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Hardware-in-the-Loop (HIL) Automation Testing

Client: global manufacturer of agricultural equipment

Technology

SW tools: MATLAB Simulink, Vector CANoe, TwinCAT

Programming \ scripting \ automation languages: Python, CAPL

HIL hardware: dSPACE, Speedgoat, Beckhoff, Vector VN series

Services

HIL design – Electrical diagram, HIL block diagram, Assembly support documentation (HW)

Manual testing – HIL set-up and maintenance; test cases creation, manual test cases execution

Automation testing – Automated testing on HIL (automated test scripts creation and execution)

Challenges

The client had decisional, technological, and financial challenges, so it joined forces with rinf.tech to address them effectively and find the best solution fast and cost-effectively.

Decisional challenges

The company faced a dilemma of what type of technical solution to choose for their hardware-in-the-loop (HIL) automation for electric control unit (ECU) testing: a known and tried-and-tested solution that has already been used in production versus a new, original and innovative solution that has never been used in production before.

The solution had to include one common test bench for multiple ECUs.

Tech challenge

The company was looking to set the hardware configuration of the HIL bench (bench configuration and Beckhoff modules setting) and they lacked internal knowledge for doing so correctly.

Financial challenge

The company had severe budget limitations, which excluded purchasing of new HIL bench parts.

On top of that, the client had communication difficulties due to new people in their in-house IT team, which resulted in inefficient processes, delays in decision-making, lack of integrity.

Solution

We performed complete software testing process optimization using V-model, namely:

  • Built from scratch a new HIL environment for manual testing (both software and hardware validation).
  • Developed HIL for automation testing (both software and hardware validation).
  • Standardized validation processes by enabling end-to-end, enterprise-grade application development on a unified, modular, browser-based software environment provided by Siemens Polarion.
  • Performed testing automation (running automated test scenarios).
  • Created automated tests using CAPL and Python.

 

These actions allowed us to guarantee high-level Quality Assurance through high-level engineering capabilities.

Methodology

  • Classic automotive V-model delivery with 2 months milestone and 2 weeks sprints.
  • Continuous delivery and continuous improvement of the product with daily validation, both manual and automated testing.

Results

  • 2 ECUs were tested with 1 common test bench.
  • Extra test cases creation resulted in 35% automation coverage (Test case creation and automation process in validation via Agile development.)
  • 40% increase in testing capabilities – we enabled our client’s business scalability via complete support for test case creation and automation process in validation via Agile development.
  • Ongoing consulting with rinf.tech’s experts enables the company to better assess their financial risks, make strategic investments and reinforce testing capabilities via new processes and increased productivity into validation area.

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