Indianapolis Office16469 Southpark DriveWestfield, IN 46074

St. Louis Office2025 Zumbehl RoadSuite 304Saint Charles, MO, 63303

www.ballsystems.com+1 (317) 509-6410

Modeling Discussion Agenda

• Problems with complex systems

• Complex machines defined

• Intro to modeling & Hardware-in-the-Loop (HIL)

• Cost and quality benefits of model-based testing

• Introduction to Ball Systems

• How can we help?

Problem Statement

Complex machines containing multiple embeddedsystems create unique and diverse testing challenges:

• Availability of product and/or test system for testing

• Cost / time to build a system prior to testing

• High cost to test (capital, facilities, maintenance,manufacturing time, scrap, redesign, etc.)

• Time consuming testing, especially for extensiveregression testing

• System validation challenging due to complexity.Unable to test to limits and beyond

• Repeatability challenging for large physical systems

• High cost of failure (production test, field, customerissues, etc.)

Complex Machines Defined

Plant

EmbeddedReal-Time Control

System

Complex machines such as Draglines, Spacecraft,Vehicle Engines, Blast Hole Drills, Jet Engines, etc.typically have multiple Embedded Real-Time ControlSystems controlling one or more complex (typically)physical components called the “Plant”

Why Modeling and Simulation?

Modeling andsimulation canreduce risk andtime to market andincrease theefficiency inmultiple areas ofthe productdevelopment cycle:

• Model-In-Loop• Software-In-Loop• Hardware-In-Loop• Rapid Control

Prototyping

NI’s VeriStandsoftware platformprovides seamlessintegration ofmodelingthroughout theproductdevelopment cycle

Product DevelopmentV-Diagram

• HIL allows a product development or product testengineer the ability to mimic (or model) the behaviorof the Plant using a combination of electronichardware and custom software

• HIL replaces the Plant under control with a softwaremodel of the physical Plant and all related dynamicsystems

• Modeling improves test and development throughsimulating the use of real world systems

• Models also allow for rapid design iteration, andvalidation at much lower cost

• These models are then “interfaced” with anelectronic control system through the use of an HILhardware test system and associated software tosimulate actuators, sensors, etc.

HIL Allows Modeling of Machines

A software modelis a mathematicalrepresentation ofa physical systemand sometimes ofa control systemas well

Plant SoftwareModel

HIL System Schematic

I/OSignals

Host PCRunning

NIVeriStand

Plant Software Model

ControlSystemReal-Time System

The Plantsoftware model,the host PCrunning NIVeriStand, andthe NI Real-TimeHIL Systemeffectively“replace” thePlant

• HIL increases the speed and scope of testing whilereducing risk and cost

• Ideally an embedded control system is tested against thereal Plant

• However frequently the real Plant imposes limitations orrisks on the scope of the testing

• For example, in the case of an electronic control system,certain testing may lead to dangerous test conditions:

• Testing at or beyond the range of the certain controlsystem parameters or Plant capabilities

• Testing and verification of the system at failureconditions and beyond (“corner cases”)

• HIL provides an efficient and safe environment where thetest or application engineer can focus on the functionalityof the controller without risk to himself or the Plant

Quality of Model-based Testing

Balance Time & Cost vs. Real World

HIL = The Best of Both Worlds

Rea

l Wor

ld C

orre

latio

n

Time and Cost

Virtual Simulation

Hardware-in-the-Loop

Proving Ground orCustomer Site

HIL simulationallows theengineer to costeffectivelybalance rapidverification,validation, andregressiontesting with real-world interaction

Who is Ball Systems?

• Founded in 1966, today Ball Systems is a leader in customelectronics and electronic test solutions and software for Fortune 500companies worldwide

• Comprehensive and strategic offerings and capabilities• Strategic consultation on design of corporate test strategies and development

processes• Test system and test software design; COTS, custom design, etc.• Software design and architectures; NI Suite, Visual Studio, Firmware• Electrical circuit and system design; Analog, Digital, FPGA, Embedded Micro• Custom PCBs/PCAs• Mechanical fixture and

machine design• Controls and machine

vision design• Contract manufacturing

including PCAs, testsystems and racks, testfixtures, customelectronics, machines, etc.

National Instruments StrategicAlliance Partner & HIL Experts

• Programming expertise w/entire NI suite• Certified architects and developers

• Strategic NI HIL / VeriStand Partner• Trained programmers who have implemented

numerous HIL & VeriStand solutions• Experience with VeriStand since inception at NI

• HIL systems developed and delivered for automotive andheavy industrial companies including:

• Caterpillar:• Design and fabrication of HIL hardware test system• Design and development of HIL software including

FPGA programming and VeriStand

• Cummins:• Development of HIL software including seamless

integration with extensive existing test architecture

• 100’s of NI PXI, cRIO, etc. systems integrated worldwide

How Can Ball Systems Help?

• Consult to develop strategies to determine theeffectiveness of an HIL approach

• Development of HIL systems and software

• Staffed on-site validation, verification, andregression testing and test management

• Development of software models

• Design and development of control systems forproducts (e.g., NI cRIO based control systems toreplace existing PLC based systems)

Contact:

Terrance Bradford+1 (317) 509-6410www.ballsystems.com