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SYSTEM AND METHOD FOR THE AUTOMATIC VALIDATION OF MOTOR CONTROL FIRMWARE OF AN EMBEDDED SYSTEM
European Patent EP3076540B1Granted On April 2020
2
P R O B L E M S T A T E M E N T
• Electric motor control embedded systems are widely used in
automotive, consumer electronic devices etc.
• It is required to validate the motor along with the embedded
system which implements control functionalities like:
position control, stall & obstacle/obstruction detection, hard
end, stop end, anti-pinch, bounce back, calibration, safety
controls, fault diagnosis, sensor-less position detection,
functional requirements, memory controls, speed control etc.
• Employing simulated motors using a combination of real time
hardware and intelligent software, does not allow us to
expose the embedded systems to the real word plant
dynamics, imperfections etc.; also the real motor is not under
the scope of validation here.
• Existing solutions when using real motor for testing the
embedded systems, does not provide precise and automated
control of the load effects.
3
Architecture
REAL TIME SIMULATOR HARDWARE
Processor Card
Mathematical Model
I/O Cards
Embedded system with firmware (DUT)
Motor control
Motor (DUT)
CouplerElectromagnetic Brake
Sensor Feedback
Optical Encoder Pulses
Brake Control Signal
Debug port interface
Protocol simulation
Button press simulation
Encoder
4
W O R K I N G
Electromagnetic brake can be energized by the
simulator, while the motor is in motion, to create
loading effect or to stop the motor under test. This
allows the test engineer to validate how embedded
system under test behaves in such situations.
Invention comprises the real motor which is
connected to the motor control embedded system,
shaft from the motor is extended to an
electromagnetic brake and an optical encoder using
couplers. A real time hardware simulator along with
intelligent software models comprise the brain of the
test system.
An encoder provides motor position and motion
information to the simulator independently, allowing it
to validate various functionalities, when coupled with
the brake control.
An intelligent software model running in real time
inside the simulator, controls, the simulated protocol
information, switch presses etc. to the embedded
system, controls the brakes and decodes the motor
position from encoder pulses. Software models can
thus validate all the functionalities of the DUT
explained in slide number 3 in an automated manner.
5
R E L A T E D S E R V I C E O F F E R I N G S F R O M T A T A E L X S I
Setting up real time HILS system for
the validation of motor control embedded systems like:
• Gym Equipments like treadmill, Electric wheel chair.
• Elevators, Lift.
• Engineering tools like: Drilling machine (all types),
Screw tighter, Construction Equipments.
• Industrial applications like: Belt driver, Mixing
machines.
• Main highlight of the invention is its capability in
validating the control algorithm used for controlling
different type of motors:
• DC Motors: Shunt motor, Separately exited motor,
Series motor, Permanent magnet DC motor,
Compounded motor.
• AC Motors: Induction motor, Synchronous motor.
• Other Motors: Stepper motor, Brushless DC motor,
Hysteresis motor, Reluctance motor, Universal motor.
• Method is applicable to systems using either: Sensor for
position detection, example: hall sensor or Sensor less
positioning using back EMF.
• Automotive: Seat, Trunk, Sunroof,
Electric vehicle motor, Power window,
Power mirror, Engine starter motor.
• Consumer electronics like: Grinder,
Mixer, Blender, Recliner, Water
pumping motor, Electric fan, Air
conditioner, Hair dryer, Shoe polishing
machine, Washing machine, Floor
cleaning machine.
6
Confidentiality Notice
This document and all information contained herein is the sole property of Tata Elxsi Ltd. No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
This document shall not be reproduced or disclosed to a third party without the express written consent of Tata Elxsi Ltd. This document and its content shall not be used for any purpose other than that for which it is supplied.
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