Comprehensive Customization Options

• Maximum flexibility thanks to a modular concept
• Minimal hardware modifications needed if requirements change
• All signals accessible on terminal stripes for additional measurement tasks and for a flexible response to changing specifications
• Clear and transparent system architecture
• Multirack systems possible

 

Flexible, Modular Hardware

• Single-processor or multiprocessor system for high computation requirements
• Freely expandable with any SCALEXIO board according to project needs
• Expandable, e.g., with hardware for fault insertion and load simulation (customer-specific configuration)
• Expandable, e.g., with flexible FPGA boards

 

Signal Conditioning

• Signal conditioning included with SCALEXIO MultiCompact I/O and SCALEXIO HighFlex hardware
• Support of almost any signal type, e.g., digital in/out, analog in/out, relay simulation, current sink/source, LVT simulation, resistance simulation, and linear lambda probe simulation
• Additional modules on request

 

Simulation of Linear Lambda Probes

LSU (Lambda Sonde Universal, universal lambda probe) is a signal conditioning module that simulates the behavior of linear lambda probes. These probes measure the air-fuel ratio in a car’s exhaust system. The engine ECU reacts by varying the injection time, so the catalytic converter can operate at an optimal performance rate.

The LSU module allows for generating Nernst cell voltage on four independent channels based on pump current and Nernst cell inner resistance. The module functions as a linear probe or as a jump probe. Parameters such as maximum/minimum Nernst cell voltage can be adjusted.

 

Load Capabilities

• Modular load concept with customer-specific configuration
• Support of single-ended and double-ended loads
• Resistive loads or other kinds of equivalent loads
• Connection of electrically equivalent loads or low-power resistive loads
• Connection of real loads, optional rack integration
• Integration of customer's load panels
• High-speed electronic loads, e.g., simulation of electric machines
• Connection to high-voltage emulation systems and test benches

 

Programmable Power Supplies

The programmable power supply unit feeds the components to be tested and allows for simulating real voltages such as a vehicle’s battery voltage during start-up. The power supply unit is remotely controlled from within the real-time model.

Various power supplies are available for different applications, for example:

• 0 ... 20 V
• 0 ... 60 V

 

Coupling Options

To increase your computational power and available I/O interfaces, you can interconnect as many SCALEXIO customized systems as needed. If the project requirements change, you can easily adapt your testing system. Coupling SCALEXIO systems is done via IOCNET.

All software for configuring the system and controlling the simulation or test automation runs on a host PC. The PC is connected via Ethernet with the SCALEXIO system.

 

Fault Simulation

For fault simulation, the SCALEXIO rack system provides I/O boards with integrated fault simulation, namely the HighFlex boards (DS2601, DS2621, DS2642, and DS2671) and MultiCompact I/O Units (DS2680 and DS2690).  

Additional Fault Insertion Units for Customized Systems

For the customized system, additional types of fault simulation are available in addition to SCALEXIO Fault Simulation. This enables you to tailor the system to your project-specific requirements. The fault simulation for customized sytems can be remotely controlled with the ControlDesk Failure Simulation Module or, optionally, with AutomationDesk.

 

Fault Simulation Variant 1

Variant 1 for fault simulation on SCALEXIO supports fault simulation on all ECU input and output pins. All digital and analog I/O boards from dSPACE can be used for fault simulation. The relay boards (DS291) for fault simulation can be used on their own for fault simulation on sensor signals (ECU inputs) or in conjunction with load boards (DS281) on actuator signals (ECU outputs). Fault relays are controlled via a serial RS232.

 

Fault Simulation Variant 2

The second fault simulation variant uses a central relay switching matrix (DS293) for fault simulation on ECU inputs and outputs. Five different system potentials (for example, Terminal 30, Terminal 31, Terminal 15) can be switched on three different rails via load modules (DS282). Further devices that can be connected, including various measurement devices (Meas0-4), an electronic source (Source), and Rsim modules for transition impedance. Fault simulation is controlled via a CAN interface.

 

High-Current Fault Simulation

The high-current fault simulation unit on SCALEXIO supports fault simulation on ECU inputs and outputs. One FIU controller card (DS5355) supports up to 19 signal channels on two high-current FIU relay trays (DS5390). Due to its modularity, the FIU controller card can be expanded to increase the number of channels. These relay trays allow for faults with currents up to 50 A and voltages of up to 300 V. The FIU is controlled from ControlDesk via a serial RS232 or CAN.

 

Customized Interfaces to Diagnostic and Calibration Hardware

Many companies already have their own diagnostic and calibration hardware to perform tasks such as reading out internal ECU variables from the fault memory. If you want to use your own diagnostic and calibration hardware, a special interface for SCALEXIO is needed, which, in some cases, might require engineering. You can connect any kind of measuring device, digital scope, and diagnostic device you like with special protocols such as GPIB or RS232.

 

Real System Components

In some cases, the real system components (such as injection valves, hydraulic components, and sensors) have to be integrated into SCALEXIO. This is necessary, for example, if components for the same ECU are provided by different suppliers and have to be checked together with the ECU within the simulated environment. Moreover, not every vehicle component can be simulated accurately enough with a justifiable amount of time and money. Some ECUs require real loads at their outputs to function.

 

Other Hardware Components

• Optional inclusion of third-party hardware, e.g., load panels, signal routing units, GPIB instruments
• Power switch modules

Overview

 

Feature	SCALEXIO FIU	SCALEXIO Customized Rack Systems Variant 1	SCALEXIO Customized Rack Systems Variant 2	SCALEXIO Customized Rack Systems High-Current
General	Integrated with SCALEXIO MultiCompact I/O units and HighFlex boards	Available with SCALEXIO customized rack systems Engineering needed	Available with SCALEXIO customized rack systems Engineering needed	Available with SCALEXIO customized rack systems Engineering needed
I/O boards with integrated FIU	DS2601 DS2621 DS2671 DS2672 DS2680 DS2690	DS291	DS282	DS5355/DS5390
Number of cards per simulator	Via the I/O boards	Configurable	Configurable	Configurable
Number of channels per card	Depends on I/O board	10	10	Up to 9
Switch type	Relay Central module with semiconductor switch	Relay	Relay	Relay
Central modules	DS2642 DS2680	-	1 x DS293	-
Max. continuous current	Up to 80 A (depends on I/O board)	8 A	8 A	50 A

 

 

Possible fault types	SCALEXIO FIU	SCALEXIO Customized Rack Systems Variant 1	SCALEXIO Customized Rack Systems Variant 2	SCALEXIO Customized Rack Systems High-Current
Broken wire	Included	Included	Included	Included
Short circuit to ground	Up to 10 channels	Included	Included	Included
Short circuit to battery voltage	Up to 10 channels	Included	Included	Included
Short circuit to another ECU pin via common failrail	Up to 10 channels	Included	Included	Included
Broken wire with additional hardware (Rsim, Meas or Source) in series	Not available	Not available	Included	Not available
Short circuit to another ECU pin via additional hardware (Rsim, Meas or Source)	Not available	Not available	Included	Not available
Short circuit to 5 reference points (potential 0 ... 4) directly or via additional hardware (Rsim, Meas or Source)	Not available	Not available	Included	Not available