
Fast iteration by implementing Simulink models

automatically on the RCP hardware at the click of
a button
Large set of easy-to-configure, comprehensive I/O

functions
Computation of
control algorithms Analog/digital
signals
MicroAutoBox or AutoBox with processor board and I/O boards Auxiliary electric
motor
Add-on: AC Motor
Analog/digital
Control Solution signals
Sensor signals
DS1768 high-current
RapidPro
half-bridge module
Actuator signals
Interface for signal

conditioning and
power stages
Ethernet
Host PC, e.g., with

AC Motor Control Solution, page 56 AutoBox, page 53
RapidPro, page 54 Processor boards, page 53
MicroAutoBox II, page 53 Real-Time Interface, page 52
15
2016
Use Cases
System Extension with Configurable Automotive

Signal Conditioning and Power Stages
RapidPro is a very compact, robust and modular hardware
that extends dSPACE RCP systems with automotive signal
conditioning and power stages. Software- and hardware-
configurable off-the-shelf modules can be installed on the
RapidPro units to set up individual systems that perfectly fit
the needs of a particular application. The modular concept
enables you to reuse, reconfigure and extend all components
with a minimum of effort in later projects or if requirements
change, for example.
The RapidPro SC Unit supports your prototyping system
wherever demanding signal conditioning tasks such as sig- quire high-current and/or high-voltage output drivers. The
nal protection, amplification, attenuation, filtering, and RapidPro Power Unit provides your prototyping system with
electrical isolation have to be performed. In turn, actuators the necessary power stages, such as a flexible inverter stage,
like electric drives, valves, injectors, lamps, and relays re- during the prototyping phase of diverse AC electric motors.
RapidPro Power Unit

For adding power stage functionalities to an existing rapid current half-bridge modules are available, which can be used
control prototyping system, dSPACE offers the RapidPro for driving electric motors (e.g., BLDC and BLAC motors)
Power Unit with a wide range of hardware- and software- in 12 V and 24 V power supply systems. Two PS-HCHBD
configurable power stage modules. Customer-specific mod- 2/2 can be used together in one RapidPro Power Unit as
ules or adaptions are also available on request. The complete a B6 bridge-based inverter with an additional channel for
compact and robust system is designed for in-vehicle and connecting a brake chopper. The half-bridge modules
laboratory use and has an integrated overvoltage, overcur- have an integrated current measurement with a software-
rent and overheat protection. configurable low-pass filter on every channel for easy and
For E-drive applications, the PS-HCHBD 2/2 (DS1768) high- comfortable phase current measurement.
Combining MicroAutoBox and RapidPro

To extend the MicroAutoBox II signal conditioning options,
many customers use the comprehensive signal conditioning
and power stage options of the RapidPro hardware.
The two systems can be combined to a one-stack system
using a special joining plate.
Such a compact system is beneficial if the mounting space

is limited.
16
2016
Use Cases
Solutions for Highly Dynamic Control Systems

The ideal tool for validating highly dynamic control systems Generation of gate driver signals, e.g., center-aligned

for different types of AC motors is the AC Motor Control 3/6 PWMs for sinusoidal commutation, PWM signals
Solution. It is available in variants for MicroAutoBox and for block commutation, and advanced customer-
AutoBox. specific PWM patterns
The solution provides the following features: Synchronization of ADC measurement with center-

Synchronization of measurements of phase and DC link aligned PWM signals (regular sampling)
currents or voltages and ADC measurements to PWM Model synchronization by interrupt generation at the

signals center position of the PWM or at user-defined motor
Position and speed measurements using typical angles
sensors, e.g., Hall sensors, incremental encoders, Trigger signal to external devices at the center position

resolvers, and single-turn/multiturn encoders with serial of the PWM
interfaces (EnDat or SSI)
PHS bus
DS1006/DS1007
Control signals
or Current signals
DS5202
Piggyback module used
EV1048 inside MicroAutoBox II
Resolver, SSI,
Hall/Encoder
EnDat
RapidPro Power Unit
RTI Blockset Motor
Housings for In-Vehicle Use

Various platforms for in-vehicle use are available for different The special strength of the MicroAutoBox hardware is its
motor types, required sample times, and project conditions. unique combination of high performance, comprehensive
AutoBox has been designed for you to use dSPACE modular automotive I/O, and an extremely compact and robust de-
hardware for in-vehicle applica- sign. It can operate without user intervention, just like an ECU.
tions. You can install it easily in
your test car, e.g., in the trunk or
the passenger cabin. AutoBox is
very robust and can be powered
directly by a car battery.
17
2016
Use Cases
HIL Systems for Emulating Small Electric Motors

Testing auxiliary systems at the electric power level
At the electric power level, the real power stages are in- Key Points
cluded in the test and only the motor is emulated by an Full access to the motor model. Motor parameters can

electronic load. For this reason, the device under test does easily be modified.
not need to be modified and only minor safety restrictions High-performance electronic loads which can sink all

apply compared to a mechanical test bench. the power coming from the ECU
Up to 60 V and up to 100 A (50 A RMS) per module,

Application Areas supporting parallel operation
Emulating electric machines (brushless DC motors,
User-programmable FPGA board for computing

induction motors, permanent magnet synchronous dynamic parts of the electric drive system
motors) at the electric power level Minimized feed-through time, supporting the

Suited for highly dynamic measurements and high-
simulation of current ripples (PWM effects)
speed operations in electric steering systems, gearbox High-speed current regulation ideal for loading PWM

actuators, fuel pumps, etc. power stages
Integrating electric drives in a virtual vehicle
High accuracy of emulated currents

environment More flexibility than mechanical test benches

Support of multiprocessor systems with more than one

Processing Unit for higher computing power

SCALEXIO® HIL simulator
Emulation of the (1 ... n)
electric machine
U
DS5381 Electronic Load Module V
W
Computation of the
Analog signal
motor model Motor control
unit with electric
Position sensor signal power stages
DS2655 FPGA Base Board
IOCNET
Power supply
SCALEXIO IOCNET SCALEXIO IOCNET SCALEXIO Discrete I/O
Processing Unit Processing Unit I/O board Bus signal
Computation of the
mechanical system Ethernet
Host PC, e.g., with

dSPACE ControlDesk® or
AutomationDesk
Please see page 14 for information on software-based FPGA configuration and page 13 for information on the dSPACE FPGA hardware.

SCALEXIO, page 54 XSG Electric Components Models, page 55
DS5380 Electronic Load Module, page 57 DS5381 Electronic Load Module, page 57
Automotive Simulation Models, page 52
18
2016
Use Cases
Electronic Load Emulation for Various Voltage Ranges

Up to 30 V Up to 60 V
The DS5380 Electronic Load Module is optimized for high- The DS5381 Electronic Load Module emulates motor and
speed operation as required for emulating electric motors, generator currents at voltages of up to 60 V. Highly dynamic
such as those in electric steering systems. It can work as both switching between the current and voltage control modes
a current sink and a current source to provide bidirectional makes it possible to emulate floating brushless DC (BLDC)
current flow, i.e., it consumes or generates real currents motor phases without additional booster components. With
of or for the motor ECU outputs. The DS5380 Electronic a voltage range of up to 60 V, the module is also ideal for
Load Module can be combined with the DS5203 FPGA use with higher onboard vehicle voltages of 48 V.
Board for a dSPACE Simulator or the DS2655 FPGA Base The module is perfect for emulating three-phase electric
Board for SCALEXIO®. In combination with the XSG Electric motor units. Energy recuperation is also included to boost
Components Library, the boards the energy efficiency of the overall system. Typical test ap-
provide the fast reaction times plication areas are electrically supported steering, starter and
required for controlling electric generator systems, and mild hybrid drives. Multiple loads can
machines. On both boards, the be operated in parallel to achieve
FPGA computes parts of the higher electric currents in the
simulation model for the elec- electronic load.
tric machine, e.g., from the XSG
Electric Components Library,
and operates the electronic load
module.
Electronic load emulation covering a voltage range up to 800 V

is also possible on request.
Coupling with Human-Machine Interface

To make the automated tests more perceptible for the cockpit for the developers to sit in and “drive” the system.
developers, the simulation systems can be extended with Simulation models such as ASM Vehicle Dynamics make the
3-D visualization software, a steering wheel, or a complete system behave realistically.
19
2016
Use Cases
Measuring and Balancing Li-Ion Cell Stack Voltages

Developing and validating battery management algorithms
Application Areas Key Features
Developing and validating battery management systems
Scalable modular system, supporting up to 846 V

and algorithms (around 200 cells)
Battery stress tests (deep discharge and overload)
Measuring range from 0 to 5 V

Test of cell chemistry and cell geometry
Accuracy of down to ±2 mV

End-of-line and approval tests for batteries and battery
Very high measurement frequency of up to 1 kHz

controllers Absolute synchronous measurement for all cell voltages

(independent of the count), cell temperatures and
battery currents with the EV1093 board
Monitoring of isolation status

Real-time state of charge (SOC) algorithms for battery

cells

Housing: in-vehicle
or rack version
Measurement of temperature
and cell voltage (1... n)
+
Battery
dSPACE EV1093 Battery Cell Measurement I
and Balancing Board with Ethernet U Load
Measurement and -
balancing resistances
Synchro-
Ground nisation
Ethernet
RF
Isolation
Ethernet switch fault
Isolation
monitoring
Ethernet
Digital I/O
dSPACE platform, e.g.,
MicroAutoBox II, MicroLabBox® Analog I/O
or DS1007
Host PC with
dSPACE ControlDesk® Computation of
control algorithms
Galvanic isolation

EV1093 Battery Cell Measurement and Balancing Board, page 56 Battery Cell Measurement and Balancing Blockset, page 55
MicroAutoBox II, page 53 ControlDesk, page 52
MicroLabBox, page 54 DS1007 PPC Processor Board, page 53
20
2016
Use Cases
Monitoring and Balancing the Voltages of Li-Ion

Batteries
Lithium-ion (Li-ion) batteries typically consist of up to several
EMK / V
hundred interconnected cells with an operation range of
around 2.5 to 3.8 V. As the voltage curve is rather flat, a
small cell voltage change causes a relatively great change
in the state of charge (SOC).
Therefore, one of the many algorithms needed for managing
batteries is the state of charge algorithm for balancing the
battery cell voltages. For this, the cell voltages have to be
SOC / %
measured and monitored with a high precision.
One Board Measuring 24 Cells – dSPACE EV1093

Since an individual cell voltage is much lower than the volt- from the measurement channels for the temperature due
age a complete battery provides (up to and beyond 500 to the high difference between the cell and the system
V), measuring the individual cell voltages is necessary. For voltages. Any Ethernet-capable dSPACE platform, such as
this, dSPACE offers the EV1093 Battery Cell Measure- MicroAutoBox II, MicroLabBox® or the DS1007 PPC Processor
ment and Balancing Board. One board covers 24 cells, Board, can be used to control the board. The Ethernet con-
and you can easily add further boards for more channels, nection lets you use distributed intelligence via the EV1093's
if necessary. The EV1093 supports the passive balancing of FPGA and the high-performance processor on the dSPACE
battery cells, where energy is drawn from the most charged platform.
cell and disposed of as heat through resistors. Due to the
high technical production quality of today’s Li-ion batter-
ies, active balancing, where energy is drawn from the most
charged cell and transferred to the least charged cells, is
often not required.
The EV1093 can be used either in a 19'' rack in the lab-
oratory or in an in-vehicle housing. In both cases, the
measurement channels for the cell voltages are isolated Example of the EV1093 board (left) and in-vehicle housing (right).
Full Flexibility, Full Control – Blockset for Battery

Cell Voltage Measurement and Balancing
For different configuration and implementation require- nisms, these can be disabled to discharge the cells completely
ments, the specialized dSPACE Battery Cell Voltage Mea- or create an overload. As each cell is monitored individually,
surement and Balancing Blockset provides maximum battery stress tests or tests of a new cell chemistry and cell
flexibility for accessing the battery directly. You can fully geometry are supported. Additionally, the EV1093 provides
control the balancing process and the algorithms. numerous temperature sensors that give you detailed infor-
For example, to passively balance the cells while the battery mation on which temperatures occur where, making it easy
is being recharged, you can define a target voltage, i.e., the for you to identify hot spots.
minimum voltage which the EV1093 will always maintain. To give you a boost start, the blockset also includes ready-
For passive balancing, resistors with a wide range of resistor to-use, configurable real-time-capable SOC algorithms that
values can be added to the EV1093 via a plug-on module. are based on Kalman filters.
Although the system comes with integrated safety mecha- 21
2016
Use Cases
HIL Tests for Battery Management Systems

Emulating battery cell voltages
Vehicle traction battery
Scalable, compact system supporting up to 32 cells

Stationary storage systems
in one 19'' 3 U subrack
HIL test for battery management systems (BMS)
Emulation range from 0 to 6 V

Simulation of high-voltage batteries at cell level
Accuracy of ±1.5 mV across the entire working

Real-time multicell battery simulation
temperature range
Failure simulation for battery management systems
Short refresh rate of more than 1 kHz

Lead-acid (Pb), nickel-cadmium (NiCd), nickel-metal
Temperature simulation by means of isolated analog

hydride (NiMH), and lithium-ion (Li-ion) batteries outputs and an advanced simulation model
Efficient computation of a large number of cells

Safety compartment for the ECU

1 A of current per channel, parallel operation possible


dSPACE HIL simulator
Emulation of terminal voltage

for battery cells (1...32) (1...m)
CAN bus
dSPACE EV1077 Battery Cell Cell measurement
Voltage Emulation Board module
BMS ECU
Ground
dSPACE EV1082 Battery Cell
Emulator Controller Board
Isolation Ethernet Analog output and

monitoring isolation amplifier
Temperature
simulation
SCALEXIO® Processing Unit
IOCNET
CAN
Computation of the Ethernet I/O boards
simulation model Discrete I/O
IOCNET and buses
Host PC with
AutomationDesk
Galvanic isolation

SCALEXIO, page 54 ASM Electric Components, page 55
EV1077 Battery Cell Voltage Emulation Board, page 56 EV1082 Battery Cell Emulator Controller Board, page 56
SCALEXIO Ethernet Solution, page 55
22
2016
Use Cases
HIL Test for Battery Management Systems

The main task of a BMS is to balance the voltages of each
cell in a multicell battery. Furthermore, it monitors the bat-
tery’s temperature continuously. For realistic tests of the
BMS, at least one cell module has to be integrated into the
HIL system. The cell modules measure the cell voltages and
provide the connection between the ECU and the battery.
The main task of the HIL simulator is to output the cell volt-
ages and temperatures with high precision.
The EV1077 supplies continuously adjustable voltages in
the range of 0 to 6 V. With this range, damaged cells can
be emulated as well. For example, a voltage higher than
the nominal voltage simulates a cell's increased internal
resistance during charging. Depending on the battery type
and the test focus, several EV1077 Battery Cell Voltage
Emulation Boards are combined in the HIL system. For each
32 EV1077s, one EV1082 controller board is needed that
controls the cell emulation boards and communicates with
the real-time system. Because one EV1077 can emulate 4
battery cells, one controller board controls up to 128 cells.
All live parts of the test system are galvanically isolated, let-
ting you connect the modules in series up to a voltage of
1.000 V. To meet safety regulations, a safety compartment
prevents accidental contact with the ECU, protecting you A HIL test system can include multiple racks, each with up to 32
against you harm stemming from high voltages. EV1077 modules.
Simulation Model
For the simulation of high-voltage batteries, a real-time-
capable simulation model has to provide plausible voltages Terminal current Reference cell Terminal voltage of
of battery model supplies reference cell
and temperatures for each cell at all times. This allows realis- reference terminal
voltage
tic tests of the balancing and thermal monitoring algorithms
in the BMS. Since the batteries consist of a series of battery
cells, the computation requirements can be demanding. Reference resistance
Terminal
and charge state
To reduce the processing load, the dSPACE ASM Multi Cell voltages of
cells
Model (in ASM Electric Components) connects single cells of Delta model for
calculating deviations
identical design to create a series string of cells. This string of cell voltages based
on individual Voltage differences
consists of a reference cell model that describes the basic parameters of cells
Balancing current
behavior of the cell type, and a delta model that computes
the deviation of each cell's voltage from the reference volt-
age. This approach reduces the required computation power,
as the complexity of the model is independent of the num- design level, new, even more detailed, models are available.
ber of cells. For advanced requirements even at the battery For more information on dSPACE ASM, please see page 24.
23
2016
Use Cases
Simulation Models for Vehicle Electrical Systems

For simulating electrical systems or drives, dSPACE provides electric circuits of an automotive system with components
open Simulink® models that are used for model-based func- such as batteries, machines, and loads. Theses models are
tion development and in ECU tests on a hardware-in-the- optimized for simulation scenarios with slower task times,
loop (HIL) simulator. The models are contained in the ASM e.g., 1 ms. The closed-loop sublibrary provides models for
Electric Components Library, which is divided into two main testing a real machine controller with a HIL system. The
sections: a sublibrary with model components to simulate a sublibraries are optimized for fast task times, e.g., 50µs.
vehicle electrical system, and a sublibrary with models for They can be combined to simulate an electric vehicle along
closed-loop applications of electric components. The ve- with its electrical system, for instance.
hicle electrical system sublibrary can be used to simulate the
ASM Electric Components
Vehicle Electrical System Components Closed-Loop Electric Components

 Electrical system  Electric drives
 Battery  Power electronics
 Starter
 Alternator
 Loads
Hybrid vehicle with Hybrid Manager as demo model
Electrical System Components

The electrical system components can be used directly to
create the electric circuits of an automotive or industrial
system, since they are already equipped with all the neces-
sary features.
The main components are:
Battery
Multicell battery
Starter
Alternator
Loads
For more information on the ASM closed-loop simulation ASM supports standard automotive system batteries and high-voltage
components, please see page 45. batteries for electric powertrains.
24
2016
Use Cases
Production Code for Battery Management Systems

Automatic code generation for safety-critical applications with TargetLink®
High-quality production code generation for battery
Quick transmission of controller models to production-

management systems code
Developing safety-related software according to ISO
Simplified testing process

26262 Certified for ISO 26262, IEC 61508, and derived

Early simulation and verification in MIL, SIL and PIL
standards
mode TargetLink reference workflow document for

developing safety-related software
Modeling Approach
High-performance, native AUTOSAR support

Create Prepare Simulink® Single-Rate and
TargetLink Model® Model for Multirate
from Scratch TargetLink Modeling
Model Simulation and

Model Exchange via
Code Specification
Reference
TargetLink Blockset
Analyzing Simulation Behavior and Optimizing Production Code
Typical Task Simulink

Behavior Validity Checks
Code Generation Settings Model Exchange
Scaling1) in Workgroups
MIL
Achieving Production Quality
Model-in-the-Loop
Validation / Verification
Production Code
Host Simulation
Precision
Typical Task Host PC

Scaling/Discretization Analysis1)
Saturation and Overflow Detection1)
Code Coverage Analysis SIL
Software-in-the-Loop TargetLink Data Dictionary
Definitions/Declarations
Variables
Production Code Data Structures
Optimization
Target Simulation Scaling Formulas
Evaluation Board
Typical Task Code Information
Memory Measurement Function Calls
Execution Time Profiling Tasks
...
Target Code Verification PIL
Processor-in-the-Loop
Calibration
Automatic Model Generating
and Code ASAM-MCD 2MC
Documentation Descriptions Calibration Tools
Generating
AUTOSAR Software
Component
Descriptions
Integrating Generated Code on ECU
Generated Code
OIL File Generation

for OSEK RTOS
Hand-Writ-
ten
Legacy I/O Typical steps for generating
Code Code
Operating Systems Code
ECU
and validating production
1)
Valid only for fixed-point software. code with TargetLink.

TargetLink, page 53 Evaluation Boards
25
2016
Use Cases
Flexible Software Design

To provide high flexibility, incremental code generation is routine automatically prepares Simulink models for code
available for Simulink subsystems that contain a TargetLink generation with TargetLink.
Function block. Each member of a development team can The TargetLink Data Dictionary is a central data container
work on a subsystem individually and generate code only that holds the relevant information for a model's design,
for this subsystem. TargetLink performs the necessary con- code generation, and implementation on an ECU. Data
sistency checks when building the overall application. Dictionary objects can be referenced from TargetLink models.
TargetLink blocks significantly enhance the functionality You can define and manage variables and their properties,
of the supported Simulink blocks with additional capabili- and you can specify structured data types and use them for
ties for fixed-point simulation. It offers an extended dialog variable declarations. Scaling formulas can be entered and
that lets you enter the implementation-specific information used to uniformly scale fixed-point signals and parameters in
necessary for code generation. Each block also provides a the model. You can import and export standardized and pro-
means of data logging and overflow detection. A special prietary data and use the data with the calibration system.
Early Verification by Simulation Developing Safety-Critical Applications

One of the advantages of model-based development is that TargetLink is certified by TÜV SÜD (German international
you can use simulation for early verification. TargetLink not certification authority) for use in the development of safety-
only generates code for production ECUs, it also greatly related systems. TÜV confirmed that TargetLink is suitable for
simplifies the testing process. Tests are performed in the software development according to ISO 26262, IEC 61508,
same simulation environment that was used to specify the and derived standards (such as EN 50128, which governs
underlying simulation model. TargetLink supports the fol- safety-related software on the railways). The certification
lowing actions: was granted for several areas:
Validating battery algorithms by model-in-the-loop Software development process and software
(MIL) simulation modification process of TargetLink
Validating software by comparing model-in-the-loop Problem handling procedures
and software-in-the-loop (SIL) simulations Fitness for purpose in safety-related development
Validating processor utilization and speed by processor- according to IEC 61508 and ISO 26262
in-the-loop (PIL) simulation
Model-in-the-Loop Software-in-the-Loop Processor-in-the-Loop

Controller model C code on host PC C code on target processor
Evaluation
board
Plant model or stimulus signals Plant model or stimulus signals Plant model or stimulus signals
26
2016
Use Cases
Developing Controller Software with RCP Systems

In-vehicle test systems for hybrid electric vehicles
Validating the overall control strategy
Comprehensive I/O including CAN, CAN FD, LIN,

Integrating the controller functions into distributed
K-Line/L-Line, FlexRay, Ethernet, and bypass interfaces
ECU networks Easy access to all variables as well as I/O and bus

Testing different control strategies
signals of the real-time application during run time
with ControlDesk®

automatically on the RCP hardware at the click of a
button

functions
Further sensors
Acts as the central
hybrid ECU
Powertrain CAN
MicroAutoBox Hybrid CAN
Analog/digital I/O
Battery
Engine E-motor Transmission
management
ECU system ECU ECU
Ethernet
High-voltage Inverter
battery
Optional host PC with Combustion

engine To drive shaft
dSPACE ControlDesk® Electric Trans-
(Vehicle
motor mission
Dynamics)

MicroAutoBox II, page 53 Real-Time Interface, page 52
TargetLink, page 53
27
2016
Use Cases
Distributed Network ECUs

The control functions for an electric or hybrid electric pow- available in different variants that support all major auto-
ertrain are often spread over a distributed network of ECUs. motive bus systems like CAN, CAN FD, FlexRay, Ethernet,
To enable you to test these functions, MicroAutoBox II is LIN, and K-/L-Line.
Universal I/O Modules for MicroAutoBox

The DS1553 AC Motor Control Module is an I/O piggyback easy-to-use RTI blockset for controlling various electric drives.
module that is optimized for controlling various electric All modeling is performed on the processor via MATLAB/
drives. It provides interfaces for Hall, incremental encoder, Simulink – no FPGA programming by the user is required.
resolver, EnDat and SSI sensors, and can be installed in Mi-
croAutoBox II 1401/1511/1514 and 1401/1513/1514. There Further I/O modules for the MicroAutoBox are the DS1552
are two use cases: Multi-I/O Module, which offers a wide range of powerful
I/O, and the DS1554 Engine Control I/O Module for the
Use Case 1: User-Specific FPGA Programming advanced control of combustion engines.
The DS1553 provides I/O interfaces for the user-programmable
FPGA of MicroAutoBox II. The XSG AC
Motor Control Library enables the imple-
mentation of controller functionalities
in both the CPU and the FPGA. With
the board’s ready-to-use, configurable FPGA I/O Extension Module
elements for common electric drives DS1552 Multi-I/O DS1553 AC Motor
I/O connector
In Out Module Control Module

control, you do not have to deal with
complex signal preprocessing and can FPGA
DS1514 FPGA (programmable)
fully concentrate on developing new Base Board
control algorithms.
DS1401
Processor
Base Board
I/O connector
Use Case 2: AC Motor Control Solution

The MicroAutoBox II AC Motor Control FPGA
MicroAutoBox II 1401/1511/1514
and 1401/1513/1514
DS1511 or
Solution uses the DS1553 module in
DS1513 In Out
conjunction with a dedicated FPGA firm- I/O Board
ware and provides a comprehensive and
Automatic Production Code Generation

TargetLink®
After validating the new functions with the RCP platform,
Model
production code has to be generated. With TargetLink®, you
can generate C code straight from the graphical develop-
ment environment of MATLAB/Simulink/Stateflow®. Simulink® Coder TargetLink
TargetLink also provides native AUTOSAR support. Devel- Prototyping code Production code
opers can specify AUTOSAR structure elements, such as TargetLink
Stand-Alone
runnables, ports, and communication interfaces, simply at Model Manager
model level. Hence model-based designs are directly imple-

mented in the form of AUTOSAR-compliant production code.
For more information on TargetLink, please see page 25. RCP system Production ECU
28
2016
Use Cases
HIL Simulation of Hybrid Control Units

Testing distributed functions
Hybrid drivetrains combine well-known state-of-the-art Unlike tests on a single component ECU, tests on an overall
powertrain technology with powerful electric motors and powertrain control system have to take the various connec-
storage devices in various configurations. tions between the devices under test into account (combus-
Compared to traditional powertrains, electric traction drives tion engine, transmission, electric motors, battery manage-
and electric auxiliaries add additional degrees of freedom ment, etc.). These may be coupled by controller networks
to the system with regard to functionality and packaging, (CAN, LIN or FlexRay bus) or by electrical and mechanical
which leads to a more complex and distributed control sys- systems which have to be covered by the system model.
tem (hardware and software).

Testing network communication between networked
Modular network of two or more SCALEXIO®

ECUs simulators
Integration testing
Extension to full virtual vehicle by adding further

Testing distributed functions in the ECU network
SCALEXIO systems
Testing network communication between electric
Automotive Simulation Models for all plant

vehicles (EV) and electric vehicle supply equipment components
(EVSE) according to CHAdeMO, ISO 15118, GB/T Building of two or more parallel CAN structures for a

18487, etc. typical realistic hybrid powertrain structure
Restbus simulation of unavailable components

Configuration of all known hybrid and electric vehicle

versions, ECUs, and CAN configurations
Decentralized setup of simulators possible


SCALEXIO, page 54 SCALEXIO I/O hardware, page 57-58
SCALEXIO Processing Unit, page 54 SCALEXIO EMH Solution for electric drives simulation, page 55
SYNECT, page 53 Automotive Simulation Models, page 52
29
2016
Use Cases
Charging
control unit
Hybrid
Customer Components
CAN
DC/DC ECU
Hybrid
BMS ECU
Powertrain controller
CAN
Transmission
Engine ECU E-motor ECU
ECU
BMS CAN
Transmission Engine & hybrid ECU E-motor, BMS, DC/DC controller Further ECU
Loads CAN I/O Loads

dSPACE Components
Host PC, e.g., with

dSPACE ControlDesk®,
AutomationDesk,
ConfigurationDesk®
I/O I/O I/O
IOCNET IOCNET IOCNET IOCNET
SCALEXIO® SCALEXIO SCALEXIO

Processing Processing Processing
Unit Unit Unit
Ethernet
Simulation of a Virtual Vehicle

The networked SCALEXIO system comes with at least one Specialized interface hardware provides functions such as
Processing Unit for computing the simulation models. Large, signal generation and measurement, failure simulation, and
complex simulation models can be distributed across three communication connections. The test scenario also cov-
or seven processor cores (depending on the version) to en- ers several CAN, FlexRay and Ethernet networks as well as
sure that they can be computed in real time. One core is restbus simulation if not all components are available. The
reserved for internal system services. If required, additional modularity and flexibility of the SCALEXIO hardware enables
Processing Units can be integrated. To distribute model parts you to add further racks to cover all the other ECUs in the
to the cores and to configure the communication behavior, vehicle, such as the ESP ECU.
simulation hardware and model connections, you can use
ConfigurationDesk®.
30
2016
Use Cases
Example of a hardware-in-the-loop system for testing distributed functions for a fully virtual truck.
Powerful Network
For the tests of distributed functions within an ECU network, For communication tests, the most common modern com-
buses and networks play a major role. One of the strengths munication standards are supported, such as CAN, LIN,
of the dSPACE SCALEXIO HIL simulator is simulating com- FlexRay, and Ethernet.
munication networks. The system is able to simulate complex
models, buses, and networks under real-time conditions.
Variant Handling with Data Management Software

A high number of ECUs and ECU variants results in a high
number of different models used for HIL simulation.
Handling the ECU versions and variants is simplified signifi-
cantly by dSPACE Workflow Management based on dSPACE
SYNECT®. It lets you centrally and conveniently configure
all the information necessary to support your workflows in
SYNECT and manage large, highly complex HIL systems with
a high number of variants and multiple software interactions.
31
2016
Use Cases
RCP Systems for DC/DC Controllers

Developing converter functions
Application Areas
Developing and validating controllers for DC/DC
Power levels from very low (small batteries) to very

converters in the vehicle high (high-voltage power transmission)
Key Points
Dedicated FPGA-based I/O interfaces with convenient
Modular hardware concept enables flexible adaptation

Simulink blocksets
®
to changing requirements
User-programmable FPGA for even the fastest control
High scalability from compact systems like

loops MicroAutoBox II to modular systems like AutoBox
XSG AC Motor Control Solution with ready-to-
or Tandem-AutoBox.
use FPGA components for fast and convenient Fast iteration by implementing Simulink models

development of FPGA-based electric motor control automatically on the RCP hardware at the click of
algorithms a button
Short sample times of < 20 μs when using the user-

programmable FPGA functions
Synchronous control of a high number of switches

DC/DC converter
MicroAutoBox II AutoBox with DS1007
with DS1553 PPC Processor Board, 12 V
or
AC Motor DS5203 FPGA Board and Control and
Control Module AC Motor Control Solution feedback signals
Ethernet
400 V
Optional host PC with

dSPACE ControlDesk® Motor

MicroAutoBox II, page 53 DS5203 FPGA Board, page 56
DS1553 AC Motor Control Module, page 57 AC Motor Control Solution, page 56
RapidPro, page 54 XSG AC Motor Control Library, page 55
DS1007 PPC Processor Board, page 53 RTI FPGA Programming Blockset, page 52
AutoBox, page 53
32
2016
Use Cases
Convenient, Graphical FPGA Programming Functionality Overview of the XSG AC Motor

The XSG AC Motor Control Library lets you program inside Control Library
the FPGA. This mainly involves the high-performance pro- All library components are open and accessible
cessing of various position sensors and, in conjunction with Incremental encoder processing (TTL or sine)
the included XSG Utils library, the flexible generation of Hall sensor processing
PWM patterns. The XSG AC Motor Control Library is used Resolver and LVDT processing
for high-performance E-drive controls with sampling rates Synchronous serial interface (SSI) and serial peripheral
above 50 kHz by computing custom control algorithms or interface (SPI) sensor processing
parts of them on an FPGA. FPGA library components (e.g., Flexible PWM generation (by using the included XSG
encoder interfaces and PWM) can be combined freely on Utils library)
various FPGA platforms with different I/O modules and can Small applications and components for control
also be connected to build custom design components. Examples of controller models for various AC motors
Hardware for Highly Dynamic Control Systems

For controlling various AC motors, e.g., asynchronous mo- this means, controller algorithms can be outsourced and
tors (ASMs), brushless DC motors (BLDCs) and permanent the controller loop can be closed directly on the FPGA. For
magnet synchronous motors (PMSMs), dSPACE offers the AC in-vehicle use, the solution hardware can be installed in
Motor Control Solution. The solution consists of hardware dSPACE AutoBox or MicroAutoBox. For stationary use, it
I/O modules for the DS5203 and MicroAutoBox with the can also be installed in an expansion box.
DS1514 FPGA Base Board as well as a convenient Simulink
blockset for easy I/O access directly from the model. For For more information on the AC Motor Control Solution,
controllers that require very high closed-loop turnaround please see page 17.
times, it is also possible to freely program the FPGA. By
Housing for In-Vehicle Applications User-Programmable FPGA Board

For more information on different housings for modular The DS5203 FPGA Board is designed for applications that
hardware, please see page 17. require very fast, high-resolution signal preprocessing. Its
FPGA is completely user-programmable via the RTI FPGA
Programming Blockset.
For more information on the DS5203 FPGA Board, please

see page 11.
33
2016
Use Cases
HIL Tests for DC/DC Converters

Testing power electronics control units
 Highly efficient isolated power supply  FPGA-based solution for electric power systems
 Power optimizer for renewable energy applications  Open real-time models for different converter
 Testing of charging control units topologies
 Testing of vehicle electrical network control units  Support of customer-specific models
 Enhanced simulation quality and reduced delay
 Support of very high switching frequencies
(e.g., 100 kHz)
 Precise handling of internal switching events

Computation of the DC/DC SCALEXIO® HIL simulator
converter model
Current signals
DS2655 FPGA
Board DS2655M1 DS2655M2
Gate driver signals
IOCNET
CAN
IOCNET I/O boards
SCALEXIO Processing Unit Discrete I/O
and buses
Computation of the
environment model Ethernet
Host PC, e.g., with

AutomationDesk

SCALEXIO, page 54 RTI FPGA Programming Blockset, page 52
DS2655 FPGA Board, page 57 SCALEXIO EMH Solution, page 55
DS2655M1 Multi-I/O Module, page 58 DS2655M2 Digital I/O Module, page 58
Electrical Power Systems Simulation Package, page 55 ConfigurationDesk, page 52
34
2016
Use Cases
The Electrical Power Systems Simulation Package

The Electrical Power Systems Simulation Package gener- libraries (XSG Electric Components and ASM Electric Compo-
ates real-time simulation models from information on the nents). You can use the Electrical Power Systems Simulation
circuitry. Combined with SimPowerSystems™, the pack- Package for applications such as auxiliary devices in vehic-
age offers an ideal development environment for testing les, traction drives for electromobility, and electrical energy
electrical systems. In addition to model splitting and the conversion of regenerative power generators.
mean value models for power electronics bridge circuits you
already know from the dSPACE
Power RealTime Library, you
can now also perform FPGA-
based model computation. The
Circuit diagram
package provides ready-to-use
FPGA applications so you can in-
tegrate your own SimPowerSys-
tems models without having to
program the FPGA for each ap- SimPowerSystems model
plication. The Electrical Power
Systems Simulation Package
therefore combines the func-
tions of the Power RealTime Li-
FPGA-based model Processor-based model
brary with a new, FPGA-based
method. In a networked sys-
tem, this combination lets you
compute each model part on
the ideal real-time platform for
the respective latency require-
ments. The automatic transla-
tion of circuitry information
into real-time code saves time
during engineering and provides
very precise, realistic simulation
results, particularly when the
FPGA-based solution is used.
This generic solution is recom-
Fast applications Slow applications
mendable especially if the re- IOCNET
~2.5 µs ~25 µs
quired topologies cannot be sim-
ulated with the dSPACE standard
35
2016
Use Cases
Graphical Configuration
To let you program the FPGA graphically in Simulink, XSG
is supported. The I/O functions and the I/O channels are
also mapped graphically with dSPACE ConfigurationDesk®.
For convenient configuration, the Electrical Power Systems
Simulation Package provides a direct interface for accessing
ConfigurationDesk.
Flexible Test Environment

The dSPACE hardware-in-the-loop system is suitable for a Additionally, the dSPACE network technology IOCNET al-
wide range of customer-specific control applications. Spe- lows for decentralized I/O setups with more than 100 device
cial hardware with user-programmable FPGAs, such as the nodes, which can be located up to 100 meters apart.
DS2655 Base FPGA Board, enables high-precision simula-
tion of electric drives and provides high computing power
for enhanced drive and control applications. For high I/O
requirements, the DS2655 can be expanded with up to five
additional I/O modules.
TCP/IP
Host
Gigalink
IOCNET
Processor IOCNET DS100x Gigalink
I/O subrack PHS I/O board

Processor IOCNET
IOCNET
I/O subrack PHS
I/O subrack I/O subrack PHS I/O board

Router Router
I/O board I/O board

I/O subrack
I/O board I/O board Router
IOCNET
I/O board I/O board I/O board
I/O board I/O board I/O board

.. .. ..
. . .
FIU/PowerSwitch FIU/PowerSwitch FIU/PowerSwitch
36
2016
Use Cases
Test Benches
Developing and testing mechatronic systems
The development and optimization of complex mechanical Mechanical test benches are capable of applying mechani-
and mechatronic systems requires practical tests to handle cal load torques or forces to those parts of the real system
the overall complexity resulting from the interaction of differ- which are physically incorporated into the test setup. If this
ent components and the lack of accurate simulation models. is just the real electric motor, a simple rotational load is
Test benches allow the evaluation of complex systems in real sufficient. Incorporating parts of the mechanics like brake
time 24 hours a day, 7 days a week. boosters, gearboxes, rack-and-pinion systems, etc., leads
to much more complicated configurations, partly requiring
more than one load drive or linear drives.

Test of inseparable drive systems, e.g., test of control
Outstanding real-time behavior (latency, jitter,
units with integrated power electronics such as synchronization even for multiprocessor systems)
steering controllers Support of communication interfaces for all application
Test of mechatronic components with integrated
areas, i.e., automotive interfaces, aerospace interfaces
sensors, e.g,. ESP controllers with integrated as well as industrial interfaces like EtherCAT, PROFIBUS,
acceleration sensors CANopen
Test of human-machine interfaces (HMI)
Proprietary interfaces for high-performance test
Test benches for:
benches, e.g., TWINsync for LTi ServoOne systems as
Steering systems well as gate driver and positions sensor interfaces for
Brake systems third-party components
Engines Open flexible implementation and instrumentation
Electric motors environment
Powertrains Open automotive plant models for closed-loop
interaction
Automated test execution for release tests and tests
during the development in 24/7 operation
Turn-key test bench concepts for all kinds of
electromechanical power steering and brake
applications
Customer-specific extensions like environment
simulation using an integrated climate chamber
through engineering

SCALEXIO, page 54 ASM Vehicle Dynamics Model, page 52
TWINsync Solution, page 59 ASM Electric Components, page 55
AC Motor Control Solution, page 56 MotionDesk, page 52
37
2016
Use Cases
Steering actuator
Steering  Max. torque: 50 Nm
system  Max. speed: 500 rpm
 Precision of positioning:
dSPACE modular < 0.1 degrees
hardware
Clamping plate
Switching cabinet
for the inverter
2.3 m
Entire test rig

 Weight: 16 t
 Connected load: 400 V/63 A
Linear motors
 Max. force: 20 kN
 Max. speed: 1 m/s 7m
 Traverse path: 155 mm
 Excitation frequency up to 30 Hz
 Precision of positioning: < 0.1 mm 1.25 m
 Precision of force control: < 40 N
Setup for a high-performance steering test bench with performance examples.
Test Bench Interfaces

dSPACE’s hardware offers the required scalability, real-time FD, LIN, FlexRay, and K-/L-Line. In addition, automation in-
performance, I/O interfaces and a powerful tool chain to terfaces like EtherCAT and PROFIBUS as well as proprietary
control a complete test bench out of Simulink®. dSPACE interfaces and protocols, e.g., LTi TWINsync for electric motor
provides interfaces to all automotive buses like CAN, CAN control, are also available.
Real-time system Device under test
I/O boards
dSPACE and customer

Processing Unit components combined
Actuator
Power Mechanical
(engineering
stage components
required)
38
2016
Use Cases
TWINsync Solution
The TWINsync Solution from dSPACE for controlling electric The typical components comprise:
drives in perfect synchronicity from a dSPACE HIL simulator SCALEXIO®: Powerful and flexible dSPACE hardware-

makes it possible to use the TWINsync protocol from LTI in-the-loop simulator
Motion. This protocol enables synchronous communication SCALEXIO TWINsync hardware: External housing with

between two or more LTi ServoOne motor controllers and a DS2656 FPGA Base Board and a DS5451 custom I/O
the dSPACE hardware. module as the interface to the TWINsync components.
The solution’s main features include: The IOCNET connection lets you use TWINsync
Perfect synchronicity with the test bench, even for hardware up to 100 m from the SCALEXIO simulator.
complex HIL simulations LTi ServoOne: Compact, high-performance motor

High-performance, low-latency connection, range of control by LTI Motion for a high number of linear and
up to 100 m rotary load motor systems from 2 to 450 A
Decentral use possible, no own processing unit needed
2x TWINsync
Power
2x Digital I/O
IOCNET
Open Simulation Models

The dSPACE ASM Vehicle Dynamics Library provides tailored ASMs’ standardized interfaces allow the vehicle dynamics
open simulation models for testing vehicle dynamics ECUs, models to be easily expanded to meet specific requirements
such as ESP, steering and active damping ECUs, with a test and even let you create a virtual vehicle.
bench. All of the Simulink blocks in the model are visible, so
it is easy to add or replace components with custom models For further information on dSPACE ASM, please see page 24.
to adapt the properties perfectly to individual projects. The
39
2016
Use Cases
From Planning to Turn-Key Systems

For test benches, dSPACE offers comprehensive support Until now, a wide range of test bench projects have been
from the first planning days to the delivery of the turn-key completed. For example:
system to on-site support.
Test system for ECUs with integrated sensors and actuators, with a Rotary steering test bench for electronic power steering (EPS) systems,
3-D motion platform that moves the ECU and thus creates the same including the steering column and assistance motors or for testing
forces that occur in a vehicle. superimposed steering systems.
No-load steering test bench to drive a steering system in closed-loop Brake test bench with the complete real hydraulic system, e.g., brake
mode for integration tests of the complete vehicle. line and pedal, for testing energy recovery during braking, for example.
40
2016
Use Cases
RCP Tests for Industrial Drive Controllers

Developing and validating controller algorithms
Application Areas
Validating the algorithms for industrial drive controllers

Easy adaptations to different motors

Key Points
Convenient implementation of new functions
XSG AC Motor Control Solution with ready-to-

developed with Simulink® on the RCP platform at the use FPGA components for the fast and convenient
click of a button development of FPGA-based electric motor control
FPGA-based I/O interfaces with convenient Simulink
algorithms
blocksets, e.g., the RTI Electric Motor Control Blockset Integration of your FPGA code into existing pre-defined

User-programmable FPGA for even the fastest control
FPGA configurations
loops < 20 µs Easy access to all variables, I/O and bus signals

of the real-time application during run time with
ControlDesk®

Processor-based 1 ... n
computation
TWINsnyc
Ethernet LVDS LTi
MicroLabBox® PGI1
ServoOne
Host PC, e.g., with

or Motor
1 ... n
Ethernet
Third-party
converter
Current
Hall/encoder
Ethernet Power
MicroLabBox using
Resolver Motor
the integrated FPGA amplifier
Gate control signal
Host PC, e.g., with FPGA-based
dSPACE ControlDesk computation

MicroLabBox, page 54 XSG AC Motor Control Solution, page 55
RTI FPGA Programming Blockset, page 52 Programmable Generic Interface (PGI), page 54
RTI Electric Motor Control Blockset, page 54
41
2016
Use Cases
Graphical Configuration
The RTI Electric Motor Control Blockset, an extension of
Real-Time Interface (RTI), is a user-friendly software inter-
face which provides a link between your real-time hard-
ware platform MicroLabBox and the development software
MATLAB®/Simulink/Stateflow® from MathWorks. The block-
set provides access to the electric motor control I/O function-
alities of MicroLabBox® and lets you configure these easily
and conveniently. Simulink-based control models can be
easily connected with the required I/O interfaces and then
be tested on MicroLabBox in a real environment with various
sensors and actuators.
The included blocks enable you to:

Access and configure dedicated I/O functions for

multichannel PWM and block-commutated PWM Control two or more independent electric motors at

outputs, Hall sensor inputs as well as incremental the same time
encoder, resolver, EnDat and SSI interfaces. This lets Combine two sensors to extrapolate the position of

you measure the position of a motor's rotor, its speed, the motor's rotor
or both, and generate the required output signals. Generate events and external triggers for algorithm

Implement control strategies for electric motors with
execution triggered by specified motor positions
up to 6 phases and 16 pole pairs
FPGA for Short Sample Times

MicroLabBox is equipped with a freely programmable FPGA
(Xilinx® Kintex®-7 XC7K325T FPGA) for fast signal prepro-
cessing and for outsourcing controllers directly to the FPGA.
Whenever your project requires sample times shorter than
20 µs, the FPGA comes into play.
For convenient FPGA programming, a fully model-based
tool chain is available. The FPGA controller model can be
+ d-current ctrl
KINTEX ®
i d* = 0A u d* u a*
developed in MATLAB/Simulink with the dSPACE RTI FPGA id -

d,q
u b*
speed ctrl q-current ctrl
Programming Blockset and the Xilinx System Generator for n*

-
i q* u q*
a,b,c
u c*
-
iq
DSP blocksets. dSPACE also offers the XSG AC Motor Con-

n
d,q ia
trol Library, which provides preconfigured function blocks ib
for all major electric motor features like PWM generation, a,b,c ic
Hall, encoder, resolver, EnDat and SSI sensor processing,

and angular computation. With these tools, it is possible to
easily combine processor- and FPGA-based control loops for
even the most demanding prototyping tasks.
42
2016
Use Cases
HIL Simulation for Industrial Drive Controllers

Testing controller algorithms
Industrial automation
Support of industrial position sensors

Robotics
Target-oriented test methods

Software tests with a high number of hardware
Support of industrial bus interfaces

configurations Flexibility, combination of electrical and mechanical

Automation regression tests
solutions
Important aid to quality assurance and development

cost reduction
Fast adaptation to a wide range of controller

Computation of the dSPACE Components Customer Components

simulation model
SCALEXIO® HIL simulator
SCALEXIO
Processing Unit Current
Hall/encoder
Ethernet IOCNET
Resolver
DS2655 FPGA Base Gate control signal
Host PC, e.g., with Board and DS2655M1
ConfigurationDesk® Multi-I/O Module
In this example, the processor-based simulation with If faster model calculation is required, the HIL hardware can
SCALEXIO® is described, where all the models are calculated also be used for FPGA-based simulation using the dSPACE
on the SCALEXIO Processing Unit. XSG Electric Components Library instead of dSPACE ASM
Electric Components Library and the EMH Solution.

SCALEXIO, page 54 ASM Electric Components Library, page 55
SCALEXIO Processing Unit, page 54 SCALEXIO EMH Solution, page 55
DS2655 FPGA Base Board, page 57 DS2655M1 Multi-I/O Module, page 58
ConfigurationDesk, page 52
43
2016
Use Cases
Processor-Based Simulation of Electric Motors

The new SCALEXIO EMH Solution provides a ready-to- is a high number of variants, entailing an enormous testing
use FPGA application with a comprehensive I/O library for workload. As the necessary controlled systems and real parts
processor-based HIL simulation of electric motors. You can be replaced by simulation models, setups and changes
can use it to configure the simulation of up to two elec- of the test scenario can be done quickly. With automated
tric motors on one DS2655 FPGA Base Board from within testing on a HIL simulator, these tests then are accelerated
ConfigurationDesk®. Thanks to the predefined function significantly.
blocks, you no longer have to program or generate FPGA In addition to the servo controller, you can also test the
code. The fast I/O of the DS2655M1 Multi-I/O Module and the energy management system if a regenerative unit is part
integrated angular processing unit (APU) with a resolution of of your system. For this, dSPACE offers simulation models
8 ns let you use high-resolution I/O to measure applications for grid simulation.
in the areas of pulse width modulation (PWM) and position
sensor simulation (PSS). The variable I/O channel mapping
and the flexible support of up to five DS2655M1 Multi-I/O Main Functions
Modules let you tap the hardware’s full potential. Position Sensor
Pulse Width Modulation

You do not have to replace hardware to switch from pro- Simulation (PSS) Six-Channel PWM In

cessor-based simulation to FPGA-based simulation. You can Resolver Out
Single-Channel PWM In

simply continue to use the existing hardware system. Sine Encoder Out
Single-Channel PWM Out

Incremental
Basic I/O Functions

Flexible Adaptation Encoder Out Multi-Bit In

Controlled electric drives are a key technology in numerous Hall Encoder Out
Multi-Bit Out

engineering applications. Handling so many applications Analog Wavetable
Multi-Voltage In

calls for a high degree of flexibility, especially for servo con- Encoder Out Multi-Voltage Out

trollers in industrial automation. And with all the possible Digital Wavetable

configuration options for the servo controller software, there Encoder Out
Gate control signals
DS2655 FPGA DS2655M1 Multi-

Base Board I/O Module
Current signals ECU
Hall encoder
Resolver
44
2016 ConfigurationDesk®
Use Cases
Closed-Loop Electric Components

The ASM Electric Components Library is optimized for 600
processor-based HIL simulations in real time. Application 500
areas include servomotors for machine drives or position- 400
ing motors, industry automation, and industrial converters.
300
n/rpm
200
The Closed-Loop Electric Components sublibrary of the
100 n Ref
ASM Electric Components Library includes components n Meas
0 n Sim
such as electric machines, controllers, and power electron-
ics. These components represent the controlled system for -10
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2
closed-loops tests of machine controllers in a HIL system. t/s
The models support real-time simulation in fast timer tasks 80
or hardware interrupt tasks like those necessary for PWM- 70 i sq, Meas
60 i sq, Sim
synchronous model calculation with extremely short sample
50
times, such as 50 µs.
40
isq/A
30
The main components for closed-loop applications are: 20
Electric motors (DC, BLDC, PMSM, asynchronous AC 10
induction motor) 0
Controllers -10
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2
Various auxiliary blocks
t/s
Three-level inverters
Discontinuous conduction mode (DCM) inverters Comparison between motor speed control in HIL simulation (red)
and in a real test setup (blue), each with a sampling rate of 125 µs.
For information on the dSPACE ASM components for electric

system simulation, please see page 24.
45
2016
Use Cases
RCP Systems for Robotic Motion Controllers

Developing and validating functions
Testing and validating robotic motion controller
Fast and flexible position sensor interfaces accessible

functions from the real-time Simulink® model
Inclusion of external sensors and robotics-specific
Easy access to all variables, I/O and bus signals

sensors, e.g., axis-force momentum sensors of the real-time application during run time with
Inclusion of camera signals
ControlDesk®
Trajectory planning and running advanced algorithms
Calculation of values for inverse kinematics with highly

for collision avoidance nonlinear functions in real time

automatically on the RCP hardware at the click of a
button

functions

MicroLabBox®
Comparison of actual I/O

6 incremental
setpoint values encoders
Calculation of I/O
Controller output
output variable
Ethernet
Host PC with
dSPACE Real-Time
Interface
The test setup varies depending on the robot.

MicroLabBox, page 54 Real-Time Interface, page 52
RTI Electric Motor Control Blockset, page 54
46
2016
Use Cases
HIL Tests for the Power Equipment of Electric Trains

Testing controllers for grid interfaces, electric drives, and power electronics
Electric trains are characterized by a broad range of compo- complete virtual test environment. Adaptable testing solu-
nents and systems. The number of electric drives and other tions are needed to fulfill the requirements of scalability and
power equipment components depends on the number of timing. Due to the complexity of the systems and the limited
electric railcars and varies considerably. Typical train appli- commissioning time, executing the majority of the tests in
cations require a high amount of I/O channels to enable a the more comfortable laboratories is a great advantage.
Application Areas Multicore applications for large simulation models

n Traction converters Large amount of I/O channels

n Auxiliary converters (on-board power supplies) Very short cycle times in the processor-based simulation

n Battery chargers by FPGA preprocessing and optimization of I/O access
n Mains connection including main transformer, rectifier Interaction of FPGA-based and processor-based

and energy distribution simulation platforms
Simulation of power equipment by drawing electric

circuits
Key Points Design of I/O boards with customer-specific I/O

Test system adaptation to individual components configurations thanks to the I/O functions library of the
Scalable from single components to a virtual train XSG Utils Library and the flexible I/O of the DS2655
Support of several parallel motors FPGA Base Board
Integration of a large amount of power electronics
Overhead line
Cooling fans Main rectifier Pantograph
DC link
Traction
inverter
Battery
3-phase Auxiliary Auxiliary Main 3-phase

traction motors rectifier inverter transformer traction motors

SCALEXIO Processing Unit, page 54 Electric Power Simulation Solution, page 55
DS2655 FPGA Board, page 57 ConfigurationDesk, page 52
DS2655M1 Multi-I/O Module, page 58 XSG Utils Library, page 56
DS2655M2 Digital I/O Module, page 58 XSG Electric Components Library, page 55
47
2016
Use Cases
Customer-specific
components
FPGA for motor models 1, 2, 3, 4
Controller for (XSG EC) & rectifier (EPSS FPGA)
driving axles 1 & 2,
AC motor Controller for:
Controller for Grid interface,
driving axles 3 & 4, Main rectifier,
AC motor DC bus, brake chopper
Controller for Standard I/O
auxiliary converter &
cooling fan Controller for battery & auxiliary rectifier
Controller for
Computation node for
auxiliary inverter &
electric motor model & FPGA interface
230 V supply
Model of the train’s vehicle dynamics
Grid model and DC bus (SimPowerSystems)
Example of a HIL simulator system for testing railway ECUs.
Support of Multiprocessor Systems Controlling and Simulating Electric Motors

To increase the computational power for large test systems, The new DS2655M2 Digital I/O Module adds 32 digital
two or more SCALEXIO® Processing Units can be coupled. I/O channels to the DS2655 FPGA Base Board, letting
The systems are coupled via IOCNET (page 36) to ensure you capture or generate more digital signals, e.g., for
sufficiently large bandwidths. For convenient modeling, position sensors. Furthermore, the I/O channels can be
you still have just one overall project in the configuration configured as senders or receivers for RS232- and RS485-
software, ConfigurationDesk®. based communication. With the appropriate FPGA-based
programming, you can thus simulate protocol-based po-
Adjustable I/O Scale sition sensors (such as SSL, EnDat, and HIPERFACE) and
For comprehensive I/O requirements, the DS2655 FPGA digital encoders (such as incremental encoders). The FPGA
Base Board can be extended with I/O modules. The example is programmed for each case via Xilinx® System Generator.
simulator setup on the right includes six DS2655 with 30 I/O The FPGA application generated by the dSPACE FPGA
modules and three Processing Units. Altogether, the system Programming Blockset is then easy to import into dSPACE
provides more than 500 I/O channels that are available via ConfigurationDesk to configure the entire SCALEXIO
Hypertac connectors. The computation performance and system graphically. The DS2655 FPGA Base Board can be
the outstanding IOCNET I/O access let you run the complete connected with up to five I/O modules via a ribbon cable,
simulation with sample times of less than 20 µs (input-to- offering a highly flexible number of available channels.
output latency of less than 2x sample time). The SCALEXIO
system can be adapted to all project requirements by dSPACE
Engineering Services.
48
2016
Use Cases
Synchronization
Due to the short sample times, jitter effects have to be
reduced as far as possible. Depending on the I/O channel
requirements, different synchronization methods are avail-
able. To minimize the jitter between two or more DS2655
FPGA Base Boards, including their modules, for gate driver
capturing, the stacks are synchronized with each other via
the appropriate I/O channels. This lets you synchronize mul-
tiple boards with a jitter of two FPGA clocks.
Faster Implementation of FPGA Models

The XSG Utils Library offers users of real-time FPGA appli-
cations enhanced function blocks for implementing their
own projects. The library is completely open and can be
used in rapid control prototyping (RCP) projects as well as
hardware-in-the-loop (HIL) simulation.
Due to the generic programming, the library can be applied
to all freely programmable dSPACE real-time FPGA platforms
with a Xilinx FPGA.
dSPACE offers a variable license model:
XSG Utils Library for developers of FPGA and processor
applications
XSG Utils Interface Library for users who embed
preconfigured FPGA applications into existing
Simulink® models
Available Function Blocks

Scope Sine Generator

PWM Measurement Discrete PT1

PWM Generator Scaling

Look-up Table Wavetable Encoder

I/O Access Functions APU

Integrator Small Apps

PI Controller Version Info

Average Calculator
49
2016
Use Cases
HIL Simulation of Power Supply Systems

Testing smart grids and distributed power generation
Power supply systems are undergoing significant changes distribution and storage to keep energy losses at a minimum.
with the increasing importance of regenerative energy and Electric vehicles are a suitable option to even out fluctua-
the growing popularity of electric vehicles. Due to variations by connecting them to the grid whenever additional
tions in energy supply and demand, these systems must be power is needed or excess power is available to be stored
highly flexible and need intelligent subsystems for energy for later use (vehicle-to-grid, V2G).

Testing microgrid and smart grid controllers
Fast simulations in different time domains to provide

Testing controllers of solar inverters, battery inverters
extremely high precision for individual components as
and fuel cells well as large grid networks
Testing solid state transformers
Very high scalability

Testing the interaction between electric vehicles and
Easy integration of the various smart grid components

the grid (V2G) into one test scenario
Simulating complex microgrids or smart grids with and
Testing at the signal and power levels

without connection to the utility grid Support of all major industrial buses

Simulating indivdiual microgrid and smart grid
Support of common smart charging protocols

components
Grid
IOCNET
Smart grid controller
I/O board
IOCNET Solid state transformer
I/O board
IOCNET
IOCNET Controller
I/O board
IOCNET Photovoltaic system Conventional power plant
IOCNET SCALEXIO
I/O board Processing Unit Solar inverter Turbine generator controller
IOCNET
SCALEXIO
I/O board Processing Unit
IOCNET
SCALEXIO Electric vehicle battery
Processing Unit
IOCNET
SCALEXIO Charging control unit
Ethernet Processing Unit
SCALEXIO®
Optional host PC with
dSPACE ControlDesk® Processing Unit Wind power plant Storage system
Wind power inverter Battery management system

SCALEXIO, page 54 SCALEXIO EMH Solution, page 55
ConfigurationDesk, page 52 Electrical Power Systems Simulation Package, page 55
50
2016
Use Cases
Smart Grid Testing

The variations in energy supply and demand throughout The load grid side, including distributed energy

the day require a close monitoring of the grid as well as an resources, to test the functionality of the smart grid
efficient energy management system that allows power sup- controller
pliers to respond immediately to any changes. To create such The grid side to learn how the integration of local

a highly flexible system, numerous power electronics devices power supply systems might affect the utility grid
are necessary. Their functionality and interactions must be The power grid without distributed energy resources by

tested thoroughly to make the power supply system reliable. connecting virtual components via a restbus simulation
The dSPACE tool chain provides comprehensive support for Power level interfaces to bring grid emulators into the

any test case needed, like hardware-in-the-loop controller simulation environment
tests or real-time simulations with SCALEXIO® to fully test
microgrids, smart grids, or V2G. One central component that For further information, please see:
needs to be tested extensively is the smart grid controller. Electric Motor HIL Simulation Solution, page 44
It lets you integrate the smart grid into the utility grid and FPGA-based simulation, page 14
manages their interaction.
With the dSPACE tools, you can simulate all parts of the
network just as you need:
dSPACE offers comprehensive support for developing and testing

ECUs for power industry applications – whether you are develop-
ing power systems, control units, energy management systems,
inverters, or other power-related systems.
Electrical Power Systems Simulation (EPSS) Package

Enables the real-time simulation of SimPowerSystems
FPGA code automatically configured according to

models from MATLAB ®
the specified SimPowerSystems model
Processor-based and FPGA-based simulation
High timing resolution

EPSS FPGA part features:
Modeling different topologies with the same FPGA

Fully integrated in the dSPACE SCALEXIO
(no need to build a new one)
environment
Easy-to-use approach using ConfigurationDesk®
For more information, please see page 35.
plug-in
51
2016
Products
General Products
Software
Name Description Application Area

Automotive Simulation Support of all automotive-relevant modeling areas with simulation models in the
Rapid control prototyping

Models (ASM) following domains: electric components, vehicle dynamics, and combustion engines Hardware-in-the-loop

Real-time-capable simulation models
simulation
Open and ready-to-use MATLAB®/Simulink® models

For ECU testing and function development

ASM models from different domains are easy to combine

AutomationDesk Test authoring and automation tool

Hardware-in-the-loop

Graphical description of test routines
simulation
Advanced custom library concept

Remote control of calibration, measurement and diagnostic tools, such as

ControlDesk®
ConfigurationDesk® Configuration and implementation software for dSPACE SCALEXIO® hardware

Graphical configuration of real-time applications
simulation
Management of signal paths between external devices and behavior model interfaces

Implementation of behavior model code and I/O function code

ControlDesk Universal modular experiment and instrumentation software for ECU development

Integrated ECU calibration, measurement and diagnostics access (CCP, XCP, ODX)

Synchronized data capture across ECUs, RCP and HIL platforms, and bus systems
simulation
Powerful layouting, instrumentation, measurement and postprocessing (ASAM MDF)

ECU Interface Manager Integration of bypass hooks for on-target and external bypassing directly into the ECU

software Hardware-in-the-loop

Quick integration of bypass hooks in ECU HEX files; no ECU source code and build
simulation
environment required
Visualization of function calls, read/write accesses to ECU variables and conditional

branches in ECU code
Support of on-target and external bypassing

ModelDesk Graphical user interface for parameterization and simulation


Seamless simulation process from MIL to HIL
simulation
Parameter changes online and offline

Road Generator, Maneuver Editor, Traffic Editor

Tool automation – remote and batch mode

Custom model parameterization

MotionDesk 3-D online animation of simulated mechanical systems in real time


Tight integration to ModelDesk and ASM
simulation
Intuitive graphical scene design

Real-Time Interface (RTI) Implementation software for running models on dSPACE hardware

Automatic implementation of MATLAB/Simulink/Stateflow® models on dSPACE

hardware simulation
Automatic code generation

Graphical I/O configuration via comprehensive Simulink block libraries

RTI FPGA Programming Integration of FPGA models in dSPACE systems


Blockset Signal preprocessing, adapting new interfaces, very fast control loops, designing and

testing new concepts for electrified powertrains simulation
Easy connection of FPGA models to processor models (Simulink, RTI)

Model-based I/O

Offline simulation in Simulink

52
2016
Products
Software

SYNECT ®
Data management and collaboration software tool with a special focus on model-

based development and ECU testing simulation
Complete traceability between requirements, models, parameters, and test cases

Integrated variant management

Direct connection to engineering tools

TargetLink® Automatic production code generator


High-quality production code generation directly from Simulink/Stateflow
ECU autocoding

Powerful software design and testing features

Highly efficient fixed-point and floating-point code

Comprehensive fixed-point support, including autoscaling

Support of modular, component-based development

High-performance, native AUTOSAR support

Efficient data management with the TargetLink Data Dictionary

Certified for ISO 26262, IEC 61508, and derived standards

Hardware

AutoBox/Tandem-Autobox Robust housing for in-vehicle use Rapid control prototyping

Mounting of processor boards and I/O boards (7 slots in the AutoBox, 15 slots in the
Tandem-AutoBox)
Power supply via car battery, for 12 V, 24 V, and 48 V electrical systems
DCI-GSI2 Interface for function bypassing, measurement, ECU calibration and flash

programming Hardware-in-the-loop

Very small communication latencies for bypassing and high data throughput for
simulation
measurement
Support of standardized XCP on Ethernet interface

Measurement and bypassing without ECU code changes

DS1006 Processor Board Computing power for complex real-time models


Quad-core AMD OpteronTM processor
simulation
Fully programmable from Simulink®

Multiprocessor system consisting of several DS1006 Processor Boards linked via fiber-

optic connection (Gigalinks)
DS1007 PPC Processor Computing power and small I/O latencies

Board Freescale QuorlQ P5020, dual-core PowerPC, 2 GHz

Fully programmable from Simulink
simulation
Multiprocessor capability via fiber-optic connection

MicroAutoBox® II Compact and robust prototyping real-time system for in-vehicle applications

Comprehensive I/O including CAN, CAN FD, LIN, K-Line/L-Line, FlexRay, Ethernet, and

bypass interfaces
Can be equipped with the AC Motor Control Solution

Variants with Simulink-programmable FPGA and Embedded PC (Windows/Linux)

available
53
2016
Products
Hardware

MicroLabBox ®
Compact prototyping unit for the laboratory

2 GHz dual-core real-time processor and user-programmable FPGA

More than 100 channels of high-performance I/O with easy access via integrated

connector panel
Dedicated electric motor control features and interfaces for Ethernet and CAN bus

RTI Electric Motor Control Blockset for providing access to the electric motor control I/O

functionalities of MicroLabBox
Access and configure dedicated I/O functions for multichannel PWM and block-

commutated PWM outputs, Hall sensor inputs, incremental encoder, resolver, EnDat
and SSI interfaces. This lets you measure the position of a motor's rotor, its speed, or
both, and generate the required output signals.
Implement control strategies for electric motors with up to 6 phases and 16 pole pairs

Control 2 or even more independent electric motors at the same time

Combine 2 sensors to extrapolate the position of the motor's rotor

Generate events for algorithm execution triggered by specified motor positions

RapidPro hardware Compact, robust and flexible hardware for in-vehicle, laboratory and test bench use

Extends dSPACE RCP systems with software- and hardware-configurable modules for

signal conditioning and power stages
Scalable, modular and configurable system architecture

Programmable Generic Centralized connection of sensors and actuators to dSPACE systems


Interface (PGI1) Emulation of sensor signals (such as yaw rate or crash sensors) with HIL simulation

Highly flexible adaptation to customer requirements via piggyback modules and
simulation
special FPGA firmware
SCALEXIO® Modular real-time system

Maximum flexibility due to extensive I/O features
simulation
Model integration via Simulink or FMI

Large number for I/O boards for different applications

IOCNET for communication

Enables a distributed HIL architecture with decentralized I/O

The individual system can comprise more than 100 device nodes, which can

be located up to 100 meters apart
Easy extension of existing systems by adding several I/O subracks that do not
need
their own processing units
For more information on the architecture of a SCALEXIO system, see page 36

SCALEXIO Processing Unit Computing core of a SCALEXIO system with high bandwidth for I/O communication

via IOCNET simulation
Distribution of large, complex simulation models across several processor cores for

computation in real time
Multiprocessor support for coupling two or more SCALEXIO systems for increased

computational power
54
2016
Products
Electric-Drives-Specific Products
Software

ASM Electric Components Open MATLAB
®
/Simulink model for automotive electrical systems and
®

electric drives simulation Hardware-in-the-loop

Simulation of electric drive components and power electronics in a closed
simulation
loop with ECU
Prepared for testing battery management controllers

Demo models for simulating a hybrid vehicle or powertrain

Variable sample times for pulse width modulation (PWM)-synchronous

calculation
PMSM machines with current-dependent differential inductances

Battery Cell Measurement and Implementation software for the Battery Management System Solution

Balancing Blockset Preconfigured library blocks

Electrical Power Systems Simulation Real-time simulation of SimPowerSystems™ circuits for hardware-in-the-

Package loop applications simulation
Processor-based approach for mid-latency simulation down to 20 µs

simulation step size
FPGA-based approach for low-latency simulation with less than 2.5 µs

simulation step size
RTI Electric Motor Control Blockset Extension of Real-Time Interface (RTI) which links MicroLabBox and the

development software MATLAB/Simulink/Stateflow® from MathWorks
Access to and configuration of dedicated I/O functions for multichannel

PWM and block-commutated PWM outputs, Hall sensor inputs,
incremental encoder, resolver, EnDat and SSI interfaces
Implementation of control strategies for electric motors with up to 6

phases and 16 pole pairs
Control of 2 or more independent electric motors at the same time

Combination of 2 sensors to extrapolate the position of the motor's rotor

Generating events for algorithm execution triggered by specified motor

positions
SCALEXIO EMH Solution I/O functions for processor-based simulation of electric drives

Predefined function blocks, so no FPGA code has to be programmed or
simulation
generated
For use with the DS2655 and up to five of its modules

SCALEXIO Ethernet Solution Adds an Ethernet I/O function to ConfigurationDesk®


Up to three independent Ethernet interfaces for SCALEXIO system
simulation
UDP/IP

TCPI/IP (client and server)

XSG AC Motor Control Library FPGA-based control design for MicroAutoBox II, MicroLabBox, SCALEXIO,

and PHS-based systems Hardware-in-the-loop

FPGA library for high-speed electric drive control
simulation
High-performance position sensor processing

Flexible PWM generation (using included XSG Utils library)

XSG Electric Component Models Open plant models for FPGA-based simulations

Simulation of extremely time-critical applications
simulation
Direct I/O access

Very high oversampling rate corresponding to the PWM switching

frequency
No PWM synchronization necessary

Current ripple (PWM effects) can be simulated

Better precision in simulating higher fundamental frequencies

55
2016
Products
Software

XSG Utils Library Faster implementation of FPGA models

Library of ready-to-use function blocks

Completely open models for Simulink and Xilinx® System Generator
simulation
(XSG)
Real-time FPGA programming

Wide range of function blocks, e.g., Scope, PWM Measurement/

Generation, Look-up Table, Integrator, PI Controller, Sine Generator,
Discrete PT1, Scaling, Wavetable Encoder, APU
Hardware

AC Motor Control Solution Prototyping highly dynamic control systems for different types of AC

motors
Fast current/voltage measurements

Control of AC motors, e.g., asynchronous motors (ASMs), brushless DC

motors (BLDCs), and permanent magnet synchronous motors (PMSMs)
Suitable PWM generation for electric drives

Connection of diverse position encoders

EV1077 Battery Cell Voltage Emulation Emulating lithium-ion battery cell voltages for HIL tests from 0 to 6 V

Board 4 galvanically isolated high-precision analog outputs with current
simulation
feedback
Ethernet-controlled

Communication with the real-time system by means of EV1082 controller

board (one for each 32 EV1077)
Compact size, up to 32 cells can be combined in one 19'', 3 height unit

(U) module or up to 128 cells in a 19'', 12 U rack
Requires the EV1082 controller board

EV1082 Controller Board Controller board for the EV1077 Battery Cell Voltage Emulation Board

One board is needed for each 32 EV1077
simulation
EV1093 Measurement and Balancing Monitors up to 24 battery cells regarding cell voltage and temperature,

Board expandable with further EV1093 boards
Ethernet interface for access to dSPACE platforms

Exchangeable balancing resistors on plug-in resistor boards

Central board for the Battery Cell Voltage Measurement and Balancing

solution
Fully galvanically isolated from the computation node

DS5203 FPGA Board Modular hardware designed for applications that require very fast, high-

resolution signal preprocessing Hardware-in-the-loop

Completely user-programmable via the RTI FPGA Programming Blockset
simulation
Uses the Xilinx System Generator (XSG) Simulink Blockset

Basic set of I/O drivers on board, I/O extendable by piggyback modules

56
2016
Products
Hardware

DS5380 Electronic Load Module Electronic load module for the HIL simulation of electric machines

(Voltage range: 30 V) For highly dynamic measurement and high-speed operations
simulation
Works as both current sink and current source

30 V and 30 A per module

Connects to dSPACE simulator and SCALEXIO

Operates with user-programmable FPGA boards

DS5381 Electronic Load Module Electronic load module for the HIL simulation of electric machines

(Voltage range: 60 V) For emulating three-phase electric motor units
simulation
Highly efficient due to energy recuperation during operation

Connects to dSPACE Simulator and SCALEXIO

Up to 60 V, ideal for 48 V on-board vehicle voltage

100 A, higher currents by parallel operation

Operates with user-programmable FPGA boards

DS1553 AC Motor Control Module Add-on module for MicroAutoBox II


I/O module with I/O optimized for controlling various electric drives

Processing of multiple rotary encoders:

Hall sensors (up to 2 interfaces)

Incremental encoders (up to 2 interfaces)

Resolvers (1 interface)

SSI and EnDat encoders (2 interfaces)

Basic support for BiSS interfaces

Up to 24 PWM output signals for block, sine or user-specific

commutation
16 output signals in standard configuration(2 x PWM6CA)

24 output signals require reconfiguration of MicroAutoBox to use

some pins of the IP modules (4 x PWM6CA)
8 fast ADCs with internal filters and synchronization to specified events

2 DACs, 4 multipurpose DigOuts, 2 additional DigIns

DS1768 high current half-bridge power 2-channel, high-current, half-bridge driver module for 12 V and 24 V

stage module (PS-HCHBD 2/2) applications
Each channel up to 60 A peak current (1 s), 42 A rms continuous per

channel (depending on ambient temperature, electric drive mode)
Electric drive mode: Control of three-phase electric motors (BLDC motors

and synchronous motors)t
General-purpose mode for controlling high-current actuators (e.g., valves,

resistive loads) (up to 30 A peak current. 19 A rms current)
Up to 30 A peak current per channel (1 s), 19 A rms continuous current

per channel (depending on ambient temperature)
Output stages in the general-purpose mode configurable as half-bridge,

low-side or high-side driver
Max. supply voltage: 30 V

Current measurement with software-configurable low-pass filter (1st

order/2nd order)
Protection against: short circuit, overtemperature, and overvoltage

DS2655 FPGA Board SCALEXIO I/O board with user-programmable FPGA using RTI FPGA

Programming Blockset and XSG-based solutions Hardware-in-the-loop

Flexible board for special I/O solutions
simulation
Up to 5 piggyback modules for I/O can be added

Available modules for additional digital and analog I/O channels

DS2655M1 Multi-I/O Module
DS2655M2 Digital I/O Module
57
2016
Products
Hardware

DS2655M1 Multi-I/O Module Digital I/O Input Rapid control prototyping

10 channels, usable
Maximum input voltage: 15 V

as input or output Threshold for each channel adjustable from
simulation
1 V to 7.5 V
Output
Push-pull drivers
One output voltage can be selected for all
channels: 3.3 V or 5 V
Analog I/O Input
5 channels

Resolution: 14 bit

Sampling rate: 4 MSPS SAR

Input voltage range selectable for each

channel: ±5 V or ±30 V
Output
5 channels
Resolution: 14 bit
Update rate: 7.8 MSPS
Output voltage range: ±10 V
DS2655M2 Digital I/O Module Digital I/O Input Rapid control prototyping

32 channels, usable as
Maximum input voltage: 15 V

input or output Threshold for each channel adjustable from
simulation
1 V to 7.5 V
Output
Push-pull drivers
One output voltage can be selected for all
channels: 3.3 V or 5 V
UART
16 channels extended with RS232/RS485
transceivers
RS232: max. 250 kBaud
RS485: max. 40 MBaud
Configuration (maximum 32 x digital input

configuration of the 32 x digital output, (push/pull or push or

functions) pull)
16 x digital output, (push/pull/tristate)

8 x RS232 RX (24 digital I/O or 8 x RS232

TX channels are free)
8 x RS232 TX (24 digital I/O or 8 x RS232

RX channels are free)
8 x RS485 RX (16 digital I/O channels are

free)
8 x RS485 TX (16 digital I/O channels are
free)
8 x RS485 RX/TX (8 digital I/O channels

are free)
58
2016
Products
Hardware

Electronic load emulation Electronic load module for simulating an electric motor at power level at

(Voltage range: up to 800 V) high voltages simulation
For testing electric drive systems, including the power stages

No restrictions regarding dynamic processes during the HIL simulation of

electric motors
TWINsync Solution Hardware for controlling electric motors via a SCALEXIO system via

TWINsync comunication simulation
High synchronization between test bench and HIL simulation for complex

simulation scenarios
Small signal latencies

59
2016
Index
Index
3-D motion platform 40 H S
Hardware-in-the-loop simulation (HIL) 6, 12, 18, 22, 29, SCALEXIO® 6, 12, 14, 19, 29, 30,31, 39, 43, 48,
A 34, 37, 43, 47, 50 51, 54
AC Motor Control Solution 56 Human-machine-interface (HMI) 19 SCALEXIO EMH Solution 44, 55
Actuator 15, 16, 18, 38, 42, 54, 57 Hybrid controller 27, 29, 30 SCALEXIO Processing Unit 12, 43, 48, 54
Automotive Simulation Models (ASM) 52 Hybrid electric powertrain 28, 29 Software-in-the-loop (SIL) 6, 25, 26
ASM Multi Cell Model 23 Hybrid electric vehicle 27 Simulation at
ASM Vehicle Dynamics Model 37, 52 Electric power level 7, 18
ASM Electric Components 45, 55 I Mechanical level 7
AutoBox 5, 17, 53 IEC 61508 6, 25, 26, 53 Signal level 7, 12
AutomationDesk 7, 52 Industrial drive control 41, 43 Smart grid 3, 50, 51
AUTOSAR 25, 28, 53 Integrated actuator 40 Steering test bench 37, 38, 40
Auxiliary system 15, 18 Integrated sensor 40 SYNECT® 7, 31, 53
In-vehicle auxiliary unit 15, 18
B In-vehicle traction 9, 12, 22, 29 T
Battery cell voltage emulation 22, 23, 56 IOCNET 35, 36, 39, 48, 54 Tandem-AutoBox 32, 53
Battery management system 20, 22, 23, 25, 27, 50, 55 ISO 26262 6, 25, 26, 53 TargetLink 5, 6, 25, 26, 28, 53
Braking test bench 37, 40 Test bench 5, 37, 54, 59
J Traction motor 12, 47
JMAG 12 Train power equipment 47
C TÜV SÜD 26
ConfigurationDesk® 44, 48, 51, 52 TWINsync protocol 39
ControlDesk® 4, 5, 7, 10, 27, 41, 46, 52 K
TWINsync solution 9, 39, 59
Controller design 4 Kalman filter 21
Controller implementation 5
V
Controller test 6 L
Virtual vehicle 18, 29, 30, 39
Converter 9, 32, 34, 41, 45, 47 Lithium-ion cell stacks 6, 21, 22, 56
Vehicle traction 9, 12, 22
LTi
D Converter 9,
X
Data management 6, 7, 31, 53 ServoOne 9, 10, 37, 39, 41
Xilinx® Kintex® 11, 13
DC/DC controller 30, 32 LVDS 9, 10, 41
Xilinx System Generator 10, 14, 42
DC/DC converter 32, 34 XSG AC Motor Control Solution 10, 28, 32, 33,
DCI-GSI2 10, 53 M 41, 42, 55
Distributed functions 29, 31 Mechatronic system 37 XSG Electric Components Library 13, 14, 19
Driving simulation 19 MicroAutoBox II 10, 16, 21, 28, 32, 53 XSG Utils Library 14, 33, 47, 49, 55, 56
DS1006 17, 53 MicroLabBox® 5, 21, 42, 54, 55
DS1007 9, 10, 53 Model-in-the-loop simulation (MIL) 6, 25, 26, 52
DS1553 10, 11, 28, 32, 57 ModelDesk 7, 52
DS2655 13, 14, 19, 34, 36, 44, 47, 48, 49, 57 MotionDesk 7, 52
DS2655M1 13, 34, 43, 44, 58
DS2655M2 13, 34, 48, 58 P
DS5203 10, 11, 14, 19, 32, 33, 56 Parameterization 7, 12, 52
DS5380 19, 57 Power supply system 50, 51
DS5381 19, 57 Powertrain 37
Fully electric 9, 24
Hybrid 12, 28, 29
E
Processor-in-the-loop simulation (PIL) 6, 25, 26
ECU Interface Manager 5, 52
Processor-based simulation 6, 44, 47, 55
ECU network 9, 27, 29, 31
Production code generation 5, 6, 25, 28, 53
Electric Motor HIL (EMH) Solution 44, 55
Programmable Generic Interface (PGI) 9, 54
Electronic load emulation (800 V) 19
Electronic load module 19, 57
Electric motors on signal level 7, 12 R
Electrical Power Systems Simulation 6, 35, 36, 55 Rapid control prototyping (RCP) 4, 9, 15, 20, 27, 32 ,37,
EN 50128 26 41, 46
Environment simulation 37 RapidPro hardware 16, 17, 54
EV1077 22, 23, 56 Real-Time Interface (RTI) 17, 28, 52
EV1082 22, 23, 56 Robotic motion controller 46
EV1093 20, 21, 56 RTI Electric Motor Control Blockset 41, 42, 54, 55
Expansion box 5, 33 RTI FPGA Programming Blockset 10, 14, 33, 42, 52,
56, 57
F
FEM 12
Function bypassing 10, 53
FPGA-based simulation 12, 14, 15, 32, 34, 35, 41, 42,
43, 44, 47, 48, 51, 55
FPGA programming 10, 14, 28, 33, 42, 48, 56
60
2016
www.dspace.com
© Copyright 2016 by dSPACE GmbH.
All rights reserved. Written permission is required for reproduction of all or parts of this publication. The source must
be stated in any such reproduction. dSPACE is continually improving its products and reserves the right to alter
the specifications of the products at any time without notice. "CalDesk", "ConfigurationDesk", "ControlDesk",
"dSPACE", "Embedded Success dSPACE", "Green Success", "MicroAutoBox", "MicroLabBox", "ProMINT", "SCALEXIO",
"SYNECT", "SystemDesk", "TargetLink", and "VEOS" are trademarks or registered trademarks of dSPACE GmbH in
the United States of America or in other countries or both. Other brand names or product names are trademarks or
registered trademarks of their respective companies or organizations.
Germany United Kingdom France

dSPACE GmbH dSPACE Ltd. dSPACE SARL
Rathenaustraße 26 Unit B7 . Beech House 7 Parc Burospace
33102 Paderborn Melbourn Science Park Route de Gisy
Tel.: +49 5251 1638-0 Melbourn 91573 Bièvres Cedex
Fax: +49 5251 16198-0 Hertfordshire . SG8 6HB Tel.: +33 169 355 060
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Fax: +44 1763 269 021 info@dspace.fr
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Power Electronics and

Power Electronics and Electric Drive Technology

Why Electric Drives? Requirements

Controller Design and Rapid Control Prototyping

Monitoring Build and

Development process with rapid control prototyping.

Fast Iterations – Maximum Freedom

Controller Implementation and Production Code Generation

tency between the specifications and the production code.

The TargetLink code easily matches the efficiency of human pro-

TargetLink Features at a Glance Support of modular, component-based development

Modeling the control algorithm Embedded

Adding software specifications

Model-in-the-loop simulation Software-in-the-loop simulation Processor-in-the-loop simulation

Controller Tests and Hardware-in-the-Loop Simulation

Function tests are possible at an early development

ControlDesk® AutomationDesk ModelDesk Automotive SYNECT®

Unit under test HIL simulator

Different Ways to Access Electric Motor ECUs

Application Motion Power stage Motor Transmission

Current Rotational speed

Use Case Overview

Use Case Application Area Rapid Hardware-

Vehicle traction – Page 9 Page 12

In-vehicle auxiliary units – Page 15 Page 18

Battery management – Page 20 Page 22

Industrial drive control – Page 41 Page 43

Railway technology – -- Page 47

Electric power industry – -- Page 50

RCP Systems for Hybrid and Fully Electric Powertrains

Processor-based dSPACE Components Customer Components

AutoBox with or Motor

Example 1: Processor-Based Control of an Electric

dSPACE Components Customer Components

AutoBox with or Motor

Example 2: ECU included

Example 3: FPGA-Based Control of an Electric Motor

dSPACE Components Customer Components

MicroAutoBox II AutoBox with

FPGA Programmable per Application

Housing for In-Vehicle Applications

Products Involved in This Use Case (Excerpt)

HIL Simulation for Vehicle Traction Motors

Application Areas Key Points

Products Involved in This Use Case (Excerpt)

dSPACE Components Customer Components

DS2655 FPGA Base Board DS2655M1 Gate signals

IOCNET Position sensor signals

DS2680 I/O Unit

IOCNET Further signals

Host PC, e.g., with

FPGA for Short Sample Times

For expanding the I/O channels of the DS2655, there are

Software-Based FPGA Conﬁguration

Plant Models for FPGA-Based Simulation

Direct FPGA I/O Access

Rapid Control Prototyping for Small Electric Motors

dSPACE Components Customer Components

Interface for signal

Products Involved in This Use Case (Excerpt)

System Extension with Conﬁgurable Automotive

RapidPro Power Unit

Combining MicroAutoBox and RapidPro

Target Simulation Scaling Formulas