CPU Model-Based Mechatronics/Hardware/Software Co-design Technology for Real-Time Embedded Control Systems

Abstract

We review practical case studies of a developing method of highly reliable real-time embedded control systems using a CPU model-based hardware/software co-simulation. We take an approach that enables us to fully simulate a virtual mechanical control system including a mechatronics plant, microcontroller hardware, and object code level software. This full virtual system approach simulates control system behavior, especially that of the microcontroller hardware and software. It enables design space exploration of microarchitecture, control design validation, robustness evaluation of the system, software optimization before components design. It also avoids potential problems. The advantage of this work is that it comprises all the components in a typical control system, enabling the designers to analyze effects from different domains, for example mechanical analysis of behavior due to differences in controller microarchitecture. To further improve system design, evaluation and analysis, we implemented an integrated behavior analyzer in the development environment. This analyzer can graphically display the processor behavior during the simulation without affecting simulation results such as task level CPU load, interrupt statistics, and the software variable transition chart. It also provides useful information on the system behavior. This virtual system analysis does not require software modification, does not change the control timing, and does not require any processing power from the target microcontroller. Therefore this method is suitable for real-time embedded control system design, in particular automotive control system design that requires a high level of reliability, robustness, quality, and safety. In this study, a Renesas SH-2A microcontroller model was developed on a CoMET™platform from VaST Systems Technology. An electronic throttle control (ETC) system and an engine control system were chosen to prove this concept. The electronic throttle body (ETB) model on the Saber® simulator from Synopsys® and the engine model on MATLAB®/Simulink®simulator from MathWorks can be simulated with the SH-2A model using a newly developed co-simulation interface between MATLAB®/Simulink® and CoMET™. Though the SH-2A chip was being developed as the project was being executed, we were able to complete the OSEK OS development, control software design, and verification of the entire system using the virtual environment. After releasing a working sample chip in a later stage of the project, we found that such software could run on both actual ETC system and engine control system without critical problem. This demonstrates that our models and simulation environment are sufficiently credible and trustworthy.