Hardware-in-the-loop Simulation Research Articles

Enhancing Clustering Performance of Failed Test Cases during HIL Simulation: A Study on Deep Auto-Encoder Structures and Hyperparameter Tuning

Over the last decade, hardware-in-the-loop (HIL) simulation has been established as a safe, efficient, reliable, and flexible method for performing real-time simulation. Furthermore, in the automotive sector, the HIL system has been recommended in the ISO 26262 standard as a powerful platform for performing realistic simulation during system integration testing. As a result of performing HIL black-box tests, the results of executing test cases (TCs) are reported as pass/fail without determining the nature and root causes of the underlying failures. The conventional analysis process of the failed TCs relies on expert knowledge. The higher the number of failed TCs, the higher the cost of manual analysis in terms of time and effort. In light of the shortcomings of existing methodologies, this study presents a novel intelligent framework capable of analyzing failed TCs without the need for expert knowledge or code access. To this end, a convolutional auto-encoder-based deep-learning approach is proposed to extract representative features from the textual description of the failed TCs. Furthermore, k-means-based clustering is used to categorize the extracted features according to their respective failure classes. To illustrate the effectiveness and validate the performance of the proposed method, a virtual test drive with real-time HIL simulation is presented as a case study. The proposed model exhibits superior clustering performance compared to other standalone k-means algorithms, as demonstrated by the David Bouldin Index (DBI) and accuracy values of 0.5184 and 94.33%, respectively. Furthermore, the proposed model shows a significant advantage in terms of feature extraction and clustering performance compared to the current state-of-the-art fault-analysis method. The proposed approach not only supports the validation process and improves the safety and reliability of the systems but also reduces the costs of manual analysis in terms of time and effort.

Black-box modeling of PMSG-based wind energy conversion systems based on neural ODEs

Abstract Integrating renewable energy sources like wind power into the power grid enhances the dynamic interactions among renewable energy-producing equipment, leading to new technological issues for the power grid. Modeling and simulation are essential to ensure the stability of the emerging power grid, but they require precise dynamic component modeling, which is often unavailable due to technical confidentiality and other factors. Conventional hardware-in-the-loop (HIL) simulation can accurately simulate the dynamics of a single renewable energy device, but not the complex dynamics of multiple devices. This research introduces a method that combines classical mechanism modeling and differential neural network modeling to create accurate wind turbine models utilizing equipment measurement data or HIL simulation data. A realistic wind turbine electromagnetic transient simulation model of a specific type is developed and validated by connecting it to the IEEE-39 node system, confirming the model’s accuracy.

Development of Hardware-in-the-Loop Simulation Test Bed to Verify and Validate Power Management System for LNG Carriers

Liquefied natural gas carrier (LNGC) orders are increasing owing to marine environment regulations. The complexity of the integrated system applied to shipbuilding and software errors have increased with the high degree of automation. Direct on-site inspection methods are associated with high costs and safety risks, whereas software-based simulations rely heavily on the accuracy of the models of power system components. Hardware-in-the-loop simulation (HILS) can be utilized for designing and testing intricate real-time embedded systems. Specifically, HILS offers a reliable means of evaluating power management system (PMS) performance for LNGCs, which are high-value vessels commonly used in offshore plants. This study proposes a PMS–HIL test bed comprising a power supply unit, consumer, simulation control console, and main switchboard. The proposed HILS test bed utilizes the real equipment data of the shipbuilding industry to replicate the conditions associated with actual LNGCs. The proposed system is verified and validated through a software acceptance test procedure. Additionally, load-sharing, load-dependent start, blackout prevention, and preferential tests are performed for the PMS function evaluation. Test results indicate that the proposed system has great potential for conventional PMS commissioning. Therefore, it exhibits the potential to replace traditional factory acceptance tests. Additional development of the system will be conducted for ship automation, utilizing PMS control and an energy management system.

Fault Detection Methods for Electric Power Steering System Using Hardware in the Loop Simulation

The development of the automotive industry is associated with the rapid advancement of onboard systems. In addition, intensive development in the electronics and control systems industry has resulted in a change in the approach to the issue of assistance systems in vehicles. Classic hydraulic systems have been almost completely replaced by modern electric power steering (EPS) systems, especially in citizen vehicles. This paper focuses on fault detection algorithms for EPS, along with the available tools to aid development and verification. The article discusses in detail the current state of knowledge in this area. The principle of operation of the EPS system and the influence of the structure of the mechanical system on its operation, in particular the characteristics of the ground–tire contact, are presented. Various error identification methods are presented, including those based mainly on a combination of tests of real objects as well as those combined with modern hardware-in-the-loop (HIL) equipment and virtual vehicle environment software, enabling the development of new diagnostic methods, enhancing the security, reliability, and energy control in the vehicle. A review of the literature indicates that although many algorithms which enable fault detection at an early stage are described, their potential for use in a vehicle is highly limited. The reason lies in simplifications, including models and the operating EPS temperature range. The most frequently used simplification of the model is its linearization, which significantly reduces the calculation time; however, this significantly reduces the accuracy of the model, especially in cases with a large range of system operation. The need for methods to detect incipient faults is important for the safety and reliability of the entire car, not only during regular use but also especially during life-saving evasive maneuvers.

QCASBC: An algorithm for hardware-in-the-loop simulation of 3-link RRR robotic manipulator

In this paper, a quick convergence adaptive structure is proposed for trajectory tracking of an articulated type robotic manipulator using the Hardware in the Loop (HIL) simulation technique. A novel Nonlinear Quick Convergence Adaptive Sliding Backstepping Control (QCASBC) algorithm is implemented on a C2000 real-time controller board. The performance of the proposed control algorithm is inspected concerning the sliding mode PID (SM-PID) control technique to estimate its correlation with the proposed algorithm. The experimental part of the HIL simulation tests has been carried out on a simulated model of a three-link serial robot manipulator. A dynamic model of the robotic manipulator has been developed using Matlab Simulink software and its performance is analyzed using the HIL technique via a C2000 real-time controller for tracking the desired trajectory. Results show that the speed of convergence while tracking the desired trajectory of the manipulator is better in the proposed algorithm. It is also estimated that the positional error of the QCASBC algorithm is superior to the SM-PID control algorithm. The observed average angle error is improved by 14% and the average response time error is improved by 11% by using the proposed QCASBC algorithm compared to the SM-PID approach.

A Virtual Testing Framework for Real-Time Validation of Automotive Software Systems Based on Hardware in the Loop and Fault Injection.

To validate safety-related automotive software systems, experimental tests are conducted at different stages of the V-model, which are referred as "X-in-the-loop (XIL) methods". However, these methods have significant drawbacks in terms of cost, time, effort and effectiveness. In this study, based on hardware-in-the-loop (HIL) simulation and real-time fault injection (FI), a novel testing framework has been developed to validate system performance under critical abnormal situations during the development process. The developed framework provides an approach for the real-time analysis of system behavior under single and simultaneous sensor/actuator-related faults during virtual test drives without modeling effort for fault mode simulations. Unlike traditional methods, the faults are injected programmatically and the system architecture is ensured without modification to meet the real-time constraints. Moreover, a virtual environment is modeled with various environmental conditions, such as weather, traffic and roads. The validation results demonstrate the effectiveness of the proposed framework in a variety of driving scenarios. The evaluation results demonstrate that the system behavior via HIL simulation has a high accuracy compared to the non-real-time simulation method with an average relative error of 2.52. The comparative study with the state-of-the-art methods indicates that the proposed approach exhibits superior accuracy and capability. This, in turn, provides a safe, reliable and realistic environment for the real-time validation of complex automotive systems at a low cost, with minimal time and effort.

Automating Fault Test Cases Generation and Execution for Automotive Safety Validation via NLP and HIL Simulation

The complexity and the criticality of automotive electronic implanted systems are steadily advancing and that is especially the case for automotive software development. ISO 26262 describes requirements for the development process to confirm the safety of such complex systems. Among these requirements, fault injection is a reliable technique to assess the effectiveness of safety mechanisms and verify the correct implementation of the safety requirements. However, the method of injecting the fault in the system under test in many cases is still manual and depends on an expert, requiring a high level of knowledge of the system. In complex systems, it consumes time, is difficult to execute, and takes effort, because the testers limit the fault injection experiments and inject the minimum number of possible test cases. Fault injection enables testers to identify and address potential issues with a system under test before they become actual problems. In the automotive industry, failures can have serious hazards. In these systems, it is essential to ensure that the system can operate safely even in the presence of faults. We propose an approach using natural language processing (NLP) technologies to automatically derive the fault test cases from the functional safety requirements (FSRs) and execute them automatically by hardware-in-the-loop (HIL) in real time according to the black-box concept and the ISO 26262 standard. The approach demonstrates effectiveness in automatically identifying fault injection locations and conditions, simplifying the testing process, and providing a scalable solution for various safety-critical systems.

Common-Mode Voltage Reduction of Modular Multilevel Converter Using Adaptive High-Frequency Injection Method for Medium-Voltage Motor Drives

This study proposes an adaptive high-frequency injection method (AHFI) aimed at mitigating common-mode voltage (CMV) on the AC side and alleviating current stress on power semiconductor devices within each arm of a medium-voltage motor propulsion system designed for modular multilevel converters. By adjusting the quantity of high-frequency components injected into each arm according to the fluctuation coefficient, the amplitude of injected high-frequency CMV and circulating currents can be reduced across medium to rated motor speeds. This approach enhances the start-up performance of medium-voltage motor drives while diminishing CMV effects on the motor side, resulting in decreased total harmonic distortion (THD) in the three-phase output waveforms. Furthermore, the effectiveness of the proposed AHFI method in SM voltage regulation and circulating current control under low-frequency operation is thoroughly analyzed. The validity of this method is established through comprehensive mathematical scrutiny and time–domain simulations performed using MATLAB/SIMULINK software, along with real-time simulations conducted employing the real-time simulator OPAL/RT via hardware-in-the-loop simulation (HILS).

Online Identification of Aerodynamic Parameters of Experimental Rockets Based on Unscented Kalman Filtering

Online identification of aerodynamic parameters of experimental rockets was completed based on unscented Kalman filtering (UKF). Numerical simulation, hardware-in-the-loop (HIL) simulation, and flight tests were conducted. The identification error of aerodynamic force in numerical simulation and HIL simulation is within 2%. For flight test data, trajectory reconstruction was performed using the identified aerodynamic forces, and the results showed that the identification results were more accurate than the interpolation table calculation results. The flight test identification results show that the identification method can complete parameter online identification under the conditions of limited performance of onboard computers, real sensor errors, and servo response. The approximate linear correlation between α and δe and the reason for their formation from the moment balance were analyzed. It was pointed out that when the recognition sampling period is long, this phenomenon will affect the identification of parameters, and a solution is proposed.

A Semi-Implicit Parallel Leapfrog Solver With Half-Step Sampling Technique for FPGA-Based Real-Time HIL Simulation of Power Converters

Field Programmable Gate Array (FPGA) based Hardware-in-the-loop (HIL) simulation is an effective tool to verify the performance of physical controllers and shorten the development cycle of power converters. In HIL simulations, sampling accuracy is of concern and is desired to be improved by reducing the step size. However, due to the cost of computational time, the step size is hard to reduce indefinitely to meet the requirements for high switching frequency applications. To improve the sampling accuracy and simulation performance of HIL simulation, this paper proposes a semi-implicit parallel leapfrog (SPL) solver with half-step sampling technique. In this solver, the switches and the rest part of the system are implemented to be computed parallel when the switch leg model operates in continuous current mode. Besides, the solver is formulated in leapfrog format to reduce computational costs and to compute at half-step as a minimum step-size. With this format, the half-step sampling technique can be employed to increase the sampling rate by onefold, even in cases where it is challenging to reduce the simulation step size further. A dual active bridge converter case is implemented on the FPGA board with a 12.5-ns sampling step-size, retaining the simulation accuracy while switched at 400 kHz. To further verify the advantages, the results are compared with other HIL method and experimental results.

Design, simulation, control of a hybrid pouring robot: enhancing automation level in the foundry industry

AbstractCurrently, workers in sand casting face harsh environments and the operation safety is poor. Existing pouring robots have insufficient stability and load-bearing capacity and cannot perform intelligent pouring according to the demand of pouring process. In this paper, a hybrid pouring robot is proposed to solve these limitations, and a vision-based hardware-in-the-loop (HIL) control technology is designed to achieve the real-time control problems of simulated pouring and pouring process. Firstly, based on the pouring mechanism and the motion demand of ladle, a hybrid pouring robot with a 2UPR-2RPU parallel mechanism as the main body is designed. And the equivalent hybrid kinematic model was established by using Eulerian method and differential motion. Subsequently, a motion control strategy based on HIL simulation technique was designed and presented. The working space of the robot was obtained through simulation experiments to meet the usage requirements. And the stability of the robot was tested through the key motion parameters of the robot joints. Based on the analysis of pouring quality and trajectory, optimal dynamic parameters for the experimental prototype are obtained through water simulation experiments, the pouring liquid height area is 35–40 cm, the average flow rate of pouring liquid is 112 cm3/s, and the ladle tilting speed is 0.0182 rad/s. Experimental results validate the reasonableness of the designed pouring robot structure. Its control system realizes the coordinated movement of each branch chain to complete the pouring tasks with different variable parameters. Consequently, the designed pouring robot will significantly enhance the automation level of the casting industry.

Representative Real-Time Dataset Generation Based on Automated Fault Injection and HIL Simulation for ML-Assisted Validation of Automotive Software Systems

Recently, a data-driven approach has been widely used at various stages of the system development lifecycle thanks to its ability to extract knowledge from historical data. However, despite its superiority over other conventional approaches, e.g., approaches that are model-based and signal-based, the availability of representative datasets poses a major challenge. Therefore, for various engineering applications, new solutions to generate representative faulty data that reflect the real world operating conditions should be explored. In this study, a novel approach based on a hardware-in-the-loop (HIL) simulation and automated real-time fault injection (FI) method is proposed to generate, analyse and collect data samples in the presence of single and concurrent faults. The generated dataset is employed for the development of machine learning (ML)-assisted test strategies during the system verification and validation phases of the V-cycle development model. The developed framework can generate not only time series data but also a textual data including fault logs in an automated manner. As a case study, a high-fidelity simulation model of a gasoline engine system with a dynamic entire vehicle model is utilised to demonstrate the capabilities and benefits of the proposed framework. The results reveal the applicability of the proposed framework in simulating and capturing the system behaviour in the presence of faults occurring within the system’s components. Furthermore, the effectiveness of the proposed framework in analysing system behaviour and acquiring data during the validation phase of real-time systems under realistic operating conditions has been demonstrated.

Initial flight test verification of software and hardware in the loop simulations of the flight stabilization system

PurposeThis paper aims to present assessment of models and simulation results used in the development process of flight stabilisation system that uses trim tabs for PZL-130 Orlik turboprop military trainer aircraft. Flight test of the system allowed to compare software and hardware simulation results with real flight recordings.Design/methodology/approachProposed flight stabilisation system was developed using modern techniques of model-based design, automatic code generation, software and hardware in the loop testing. The project reached flight testing stage which allowed to gather data to verify models and simulation results and asses their quality.FindingsResults of the comparison showed that the trim tab actuator model used in simulation can be improved by adding play. This reduced the difference between simulation and real flight system output – actuator angle. The influence of airloads on the flying actuator angle compared to hardware in the loop simulation in lab is less than ± 0.6°.Originality/valueProposed flight stabilisation system that uses trim tabs has several benefits over classic automatic flight system in terms of weight, energy consumption and structure simplicity and does not need aircraft primary control modification. It was developed using modern techniques of model-based design, automatic code generation and hardware in the loop simulations.

Hardware in the loop simulation of single-phase PWM rectifiers for improved power quality via ASWFA

Hardware in the loop simulation of single-phase PWM rectifiers for improved power quality via ASWFA

Indirect Matrix Converter Hardware-in-the-Loop Semi-Physical Simulation Based on Latency-Free Decoupling

In the process of hardware-in-the-loop simulations (HILs) of indirect matrix converters (IMCs), solving the mathematical models of complex multiswitching converter topologies has become a major problem. The conventional approach is to split the complex mathematical model into multiple serial subsystems; however, this inevitably produces delays in the simulation steps between different subsystems, leading to numerical oscillations. In this paper, the method of latency-free decoupling is adopted, which has no time-step delay between different subsystems, making each subsystem a parallel operation. This can improve the numerical stability of the simulations and can effectively reduce the step size of the real-time simulation and alleviate the problem of real-time simulation resource consumption. In this paper, we discuss in detail the modeling process of IMC hardware-in-the-loop simulations with Finite Control Set Model Predictive Control (FCS-MPC), and experimentally validate our method using the Speedgoat test platform, resulting in a simulation step size of less than 200 ns. The simulation results are compared with the results of Matlab’s Simpower power system, which allows us to evaluate the accuracy of our model.

Development of an Arduino-based, open-control interface for hardware in the loop applications

This article presents a flexible control interface based on low-cost hardware solutions for electric drives which classically come either with a proprietary hardware solution or a high-cost interface solution. The interface presented can be used to connect a standard PC with an electric drive to enable testing simulation and control applications. The control interface is developed based on the open-source Python scripting language and Arduino’s open-source and accessible hardware. The new interface communicates with the test stand through its I/O terminals via developed electronic amplifiers and creates a solid base for further development towards more extensive hardware in the loop simulations.

Enhanced Non-Communication-Based Protection Coordination and Advanced Verification Method Using Fault Impedance in Networked Distribution Systems

In recent years, the networked distribution system (NDS), which is normally connected to the distribution line (DL), was actively studied as the topology of the future distribution system for reasons such as improving supply reliability, improving line utilization, and increasing the capacity of distribution generators (DGs). However, the NDS creates new issues in terms of protection coordination because of its bidirectional power flow and fault current flow. The issues associated with conventional protection schemes in the NDS include malfunction of protective devices due to bi-directional fault currents and failure of protection coordination due to communication failures between protective devices. When applying a conventional protection method in the NDS, the protection schemes become complicated, and there is a risk of protection coordination failure due to communication failure between protective devices. To solve this problem, this paper proposes an effective and innovative non-communication-based protection algorithm for protection coordination in the NDS. The proposed protection algorithm utilizes fault impedance characteristics, which allow not only determination of whether a fault occurred, but also the ability to identify the exact fault point. Therefore, the proposed method is expected to be sustainably utilized and contribute to developing protection schemes and devices in various system topologies and scenarios in the future. Additionally, this paper addresses the overall concept of hardware-in-the-loop simulation (HILS) and directly verifies the proposed protection algorithm using HILS. Therefore, this study establishes a sustainable foundation for future research on protection coordination using HILS.

Design and Implementation of Hardware-in-the-Loop Simulation Environment Using System Identification Method for Independent Rear Wheel Steering System

In the automotive field, with the advancement of electronic and signal processing technologies, active control-based chassis systems have been developed to enhance vehicle stability. In this study, a Hardware-in-the-Loop (HiL) simulation environment was developed to effectively improve time and cost during the development process of an independent rear-wheel steering system. The HiL Simulation Environment was developed—a specific test bench capable of simulating driving loads on the prototype. Based on the system identification method, a reaction force modeling technique for the target driving loads was proposed. The full vehicle dynamics simulation model was developed with a lateral maximum error of 4.5% and a correlation coefficient of 0.98, as well as a longitudinal maximum error of 0.1% and a correlation coefficient of 0.99. The reaction force generation system had a maximum error of 2.9%. Using the developed HiL simulation environment, performance verification and analysis of the independent rear-wheel steering system were conducted, showing reductions of 5.1% in lateral acceleration and 5.2% in yaw rate.

Robust Position Control for an Electrical Automatic Transmission under Gear-Shifting Link Friction

The automotive industry is evolving, with software becoming a vital part of vehicles. Conventional automakers are shifting to software-centric entities, embracing over-the-air (OTA) updates and service-centric models. To move software-driven vehicles, the vehicle must also be electrified. Several automobile manufacturers are electrifying vehicle parts, and recently, a gear shift selector for automatic transmissions was adapted from mechanical to electronic. However, as conventional mechanical systems are modified to electrical systems, problems such as shift delay and accuracy emerge. This study addresses these problems that emerge in the electronic system type of automatic transmission, including a gear shift selector developed to electrify automobiles. Accordingly, we first analyze the structure of automatic transmission systems, then define the operation sequence. Next, a novel position control algorithm based on a disturbance observer is proposed to reduce shift delay and increase accuracy. The proposed algorithm operates harmoniously with the vehicle control unit (VCU). To verify the proposed algorithm, a hardware-in-the-loop simulation (HILS) was developed to experiment with vehicle shifting using a commercial electronic gear shift selector. Moreover, the proposed control algorithm for gear shifting in an automatic transmission was analyzed using experimental results obtained by assuming a specific driving situation in the HILS.

Hierarchical distributed MPC method for hybrid energy management: A case study of ship with variable operating conditions

The energy management (EM) strategy, power controller, and local controller of the EM system are coupled, and together affect hybrid power system performance. To achieve coordinated control and multi-objective optimisation of a hybrid power system, a hierarchical distributed control method was proposed, and a validation study was conducted based on model-in-the-loop simulations (MILs) and hardware-in-the-loop simulations (HILs). First, a real-time EM strategy based on a combination of forward dynamic programming (FDP) and model predictive control (MPC) methods was proposed to optimise the power allocation for multiple energy sources. Second, a distributed controller based on a consistency algorithm was proposed to coordinate the differences in the characteristics of multiple energy sources. A dynamic virtual impedance-based droop controller was designed for dynamic tracking of the reference power. The performance of the three-layer control structure was comprehensively validated through MILs and HILs. The results show that the dynamic virtual impedance-based droop control method can track the nonlinear reference power with control deviation within 5 %. The distributed controller is able to keep the bus voltage stable. The global control accuracy of the DC bus voltage is improved by 18.08 %, and the battery current global fluctuations is reduced by 17.4 %. The real-time FDP-MPC-based EM strategy can achieve 99.89 % energy savings and emissions reduction compared to the global DP-MPC-based method, with greater robustness, real-time performance. The results demonstrate that the proposed method is effective for real-time applications and can achieve hierarchical and multi-objective optimal control of the hybrid power system.