Applying a Model-Based I/O Simulator to ECU Development Process

The rapid evolution of feature requirements throughout the commercial vehicle industry dictate the need for optimal engineering processes and methods. In this paper, a controller design and development process based on Motohawk and Opal-RT Hardware-in-the-Loop solutions will be presented. The process features a Rapid Prototyping system with the ability to develop, test, and validate control applications using Simulink/Stateflow models on real production Electronic Control Unit (ECU) hardware in a virtual environment. This model-based engineering solution enables engineers to investigate alternative designs, determine system sensitivities, and inter-system compatibility prior to deployment. The deployment process is also greatly simplified since development was performed on deployable ECUs rather than on a traditional, cumbersome RP system. Prerequisite tools and methods are discussed.