Hardware in Loop Simulation

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Dr G.

Muralimohan
Hardware-in-the-Loop Simulation

Hardware-in-the-Loop (HIL) simulation is a technique that is used for the development and
testing of control systems which are used for the operation of complex machines and systems

With HIL simulation the plant is replaced by a


simulation of the plant (which we call the HIL
simulator). If the HIL simulator is designed well,
it will accurately mimic the real plant, and can
be used to test the control system. Therefore it is
also named HIL testing.

Some HIL simulators are equipped with 3D


visualization and represent the plant so well that
they can be used for training. These HIL
simulators are called Training Simulators
Hardware-in-the-Loop Simulation
Modern machines have many actuators and are loaded with sensors. A control system will
therefore have many connections with the machine to convert actuator setpoints and read
sensor data

A pure HIL simulator will mimic the plant at


the connection level and allow the wires to be
switched from the plant IO to the HIL simulator
IO.

If the HIL simulation has been completed, you


switch the wires to the plant and start the
machine
Training Simulator

When a HIL simulator is equipped with 3D


visualization and can represent the plant very
well, it can be used for training. These HIL
simulators are called training simulators.

Training simulators are very useful when


operating on a real machine can be hazardous or
is very costly. It allows operators to be trained
in a secure environment in standard and non-
standard situations
Application
HIL testing is a technique where real signals from a controller are connected to a test system
that simulates reality, tricking the controller into thinking it is in the assembled product. Test
and design iteration take place as though the real-world system is being used. You can easily
run through thousands of possible scenarios to properly exercise your controller without the
cost and time associated with actual physical tests.

Again, consider a car. The engine ECU is responsible for converting sensor measurements
into action such as adjusting air intake when the accelerator is depressed
Application
An HIL test replaces the engine with a simulation comprising hardware and software that
interacts with real I/O as though the physical engine were present. Because updates can be
made in software, you can quickly incorporate ECU or engine software changes, test a wide
breadth of relevant scenarios, and expand test coverage as needed to fearlessly and
comprehensively test without risk to a physical, costly system.  
Classical control experimental set-up Hardware-in-the loop method

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